PD_Packaging Digest

Packaging Digest, June 2013

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34 BEST PRACTICES // JUNE 2013 www.PackagingDigest.com Chemolux acquired its first Bosch machine, a Model HSM flow wrapper, in 1997 and now operates 15 lines consisting of two different machine types. Obsolescence Kits for HSM  flow wrappers "Our goal was to switch from a customer-supplier relationship to a real partnership, and we have achieved this to our complete satisfaction." — Ludovic Ghesquière, maintenance manager, Chemolux Annual maintenance plans for each line were established, focusing on the entire production process and integrating all departments, particularly supply chain management. "With our maintenance program fixed a year ahead, we can prepare all interventions and encounter few, if any, last-minute surprises," says Philippe Gosset, plant director at Chemolux. This is especially important in Luxembourg, as all suppliers must be registered with and identified to government authorities. Different levels of PM Today, Chemolux has a preventive maintenance program in place that is conducted at different levels on the different lines. The machines are checked and cleaned every shift, day, week or month, depending on the requirements of the individual lines. "Thanks to the scheduled intervals, we have our lines under control and can deliver a high service level for our customers," says Ghesquière. The organization of maintenance activities is now much more fluid and predictable, resulting in reduced costs. Plant manager Gosset adds, "Thanks to the preventive maintenance program, we have higher overall product quality and less waste." This is also important with regard to the external audits that Chemolux customers conduct before concluding a contract. As a result, no major production stops have occurred at Chemolux for the past five years. The preventive maintenance program at Chemolux has decreased maintenance costs by 11 percent and increased machine efficiency by 13 percent between 2008 and 2011. magenta cyan yellow black As part of its after-sales service, Bosch Packaging Services offers obsolescence kits that upgrade drives and controls. A number of kits are available for the HSM wrappers at Chemolux. Until about 10 years ago, these machines were manufactured with a controls architecture based on PMAC motion controllers and IRT servo drives. Obtaining spares or repairing these components becomes increasingly difficult. To upgrade these older machines, Bosch has developed five distinct obsolescence kits: t ,JU 3FQMBDFT UIF PCTPMFUF *35 ESJWFT BOE NPUPST with new Bosch Rexroth IndraDrives and motors t ,JU 3FQMBDFT UIF PCTPMFUF (4 GBNJMZ ).* XJUI B new XVS-MC2 HMI t ,JU 3FQMBDFT UIF PCTPMFUF 1."$ BSDIJUFDUVSF with a new Allen-Bradley ControlLogix architecture from Rockwell Automation t ,JU 'JSNXBSF VQHSBEF PG UIF PME 1."$ DPOUSPMMFS t $-9 $POUSPMT 6QHSBEF -JHIU 3FQMBDFT 1."$ XJUI ControlLogix; original IRT drives and BAG motors remain 5IF #PTDI SFDPNNFOEFE PQUJPO JT UP JOTUBMM ,JUT BOE BU UIF TBNF UJNF "OPUIFS PQUJPO JT UP JOTUBMM ,JUT BOE BU UIF TBNF UJNF "MM LJUT are customized to each individual machine and are installed by experienced Bosch controls technicians. Measurable results Chemolux has implemented a key performance indicator to assess the results of the preventive maintenance program. It measures the improvement in terms of costs and efficiency, and they have been considerable: maintenance costs decreased by 11 percent between 2008 and 2011. Machine efficiency has increased by 13 percent during the same period. As with all long-term projects, improvements are permanently ongoing. Another key benefit for Chemolux is the transparency of maintenance costs. When buying new machines, every company wants to know the total cost of ownership. "No other provider of packaging machines could give us such transparency," Gosset emphasizes. The establishment and audit of the maintenance program also had the positive side effect of intensifying the relationship between Chemolux and Bosch. Regular inspections are always carried out by the same Bosch maintenance technicians with Chemolux-specific expertise. In turn, Chemolux took the opportunity to develop internal training programs. "Today, we achieve faster product changeovers and have real experts working on our machines," says Gosset. Ghesquière adds: "Our goal was to switch from a customer-supplier relationship to a real partnership, and we have achieved this to our complete satisfaction." Bosch Packaging Services Inc., 919-877-0886, www.boschpackagingservices.com Bosch Rexroth Corp., 800-739-7684, www.boschrexroth-us.com Rockwell Automation, 414-382-2000, www.rockwellautomation.com ES255545_PD1306_034.pgs 05.24.2013 20:36 UBM

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