2015065 Brunel Engineering Services Limited

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Project List RMA List Equipment List Representative List Parts Cost Analysis Service Cost Analysis Brunel Engineering Services Limited 2015065.xlsm Workorders Folder

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Project Scope: The revised proposed system consists of a Multifeeder Technology Industrial Performance tipping system to tip CR 80 cards onto pre scored backer cards with an accuracy of +/- .5mm as per the performance warranty listed below at a rate of up to 416 per minute. A Multifeeder Technology MFT 550 IP Industrial Performance Friction Feeder will gently separate backer cards up to 400mm (15.74") from a vertical stack of the in feed hopper of the feeder. As the products are fed wide edge leading they are transported individually through the 375mm (14.76") long discharge of the feeder. The pre scored backer cards will be transferred one at a time into the second powered lugged discharge section using Accutipping Controls. The backer cards will be registered to the leading edge of the lugs as they travel on the lugged discharge section. The second stage will precisely transfer the backer cards onto a Multifeeder Technology VTC 4000-550 Vacuum Track Conveyor (4000mm x 550mm) with precise repeat using Accutipping Repeat Controls. Discharge guiding and conveyor registration will be used to register the product on the discharge of the feeder and on the Vacuum Track Conveyor. An APL 1000-490 Automatic Product Loader (1000mm x 490mm) will be used for increased in feed magazine capacity. After the carrier is securely positioned on the vacuum transport it will be transported under a customer-supplied and integrated Hot Melt Glue system will apply a single bead of glue in the precise area where the CR80 card is to be attached. Next a straddle mounted Dual Stage Tipping Feeder system will be signaled to tip a card onto the spot glued surface of the base carrier by a Photo Optic Start Sensor Assembly. The Dual Stage Tipping Feeder system consists of a MFT 250 IP XED HCP Industrial Performance Friction Feeder to feed cards with the same repeat as the base product traveling below into a second lugged powered discharge section using Accutipping Controls. Air Injection will be added to the tip on feeder to insert air in the side of the stack from the left and the right to reduce friction between the cards as they are fed. The CR 80 cards will be registered to the leading edge of the lugs as they travel on the lugged discharge section. Next the second stage will use Accutipping Controls to fine tune the placement and precisely tip the cards onto the spot glued surface of the base products traveling below. The cards will be fed into the pinch point of a Powered Pressure Roller Assembly to assure proper placement of the card onto the spot glued surface of the backer card. The Dual Tipping system will be mounted onto an Extruded Aluminum Mount with Hand Crank for Y Adjustment. Both feeder systems will be configured with Dual Vacuum Track Assemblies each consisting of a vacuum chamber and a feed belt with holes to allow the feeder to best grip the products as they are fed. Continuous Motion Accutipping consists of an encoder with wheel mounted on the transport to monitor the speed. If the speed of the transport changes, the computer timing compensation package will vary the speed and timing of the feeder to ensure that the insert is placed accurately regardless of the transport velocity. After the card has been applied, two inline folding devices with hold down belts assemblies will be used to fold the pre-scored carrier cards right to left and left to right. The completed products will be transferred onto a SC 2000-350 Shingling Conveyor (2000mm x 350mm) positioned perpendicular to flow in batches of 20 or 50 for further processing. The Shingling Conveyor will have an accumulation plate at the end and will be integrated with the VTC to start and stop with the VTC. The system will be configured to be stop on error so if either feeder runs empty or has a fault the conveyor will be signaled to stop. Two Spare Parts Kits are included in the purchase price of the system. Multifeeder's Engineering team will create a system drawing for customer approval. System Integration includes a Factory Acceptance Test to verify system performance before shipment. System Integration and testing includes testing of all individual pieces to perform as one complete system. Integration also