Latest pack house technology identifies unwanted packing line downtime, improves UPWH
An important parameter in measuring pack house productivity is the UPWH (Units Packed per Worker Hour). Empirical evidence shows that in most pack houses, at best, only 50 minutes in any hour are productive, with typical performance running around 45 minutes per hour. Clearly these losses have a major impact on the UPWH and hence overall productivity.
Productivity is dependent on a range of factors that can be divided between actual packing line efficiencies and operational ‘downtime’ issues, both of which reduce available packing time and the UPWH. The key factors which affect productivity include:
• lack of product at the line
• lack of packaging materials at the line
• insufficient operators on the line (lateness, extended breaks etc)
• equipment failure
• shift change delays
• packing film / label change delays
The latest pack house technologies can identify the reasons for downtime, providing excellent control in busy fresh produce packaging environments. Marco’s Murray Hilborne has first-hand experience of the problems associated with downtime: “The main difficulty is being able to identify and measure this downtime in order to understand its overall effect. It is typically an accumulation of minor delays or interruptions, which, in isolation, do not appear to threaten productivity and are therefore often dismissed or overlooked.
The Marco system can be pre-configured to provide our customers with important data on downtime, highlighting where, when and why packing lines are not operational in any given time period. The YCM screen will flash red when downtime is logged and the supervisor then has to select one of the pre-determined reasons for the interruption. Management have the option to do this straightaway or at the end of a batch or shift and this vital information can then be used to improve overall efficiencies.”
Marco’s YCM Yield Control System has an excellent proven reputation in reducing giveaway/overpack, minimising waste and increasing productivity at pack houses around the world. Uplifts in productivity of 30% or more are regularly achieved for clients, with returns on investment of 6 months or less.
Murray also points out that other important issues should be considered when investing in pack house technology. “New technologies are reducing labour overheads. Although this is good news financially, pack houses can be stretched, allowing unnecessary downtime to creep in. Choosing the right equipment for your pack house is essential and initial cost should not always be the driving factor. For instance, although a twin head labeller is initially more expensive than a single head, the benefits can soon be realised. As soon as one head runs out of label stock the second head will automatically take over, with no packing time lost due to label replenishments or changeovers. As another example, intelligent multi-tiered conveyors provide a consistent and un-interrupted flow of product to and from each operator ensuring they remain packing at their workstations and delivering maximum productivity within each working hour.”
For more information:
Becky Hart
Marco Limited
Tel: +44 (0) 1732 782380
Fax: +44 (0) 1732 863674
Email: becky.hart@marco.co.uk
www.marco.co.uk