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End Manufacturing at Rocky Mountain Metal Container, with views on emerging technology

End Manufacturing at Rocky Mountain Metal Container, with views on emerging technology. Paul Schrock MillerCoors LLC. Rocky Mountain District MBAA Technical Meeting 9/20/2008. What is an End?.

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End Manufacturing at Rocky Mountain Metal Container, with views on emerging technology

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  1. End Manufacturing at Rocky Mountain Metal Container, with views on emerging technology Paul Schrock MillerCoors LLC Rocky Mountain District MBAA Technical Meeting 9/20/2008

  2. What is an End? • Ends Come in a variety of Sizes and Variations but all are an integral component of the 2 Piece Aluminum Can. • The End is seamed on the top of the can and forms the beverage consumption point.

  3. Raw Materials • There are 2 main Direct Raw Materials associated with End Manufacturing • Aluminum • Liquid Latex

  4. Aluminum • The Aluminum comes in 2 Forms • Shell Coil (End Stock) • Tab Coil (Tab Stock)

  5. Latex • Latex or Compound is placed in the curl of the shell as it cures it becomes the gasket as the end is seamed to the filled can.

  6. Raw Material Usage • Use ~ 1 Million lbs of Aluminum / Week • Use ~ 86 Gallons of Latex / Week

  7. End Manufacturing Process • Main processes to produce an End • Blank and Curl the Shell • Line the Curl • Convert the End

  8. Shell Press and Curlers

  9. Shell Press Coil In Feed Manufacturing Process - Blank the Shell

  10. Shell Press Manufacturing Process - Blank the Shell

  11. Single Stroke, Pneumatic Assist Forming Die Manufacturing Process - Blank the Shell

  12. Curler Manufacturing Operation - Curl the Shell

  13. Shell Press / Curler Info • 7 Shell Presses at RMMC • Press Strokes at 560 SPM • 2800 EPM, 4,032,000 EPD • Each Consumes ~ 750 LBS Aluminum / HR Curled Shell Work In Process / Machine Info

  14. Stick Feeds Material Handling

  15. Traffic Cop Material Handling

  16. Six head Rotary Liner Manufacturing Process – Line the Curl

  17. Compound Dryer Manufacturing Process – Line the Curl

  18. Lined Shell • Liner Info • 14 Liners at RMMC • Liner Runs 1480 RPM • 3 Turns of Lining Manufacturing Process – Line the Curl

  19. Balancer Material Handling

  20. Conversion Press

  21. Tab Stock In feed Manufacturing Process – Convert the End

  22. Form Tab Manufacturing Process – Convert the End

  23. Form Shell Manufacturing Process – Convert the End

  24. Form Shell - Progression Bubble Button Manufacturing Process – Convert the End

  25. Form Shell - Progression Rehit Score Manufacturing Process – Convert the End

  26. Form Shell - Progression Deboss Inserter Manufacturing Process – Convert the End

  27. Form Shell - Progression Tab Ear Wipedown Incise / Emboss Manufacturing Process – Convert the End

  28. Converted End • Conversion Info • 9 conversion Presses at RMMC (3-Sys 7, 6-Sys 8) • Press Runs 650 SPM • Plant Constraint Operation • Overall Plant Capacity 15,600 EPM 22,464,000 / Day Manufacturing Process – Convert the End

  29. Semi – Auto Bagger • Packaging Info • 3 Pack Types • Small Pack – 198,000 EPP • Secured Pack – 228,000 EPP • Large Pack – 257,400 EPP Material Handling

  30. In Line Inspection Systems 100 % Camera Inspection of all ends exiting the Liners Process Quality Control

  31. In Line Inspection Systems 100% Light Testing for Leaks Process Quality Control

  32. In Line Inspection Systems 2% Pressure Test for Leaks Process Quality Control

  33. Off Line Inspection Systems Offline Colt SPC Pressure Check for Leaks Process Quality Control

  34. Off Line Inspection Systems SPC Check for Compound Weights Process Quality Control

  35. Off Line Inspection Systems SPC Check for Tab Strength and Opening Characteristics Process Quality Control

  36. QC Lab Finite End Measurements Process Quality Control

  37. Warehouse / Ship • Shipment • 26 Large Pack Pallets / Trailer – 6,692,400 Ends Material Handling

  38. Scrap Bailer Supporting Process – Scrap Collection

  39. Palletizer • Bailer / Palletizer Info • Briquettes ~ 40 lbs each • 46 Briquettes / Pallet • Generate ~ 3 Pallets / 8 Hour Shift Supporting Process – Scrap Collection

  40. Tab Scrap • Overall Scrap Recycling • Total Waste Stream generates ~ $1 Million revenue each month. Supporting Process – Scrap Collection

  41. Emerging Technology in Operations 24 Out Shell Press with Stacked Curlers

  42. Emerging Technology in Operations Advanced Camera System for Finished End Inspection

  43. Emerging Technology in Operations Robot arm for bailed scrap collection

  44. Emerging Technology in Operations Complete Auto End Bagging System

  45. Questions ?

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