Front End Performance
About IPS Mission Statement
“To provide state of the art engineering, technical and operational support and service to the packaging and
container manufacturing industries. Providing optimized solutions designed to effectively utilize current assets with the result of improved cost performance to our customers”
1.Services Supports customers to better use existing Capital and
Human Assets
Engineering, Operations and Integration
Support and Training
2.Products Developed to support effective use of assets
3.Design and Development Focus on technology to improve can making processes
About IPS Three (3) Main Areas of Business
About IPS Our Resources
15 Full time Employees 10 Languages spoken by IPS 11 Countries with IPS Representation 60+ Associates with a wealth of experience
• 15 with 30+ years can-making experience • 25 with 20+ years can-making experience • 20 Long-term operational can-makers • 21 Degreed Engineers • 10 Software Engineers • 7 Masters Degrees and 1 PHD • 3 Professional Engineers • 8 Millwrights • 2 Six Sigma Certifications
Our Customers
Definition of “Front End Performance” • Cup
• Trimmed Cylinder
• Bright or Washed Can
Back End performance problems due to Front End quality / defects
Examples of technical variables include: • Metal Quality and Proper Specification
• Cup…Design, Tooling, Quality, etc.
• Proper Lubrication, Surface Chemistry, Materials Compatibility
• Body Maker…Machine Set-up, Proper Coolant, Blow-off, etc.
• Body Maker Tooling… Design, Control, Rework, Inspection, etc.
• Washer… Set-up, Speed, Nozzle Orientation, Hold-down, etc.
• Many More
Front End Performance
1. Control the Process
2. Tooling
3. Machine Setup and Maintenance
Front End Performance Most Important Factors
80% of Front End Performance Issues are related to the following 3 Items:
Aluminum Specifications • Metallurgical specifications
• Physical specifications
o Camber, bow, etc.
• Surface roughness / profile
• Post Lube
Cupper Lube • Quality and Quantity
• Application Method
• Compatibility with Mill Oil
Soluble Oil (Die Coolant) • Temperature
• Tramp Oil %
• Quality of Filtration
Process - Materials
Cupper Lube • Application method (emulsion, neat, post-mill)
• Lube weight on cup (inside and out)
• Cupper Lube and Residual Mill Oil must be compatible
• Top coil lube (inside of cup) impacts stripping can off punch
• Bottom coil lube (outside of cup) impacts BM tooling buildup
Quality of Cup • Defects, wrinkles, pinched ears, hairs, tear-offs,
cracked flanges, etc…
• Concentric wall thickness
Process - Cupper
Transportation to Bodymaker • Avoid mechanical damage to Cup
Bodymaker Coolant • Coolant is primarily coolant, not lubrication
• Compatibility of coolant and Cupper Lube
Bodymaker Lubrication • Comes from residual Cupper lube inside/outside of cup
“Polishing” the Coolant • Magnetic filter for coolant prep prior to coolant ring
Coolant Flow • Should not wash off Cupper lube
• Coolant Presentation to Die Pack… Volume, distribution, etc.
Process - Bodymaker Transport, Lube and Coolant
Forming Reductions are Critical • Max reductions maintained in Redraw and Ironing
Ironing in Multiple Dies • Die Charts are critical
Dome Forming • Tooling for proper geometry to give proper dome strength
Process - Bodymaker Reductions and Forming
Air Blow Off • Timed Air vs. Constant Air
• Avoid hydraulic lock
• Pressure and Volume of Air
Punch Finish
Alignment
Mechanical Bodymaker
Strippers • Plastic Disposable
• Ceramic
• “Scottie Dog” Strippers
• IPS brand Bodymaker Strippers
Process - Bodymaker Stripping the Can
Large Range of Operation • Operational range > 0.006”
• No need for multiple size assemblies
Low Profile Design
Easy Assembly • Assembles in minutes
Simple Rework • Reworked at assembly level
• No dis-assembly required
Proprietary Finger / Spring Design • Reduces scratched cans and chatter marks
Trim Quality is Important • Inconsistent trim can cause problems down stream
• Avoid Step Trim
Burr on Inside of Can • Loading issues onto Deco Mandrel
Burr on Outside of Can • Crack propagation / Split flange issues
Process - Trimmer
Chemicals • Reduced chemical usage results in lower costs
• Minimize usage resulting in cost savings
• Minimizes opportunity for over etching the can
that could lead to deco loader problems
Heat / Increased Process Temperatures
Mechanical Scrubbing / Impingement • Pre-spray and recycle recovered coolant
• Proper nozzle selection and placement to optimize cleaning
• Maximize pressure throughout (Hold Down Mat / Side Support)
Process – Washer Proper Balance of 3 Essential Variables
Oven & Washer Spoilage Reduction System • Reduces tipped can spoilage
• Supports can pack throughout Washer
• Easily Adjustable
• Aligns can center-line to nozzle center
¼ Turn Washer Fittings • Reduced Costs
• Proven, Chemical-resistant Polymer
