Design Approach for the Development of Format-Flexible Packaging Machines
The rising demand for format-flexible packaging
machines is caused by current market changes. Increasing the formatflexibility
is a new goal for the packaging machine manufacturers’
product development process. There are no methodical or designorientated
tools for a comprehensive consideration of this target. This
paper defines the term format-flexibility in the context of packaging
machines and shows the state-of-the-art for improving the
changeover of production machines. The requirements for a new
approach and the concept itself will be introduced, and the method
elements will be explained. Finally, the use of the concept and the
result of the development of a format-flexible packaging machine
will be shown.
[1] R. Neugebauer (Eds.), “Werkzeugmaschinen - Aufbau, Funktion und
Anwendung von spanenden und abtragenden Werkzeugmaschinen”,
Springer Vieweg Verlag, Berlin, Heidelberg, 2012.
[2] H. Rudolf, “Wissensbasierte Montageplanung in der Digitalen Fabrik
am Beispiel der Automobilindustrie”, Herbert Utz Verlag, München,
2006.
[3] S. Jäger, “Absatzsysteme für Mass Customization: Am Beispiel
individualisierter Lebensmittelprodukte”, Deutscher Universitäts-Verlag,
München, 2004.
[4] Roland Berger, “Mastering product complexity 2012”,
http://www.rolandberger.us/media/pdf/Roland_Berger_Mastering-
Product-Complexity_20121107.pdf, 2012.
[5] K. Jonas, “Packaging Machinery and Equipment”, U.S. Commercial
Service Germany, 2005.
[6] P. Römisch, M. Weiß, “Projektierungspraxis Verarbeitungsanlagen –
Planungsprozess mit Berechnung und Simulation der
Systemzuverlässigkeit”, Springer Vieweg Verlag, Wiesbaden, 2014.
[7] E. Dumoulin,” Changes and Perspectives in Food Studies”, International
Journal of Food Studies IJFS, vol. 1, pp. 211-221, 2012.
[8] Alliance for Innovation and Operational Excellence, “Overall
Equipment Effectiveness: Guidelines for the CPG Industry And Its
Suppliers”, 2012 [9] N. Mahalik, A. Nambiar, “Trends in food packaging and manufacturing
systems and technology”, Trends in Food Science & Technology, vol.
21, pp. 117–128, 2010.
[10] R. McIntosh, G. Owen, S. Culley, T. Mileham, ”Changeover
Improvement: Reinterpreting Shingo’s „SMED“ Methodology”, IEEE
Transactions on Engineering Management, vol. 54, no. 1, pp. 98–111,
2007.
[11] E. Abele, G. Reinhart, “Zukunft der Produktion - Herausforderungen,
Forschungsfelder, Chancen”, Carl Hanser Verlag, München, 2011.
[12] G. Spix, ”Verpackungslösungen müssen richtig dimensioniert sein –
Interview”, Neue Verpackung, no. 04/2014, pp. 58-60, 2014.
[13] M. Weyrich, P. Klein, ”Modulbasiertes Engineering von
Produktionsanlagen – Wissensbasierte Konzeption mit
funktionsorientierter Modularisierung”, wt Werkstattstechnik online,
vol. 102, no. 9, pp. 592–597, 2012.
[14] H.-P. Wiendahl, ”Veränderungsfähigkeit von Produktionsunternehmen –
Ein morphologischer Ansatz”, ZWF, vol. 104, no. 1–2, pp. 32-37, 2009.
[15] M. Zäh, N. Möller, W. Vogl, ”Symbiosis of Changeable and Virtual
Production - The Emperor's New Clothes or Key Factor for Future
Success?”, CARV 05 International Conference on Changeable, Agile,
Reconfigurable and Virtual Production. pp. 3–10, 2005.
[16] A. Sethi, S. Sethi, “Flexibility in Manufacturing: A Survey”, The
International Journal of Flexible Manufacturing Systems, vol. 2, pp.
289–328, 1990.
[17] H.–P. Wiendahl, H.A. ElMaraghy, P. Nyhuis, M.F. Zäh, H.–H.
Wiendahl, N. Duffie, M. Brieke1, “Changeable Manufacturing –
Classification, Design and Operation”, Annals of the CIRP, vol. 56/2,
pp. 783–809, 2007.
