How do you improve the performance of a filling machine? How do you reduce downtime and running costs? How do you make production more efficient?
With training foroperators!
This answer comes from analysis that we carried out by monitoring the methods of use of our fillers on site in our customers’ premises.
Up to then, we had focused on the reliability of the machines themselves, trying to eliminate accidental breakages due to defective parts with the collaboration of our suppliers as well.
Direct observation of the packaging machines in production, however, showed how production performance also depends on the human factor, and above all the experience factor: different operators performed differently, with the most experienced operators producing a significantly higher number of parts by the end of their shift.
Closer analysis also revealed why: the difference was mainly due to the ability to restart the filler in the event of a stop due to external causes - caps or boxes to be refilled, process or end-of-line alarm resets, or identification of carton defects already during the machine loading phase.
Hence the idea of 3 services was conceived, whose goal is to reduce downtime, by providing greater training for operators:
A service that offers the possibility of having a Galdi technician available on site in the days following installation and start-up of the machine, in order to train customer’s operators and maintenance personnel thoroughly and completely.
TRAINING ON DEMAND
New operator? Galdi can send an expert trainer to the company to instruct new arrivals and allow them to work independently, ensuring continuity of production regardless of staff turnover.
A package that guarantees daily monitoring by Galdi experts, with timely warnings in the event of performance declines. The result? Anticipation of waste and preventive elimination of maintenance costs.
By monitoring the performance of our customers who have activated these services, a significant performance improvement has been demonstrated:
• + 25% MTBF (Mean Time Between Failure) or down time between one stop and another.
• - 84% of MTTR (Mean Time To Restart) or time to restart the line
In conclusion, to optimize production, a good deal of the secret is in the training: better-trained operators result in better-performing fillers and happier customers!