Material
Washer Process IPS Recommended Washer Arrangement
Typical Washer Setup
Washer Setup
Down Can Due to
Excess Spacing
Nozzle Spray NOT Aligned
With Can Center
Tight Can Pack
With No Down Cans
Nozzle Spray Aligned
With Can Center
Tooling Design • Optimized design / Overall design criteria
• Reductions – staying below maximums
• Specifying correct materials
• Critical Dimensions
• Critical vs. Non-Critical tolerances
• IPS has experienced tooling design staff available
Quality Supplier • Vendor relationships are important
• Turnaround times
• Reliability
• Quality and Consistency
Tooling
Tooling Inventory Management • Set up Shelving by Size
• Rework to specific size
• Retire spent tools
Inventory Tracking • Understand what is available
• Manual vs. Digital
• The IPS brand is an integrated tool tracking software
o Easy-to-Use
o Modular and Expandable
Cost Savings
• Tracking provides information to assure cost effectiveness of tools
Tooling Inventory, Tracking and Rework Theory
What to Inspect • Punch (diameters, profile / transitions)
• Die (diameters, profile)
• Historically over designed, hard to measure (Ex: Ironing Die Features)
When to Inspect • New tooling
• After Rework
• Temperature stabilization
How to Inspect • Accuracy & Repeatability
• Contact vs. Non-Contact
• Technology
• Ease of Use and SOPs
Tooling Inspection
Tooling Inspection Measuring Punch Profile
*Measured with
Punch Transition – No Use
Punch Transition – 2 Months of Use
Blend Radius Before
Blend Radius After
Tooling Inspection How Punch Profile Impacts Metal Usage
21” Monitor
Aux. Light and Magnifying Glass
Multi Use
Tool Pad
Rotary Die
Fixture
Digital Microscope
In-house rework • Dies
• Punches
Outside Vendors • Turnaround Time
• Reliability
Inventory Tracking • Where are the tools?
• What is available in house?
Inspection after Rework is Critical • Verifying size
• Verifying profile
Tooling Rework
Cleaning Aluminum Buildup • Punches and Dies
• Important to use non-abrasive methods
o IPS ToolCLEAN
• Well Suited for Necker Tooling as well
Proven Process using Ultrasonic Technology • Temperature control
• Tool specific chemical process
• Mechanical scrubbing
Punch Surface Finish Options • Cross Hatch surface finish
• Other surface finish
Tooling Cleaning and Surface Finish
Cross Hatch Overview
“Cross Hatch” is a type of Bodymaker Punch surface finish
Benefits of Cross Hatching include: • Performed in house
• Improved Stripping
• Reduced Tear Offs
Methods for applying Cross Hatch include: • Hand Cross Hatching
• Machine Cross Hatching
Types of Diamond Media include: • Diamond Stick, Stone or Paper
• Diamond IPS Proprietary Flexible Diamond Media
Performance Improvements • Example #1 – Line Performance:
• Day Before X2 Install – 1.3M Cans
• Day After X2 Install – 1.8M Cans
• Example #2 – Individual Bodymaker Performance :
• Day Before X2 Install – 14 Tear Offs
• Day After X2 Install – Zero Tear Offs
Negligible Impact to Punch Size and Profile
Precise and Consistent • Custom timed programs assure uniform finish
• Repeatable cross hatch independent of operator
Multi Language HMI User Interface
Roll Feed Adjustment • Mechanical
• Servo
Timing Adjustment • Inner Slide adjustment
• Outer Slide adjustment
• Phase angle – relationship between the two
Symptoms of Bad Timing • Wrinkled Cups
• Pinched Ears
Timed Blow Off
Machine Setup Cupper
Ram Alignment is Critical • Ram Alignment to Tool Pack
o Static Alignment – Using Indicators
o Dynamic Alignment – Software based
• Ancillary Alignment (IPS brand ))
o Cup locator, redraw sleeve, stripper
Account for Droop due to Punch
Weight • Use of Dynamic Alignment tool
Assure Wall Thickness Variation at Minimum
Avoid “Shimming of Dies” • Temporary fix, not long term solution for uniform cylinder
Machine Setup Bodymaker
Production Line Audits • Line Speed Up Programs
• Production Line Improvement Programs
• Equipment Improvement Recommendations
• Metal Substrate Conversions
• Product Quality Improvement
• Business Improvement Assessment
Can and End Line Startup Services • Installation Support
• Troubleshooting
Cost Reduction Programs • Materials, Metal and Coating
• Production Efficiency Improvements
• Spoilage Reductions
Can and End Line Integration • Customer Sponsored Approach
• Cost Effective
Operational Assistance • On-Site Staffing
• Training Programs
• QC Systems
• Store Room/Inventory Control Systems
• Tooling Control Systems
• Maintenance Programs
Product Development • Tooling Design
• Product Design
Product Specifications • Material Specification
Recommendations
• Equipment Specification Recommendations
IPS Services Offered
IPS Product Line
Special thanks to: Neil McRitchie/Conference Director
Megan Freeman/Event Manager And all of the Asia CanTech attendees
www.intpacsol.com 4010 Youngfield Street
Wheat Ridge, Colorado 80033 USA
+1 (303) 426-4881