[18] E. Abele, T. Liebeck, A. Wörn, “Measuring Flexibility in Investment
Decisions for Manufacturing Systems”, Annals of the CIRP, Vol. 55/1,
pp. 433–436, 2006.
[19] N. Slack, “Flexibility as a Manufacturing Objective”, International
Journal of Operations & Production Management, vol. 3, no. 3, pp. 4–
13, 1983.
[20] G. Bleisch, H. Goldhahn, G. Schricker, H. Vogt (Eds.), ”Lexikon
Verpackungstechnik”, Behr’s Verlag, Hamburg, 2003.
[21] S. Shingo, “A Revolution in Manufacturing: The SMED System”.
Productivity Press, Cambridge, 1985.
[22] R. McIntosh, S. Culley, A. Mileham, G. Owen, “Improving Changeover
Performance – A strategy for becoming a lean, responsive
manufacturer”, Butterworth-Heinemann, Oxford, 2001.
[23] K. Ehrlenspiel, A. Kiewert, U. Lindemann, ”Kostengünstig Entwickeln
und Konstruieren”, Springer-Verlag, Berlin, 2007.
[24] K. Sekine, K. Arai, “Kaizen for Quick Changeover – Going Beyond
SMED”, Productivity Press, Cambridge MA., 1992.
[25] A. Mileham, S. Culley, G. Owen, R. McIntosh, “Rapid changeover –
pre-requisite for responsive manufacture”, International Journal of
Operations & Production Management, vol. 19, no. 8, pp. 785–796,
1999.
[26] D. van Gouberger, H. van Landeghem, “Rules for integrating fast
changeover capabilities into new equipment design”, Robotics and
Computer Integrated Manufacturing, vol. 18, pp. 205–214, 2002.
[27] M. Reik, R. McIntosh, S. Culley, A. Mileham, G. Owen, “A formal
design for changeover methodology. Part 1: Theory and background”,
Journal of Engineering Manufacture, vol. 220, pp. 1225–1235, 2006.
[28] M. Reik, R. McIntosh, S. Culley, A. Mileham, G. Owen, “A formal
design for changeover methodology. Part 2: methodology and case
study”, Journal of Engineering Manufacture, vol. 220, pp. 1237–1247,
2006.
[29] G. Owen, J. Matthews, R. McIntosh, S. Culley, “Design for Changeover
(DFC): Enabling Flexible and Highly Responsive Manufacturing”, in:
Fogliatto, F.; da Silveira, G. (Eds), Mass Customization, Springer-
Verlag, London, 2011.
[30] K. Ehrlenspiel, H. Meerkamm, ”Integrierte Produktentwicklung -
Denkabläufe, Methodeneinsatz, Zusammenarbeit”, Carl Hanser Verlag,
München, Wien, 2013.
[31] U. Lindemann, “Methodische Entwicklung technischer Produkte –
Methoden flexibel und situationsgerecht anwenden”, Springer-Verlag,
Berlin, Heidelberg, 2009.
[32] G. Schuh, J. Harre, S. Gottschalk, A. Kampker, “Design for
Changeability (DFC) – Das richtige Maß an Wandlungsfähigkeit
finden”, wt Werkstatttechnik online, vol. 94, no. 5, pp. 100–106, 2004.
[33] R. Hernandez Morales, ”Systematik der Wandlungsfähigkeit in der
Fabrikplanung”, VDI Verlag,, Düsseldorf, 2003.
[34] G. Schuh, W. Schultze, M. Schiffer, A. Rieger, S. Rudolf, H. Lehbrink,
“Scenario-based determination of product feature uncertainties for
robust product architectures”, Production Engineering, vol. 8, vol. 3, pp.
383–395, 2014.
[35] Y. Koren, U. Heisel, F. Jovane, T. Moriwaki, G. Pritschow, G. Ulsoy, H.
Van Brussel, “Reconfigurable Manufacturing Systems”, Annals of the
CIRP, vol. 48/2, 1999.
[36] J. Feldhusen, K.-H. Grote (Eds.),”Pahl/Beitz Konstruktionslehre”,
Springer-Verlag, Berlin, Heidelberg, 2013.
[37] VDI-guideline 2221, ”Methodik zum Entwickeln und Konstruieren
technischer Systeme und Produkte”, Beuth-Verlage, Berlin, 1993.