includes testing of the feeding performance of each product size at the rate specified. A detailed set up video will be created showing step by step how to set up and operate the equipment with each of the different samples provided at the rates specified prior to shipment. Performance Guarantee: Multifeeder Technology, Inc. warrants that the system will adhere product with a tolerance of (+/- 0.5mm) for speeds up to 65 MPM correlating to speeds of up to 416 per minute with a 98% confidence for approved product samples. Multifeeder must receive and approve samples prior to system shipment (at least 5,000) of each product listed in Table # 2 provided the following criteria is met. The performance warranty is a demonstration warrant subject to all of the conditions specified herein: 1. The speed shall be up to 65 MPM or 416 PPM. 2. The accuracy shall be +/- 0.5mm subject to the following: A. For the purposed of the performance warranty the card and the substrate shall be considered ideal or zero tolerance parts. Any actual tolerance will be added appropriately on top of the specified tolerance. B. The target will be a rectangle that is 1mm larger than the card in the length and width dimensions and located in a specified location on a zero tolerance substrate. C. Multifeeder shall have total control of the set up. D. The demonstration run shall be one hour of run time. E. If adjustment are require the test will be restarted. F. If the test passes, the warranty will be considered fulfilled. 3. The equipment must at all times be operated and maintained in accordance with the applicable manuals and Multifeeder instructions. 4. Product requirements. The products must be uniform and free of defects such as bent corners, dog ears, warp age, tears, bends, folds, out of dimensional tolerance, out of square tolerance, out of flatness tolerance, out of thickness tolerance or other non-uniform factors that affect the feeding process. The products shall be free of foreign material and contamination. The equipment must be at all times operated by properly trained personnel. 5. All lost production time due to non-conformance factors, changeovers or factors out of Multifeeder’s control shall be subtracted from production time and results for the purposes of these calculations. 6. If any performance issue arises Multifeeder must be notified in writing about the specific problem and provided with a detailed description of all of the factors leading up to the problem including digital pictures where appropriate. In addition Multifeeder needs to be provided with samples of the product used during the performance problem time. Multifeeder will have 30 days to diagnose and implement any appropriate fixes. Should the problem be beyond Multifeeder’s control the customer will be so notified and no further action by Multifeeder will be required. Should the problem be within Multifeeder’s control and Multifeeder cannot remedy the problem, the customer will qualify for a refund of the purchase price minus any custom part charges, installation and training charges, and any outstanding invoices at that time, provided that no damage has occurred to the equipment. If damage has occurred to the equipment an appropriate charge will be subtracted for that. The customer can qualify for a refund only for problems that Multifeeder receives written notification for within 60 days of equipment delivery. Brunel Engineering will install the system. Multifeeder will provide up to five days of startup assistance working with Brunel if requested. Additional days of startup assistance can be purchased at our standard rates (see attached). Discount listed is for an order placed on or before May 1st, 2015.
Notes: 6/18/2015 Aaron has sent drawing to customer 6/18/2015 Waiting on samples 6/18/2015 Ed and Peter to meet on belt 6/23/2015 We will use a single, 13” 6/23/2015 Belt will be V-guided, two v-guides on the outer edges of the pulley 6/23/2015 Silicone or PVC Belt? I heard both suggestions. 