Roller Replacement Project
- 1. Project Name: Roller Replacement Current Problem(s): Boxes (4X1’s,in particular) arecatchingon the roller and tippingdue to the largegap between the rollers. Suggested Solutions(s): By getting rollers with a much smaller gap,the boxes will havenothing to catch on, preventing them from topplingover. This will allowDevin to keep his attention on his machineinstead of manning the conveyor belt. Itwill also preventthe boxes from fallingdown and blockingthe flow throughout the conveyor set up. Suggested Products & Quotes: Conveyor #11F10EG15B15 - $1,300 (Ashland Conveyor) Model: RS14G-18-1.5-30 - $1,503 (SJF Material Handling) Roller Conveyors - $1,422 (IngallsConveyors) Gravity Conveyor - $1342 (FloStor Engineering) Highlighted is not recommended, but still an option *Does not includeshipping Savings/Results: Accordingto data compiled by Chris,the intern last summer, the casepacker is responsiblefor approximately 22%of machine downtime. With new rollers,thatdowntime can reasonably cutby 2%, consideringthatone of the issues Devin has is turning the machine off to forcibly remove an incorrectly oriented box from the box queue. I only estimate a 2% elimination becausethe topplingoccurs primarily with 4X1’s,and keeping the boxes upright does not correct the issueof the boxes being improperly turned. ROI Calculation: Estimatinga 2600 hour work year and usingChris’ calculationsof 26%of total worktime being occupied with maintenance issues, 2600 hours X .26 X .02 X $200/hr = $2,704/yr Estimated Cost: $1600 ROI: 1600/2,704 = 7 months (approximately)