[1] R. Neugebauer (Eds.), “Werkzeugmaschinen - Aufbau, Funktion und
Anwendung von spanenden und abtragenden Werkzeugmaschinen”,
Springer Vieweg Verlag, Berlin, Heidelberg, 2012.
[2] H. Rudolf, “Wissensbasierte Montageplanung in der Digitalen Fabrik
am Beispiel der Automobilindustrie”, Herbert Utz Verlag, München,
2006.
[3] S. Jäger, “Absatzsysteme für Mass Customization: Am Beispiel
individualisierter Lebensmittelprodukte”, Deutscher Universitäts-Verlag,
München, 2004.
[4] Roland Berger, “Mastering product complexity 2012”,
http://www.rolandberger.us/media/pdf/Roland_Berger_Mastering-
Product-Complexity_20121107.pdf, 2012.
[5] K. Jonas, “Packaging Machinery and Equipment”, U.S. Commercial
Service Germany, 2005.
[6] P. Römisch, M. Weiß, “Projektierungspraxis Verarbeitungsanlagen –
Planungsprozess mit Berechnung und Simulation der
Systemzuverlässigkeit”, Springer Vieweg Verlag, Wiesbaden, 2014.
[7] E. Dumoulin,” Changes and Perspectives in Food Studies”, International
Journal of Food Studies IJFS, vol. 1, pp. 211-221, 2012.
[8] Alliance for Innovation and Operational Excellence, “Overall
Equipment Effectiveness: Guidelines for the CPG Industry And Its
Suppliers”, 2012 [9] N. Mahalik, A. Nambiar, “Trends in food packaging and manufacturing
systems and technology”, Trends in Food Science & Technology, vol.
21, pp. 117–128, 2010.
[10] R. McIntosh, G. Owen, S. Culley, T. Mileham, ”Changeover
Improvement: Reinterpreting Shingo’s „SMED“ Methodology”, IEEE
Transactions on Engineering Management, vol. 54, no. 1, pp. 98–111,
2007.
[11] E. Abele, G. Reinhart, “Zukunft der Produktion - Herausforderungen,
Forschungsfelder, Chancen”, Carl Hanser Verlag, München, 2011.
[12] G. Spix, ”Verpackungslösungen müssen richtig dimensioniert sein –
Interview”, Neue Verpackung, no. 04/2014, pp. 58-60, 2014.
[13] M. Weyrich, P. Klein, ”Modulbasiertes Engineering von
Produktionsanlagen – Wissensbasierte Konzeption mit
funktionsorientierter Modularisierung”, wt Werkstattstechnik online,
vol. 102, no. 9, pp. 592–597, 2012.
[14] H.-P. Wiendahl, ”Veränderungsfähigkeit von Produktionsunternehmen –
Ein morphologischer Ansatz”, ZWF, vol. 104, no. 1–2, pp. 32-37, 2009.
[15] M. Zäh, N. Möller, W. Vogl, ”Symbiosis of Changeable and Virtual
Production - The Emperor's New Clothes or Key Factor for Future
Success?”, CARV 05 International Conference on Changeable, Agile,
Reconfigurable and Virtual Production. pp. 3–10, 2005.
[16] A. Sethi, S. Sethi, “Flexibility in Manufacturing: A Survey”, The
International Journal of Flexible Manufacturing Systems, vol. 2, pp.
289–328, 1990.
[17] H.–P. Wiendahl, H.A. ElMaraghy, P. Nyhuis, M.F. Zäh, H.–H.
Wiendahl, N. Duffie, M. Brieke1, “Changeable Manufacturing –
Classification, Design and Operation”, Annals of the CIRP, vol. 56/2,
pp. 783–809, 2007.
[18] E. Abele, T. Liebeck, A. Wörn, “Measuring Flexibility in Investment
Decisions for Manufacturing Systems”, Annals of the CIRP, Vol. 55/1,
pp. 433–436, 2006.
[19] N. Slack, “Flexibility as a Manufacturing Objective”, International
Journal of Operations & Production Management, vol. 3, no. 3, pp. 4–
13, 1983.
[20] G. Bleisch, H. Goldhahn, G. Schricker, H. Vogt (Eds.), ”Lexikon
Verpackungstechnik”, Behr’s Verlag, Hamburg, 2003.
[21] S. Shingo, “A Revolution in Manufacturing: The SMED System”.
Productivity Press, Cambridge, 1985.
[22] R. McIntosh, S. Culley, A. Mileham, G. Owen, “Improving Changeover
Performance – A strategy for becoming a lean, responsive
manufacturer”, Butterworth-Heinemann, Oxford, 2001.
[23] K. Ehrlenspiel, A. Kiewert, U. Lindemann, ”Kostengünstig Entwickeln
und Konstruieren”, Springer-Verlag, Berlin, 2007.
[24] K. Sekine, K. Arai, “Kaizen for Quick Changeover – Going Beyond
SMED”, Productivity Press, Cambridge MA., 1992.
[25] A. Mileham, S. Culley, G. Owen, R. McIntosh, “Rapid changeover –
pre-requisite for responsive manufacture”, International Journal of
Operations & Production Management, vol. 19, no. 8, pp. 785–796,
1999.
[26] D. van Gouberger, H. van Landeghem, “Rules for integrating fast
changeover capabilities into new equipment design”, Robotics and
Computer Integrated Manufacturing, vol. 18, pp. 205–214, 2002.
[27] M. Reik, R. McIntosh, S. Culley, A. Mileham, G. Owen, “A formal
design for changeover methodology. Part 1: Theory and background”,
Journal of Engineering Manufacture, vol. 220, pp. 1225–1235, 2006.
[28] M. Reik, R. McIntosh, S. Culley, A. Mileham, G. Owen, “A formal
design for changeover methodology. Part 2: methodology and case
study”, Journal of Engineering Manufacture, vol. 220, pp. 1237–1247,
2006.
[29] G. Owen, J. Matthews, R. McIntosh, S. Culley, “Design for Changeover
(DFC): Enabling Flexible and Highly Responsive Manufacturing”, in:
Fogliatto, F.; da Silveira, G. (Eds), Mass Customization, Springer-
Verlag, London, 2011.
[30] K. Ehrlenspiel, H. Meerkamm, ”Integrierte Produktentwicklung -
Denkabläufe, Methodeneinsatz, Zusammenarbeit”, Carl Hanser Verlag,
München, Wien, 2013.
[31] U. Lindemann, “Methodische Entwicklung technischer Produkte –
Methoden flexibel und situationsgerecht anwenden”, Springer-Verlag,
Berlin, Heidelberg, 2009.
[32] G. Schuh, J. Harre, S. Gottschalk, A. Kampker, “Design for
Changeability (DFC) – Das richtige Maß an Wandlungsfähigkeit
finden”, wt Werkstatttechnik online, vol. 94, no. 5, pp. 100–106, 2004.
[33] R. Hernandez Morales, ”Systematik der Wandlungsfähigkeit in der
Fabrikplanung”, VDI Verlag,, Düsseldorf, 2003.
[34] G. Schuh, W. Schultze, M. Schiffer, A. Rieger, S. Rudolf, H. Lehbrink,
“Scenario-based determination of product feature uncertainties for
robust product architectures”, Production Engineering, vol. 8, vol. 3, pp.
383–395, 2014.
[35] Y. Koren, U. Heisel, F. Jovane, T. Moriwaki, G. Pritschow, G. Ulsoy, H.
Van Brussel, “Reconfigurable Manufacturing Systems”, Annals of the
CIRP, vol. 48/2, 1999.
[36] J. Feldhusen, K.-H. Grote (Eds.),”Pahl/Beitz Konstruktionslehre”,
Springer-Verlag, Berlin, Heidelberg, 2013.
[37] VDI-guideline 2221, ”Methodik zum Entwickeln und Konstruieren
technischer Systeme und Produkte”, Beuth-Verlage, Berlin, 1993.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:71925", author = "G. Götz and P. Stich and J. Backhaus and G. Reinhart", title = "Design Approach for the Development of Format-Flexible Packaging Machines", abstract = "The rising demand for format-flexible packaging
machines is caused by current market changes. Increasing the formatflexibility
is a new goal for the packaging machine manufacturers’
product development process. There are no methodical or designorientated
tools for a comprehensive consideration of this target. This
paper defines the term format-flexibility in the context of packaging
machines and shows the state-of-the-art for improving the
changeover of production machines. The requirements for a new
approach and the concept itself will be introduced, and the method
elements will be explained. Finally, the use of the concept and the
result of the development of a format-flexible packaging machine
will be shown.", keywords = "Packaging machine, format-flexibility, changeover,
design method.", volume = "10", number = "1", pages = "108-10", }