6/23/2015 ME to revise drawing and send to customer 6/23/2015 We will install a Nordson for testing, remove Nordson and customer will use their own glue supply 6/23/2015 FAT is only for the feeding and tipping, not the folding 6/23/2015 We will supply the folds, line them up, but customer will integrate the folding 6/23/2015 Accuracy is for the tipping only, not the folding. Aaron to send updated Order Ack. indicating this 6/25/2015 Single 13" belt, v guides on outside of pulleys 6/25/2015 Layout due Friday, 6/26, aaron to resend to customer 6/29/2015 Layout drawing done, Aaron sent to customer 6/29/2015 Steve west out of office until July 3rd, may not get to customer until week of July 6th 7/7/2015 Steve wasn't happy about switching design, we'll stick to original design of three belts 7/7/2015 aaron emailed saying we will stick with three belts and Aaron asked for samples and signed drawing 7/8/2015 Brunel signed off on drawing for original three belt design 7/9/2015 Customer has approved drawing and sent us signed version 7/9/2015 We are sticking with the original 3 belt VTC 7/20/2015 Samples arrived 7/28/2015 Aaron asked for proofreading on updated Order Ack before sending Customer has been told that we need samples to be official 8/5/2015: After a lot of back and forth, the end customer is very pissed about the lead time, even though Brunel tends to see our side of things. They have said they will send in the CR-80 cards, but they are still pushing the .04 vs .05 issue that could still cause problems. As of now, project is still on. 8/13/2015: Peter and Steve West came to terms that they had a valid point on why they think they can hit .04 at a slower speed. It was agreed to build to the spec, we can hit .5 and hopefully we'll hit .4 at the slower speed. 8/13/2015: Partial release by 8/14 8/14/2015: ME to release WO on 8/14/15 8/14/2015: CR-80 samples arrived 8/20/15: Released on 8/20 8/20/15: Belts Ordered, Pulleys have not been ordered 8/27/15: Still not fully released from ME
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Edit	XID	Part Number	Serial Number	Part Name	Complete	Total Hours	Hours Remaining	Qty	Cost	Price	Discount	Cal Price	On Hand
Edit	22515	9110306	1537-09289	FEEDER IP3 DCC 550 XED 1"	Set Complete	20 Standard Production Build	20 hrs	1		$20,089.00			0
Edit	22516	7005190		STACKLIGHT TL50 GRY M12 CBL	Set Complete	2 Standard Production Build	2 hrs	2		$439.00			18
Edit	22517	8202310		D DISCH LUG 550K-450 G3 NO RODS	Set Complete		0 hrs	1		$19,995.00			0
Edit	22518	CUSTOM		UPGRADE TO LUGGED HCP DISCHARGE	Set Complete		0 hrs	2		$4,995.00
Edit	22519	9279700		ACCUTIPPING REPEAT W/ENCODER	Set Complete	2 Integration and Testing 1 Standard Production Build	3 hrs	1		$3,205.00			1
Edit	22520	9248690	1537-13604	VTC 4000 550 50-75-50 END VAC	Set Complete	2 Pre-Production 7 Shipping 32 Standard Production Build	41 hrs	1		$42,795.00			0
Edit	22521	8719401		VAC ASSY 6300W NO ENCLOSURE	Set Complete		0 hrs	1		$8,020.00			0
Edit	22522	CUSTOM		(4) VTC CONVEYOR E-STOPS ( VTC WILL STOP IF FEEDERS AND/OR CC HAVE A FAULT)	Set Complete		0 hrs	1		$1,855.00
Edit	22523	9193910	1537-13603	APL 1000 485 STD CONFIG	Set Complete	10 Standard Production Build	10 hrs	1		$8,577.00			0
Edit	22524	CUSTOM		EXTRUDED ALUMINUM STRADDLE MOUNT (FEEDER AND DD)	Set Complete		0 hrs	1		$2,455.00
Edit	22525	9109323	1537-09285	FEEDER 250 DCC HCP G3 XED SCFG	Set Complete	14 Standard Production Build	14 hrs	1		$17,864.00			0
Edit	22526	8202306		D DISCH LUG 350K-350 G3 NO RODS	Set Complete		0 hrs	1		$16,045.00			0
Edit	22532	8320000		HIGH PERFORMANCE PACKAGE	Set Complete	4 Standard Production Build	4 hrs	4		$2,140.00			0
Edit	22533	9279400		ACCUTIPPING W/ENCODER	Set Complete	12 Integration and Testing	12 hrs	3		$5,345.00			1
Edit	22534	4291800		VACUUM CHAMBER 30 MM	Set Complete		0 hrs	4		$978.00			8
Edit	22535	CUSTOM		FAST RESPONSE PRODUCT SENSOR	Set Complete		0 hrs	5		$1,295.00
Edit	22536	4101310		WHEEL TRACK 350 MOD	Set Complete		0 hrs	2		$1,077.00			0
Edit	22537	4571950		PR 350 MDW GBX	Set Complete		0 hrs	1		$7,485.00			0
Edit	22538	4606500		OVERHEAD FOLDING ASSY R TO L	Set Complete	2 Standard Production Build	2 hrs	1		$3,205.00			0
Edit	22539	4606400		OVERHEAD FOLDING ASSY L TO R	Set Complete	2 Standard Production Build	2 hrs	1		$3,205.00			0
Edit	22540	CUSTOM		HOLD DOWN BELT TRACK 25 OCTM	Set Complete		0 hrs	2		$1,259.00
Edit	22541	7066200		RELAY INTERFACE BOX W/M12 CBL	Set Complete	2 Electrical Technician	2 hrs	2		$1,072.00			7
Edit	22542	CUSTOM		SHINGLING CONVEYOR TRANSFER ROLLER AND END STOP	Set Complete		0 hrs	1		$945.00
Edit	22543	CUSTOM		SHINGLING CONVEYOR START STOP WITH VTC	Set Complete		0 hrs	1		$1,265.00
Edit	22544	9212600	1537-13605	SC 2000 350 RR STD CONFIG	Set Complete	14 Standard Production Build 1 Pre-Production	15 hrs	1		$4,489.00			0
Edit	22545	CUSTOM		START UP ASSISTANCE (UP TO FIVE DAYS)	Set Complete		0 hrs	1		$9,995.00
Edit	22546	9290500		DCC IP STANDARD SPARE PARTS KIT	Set Complete	2 Pre-Production	2 hrs	2		$1,260.00			8
Edit	22547	CUSTOM		SYSTEM DRAWING, FAT , AND INTEGRATION	Set Complete		0 hrs	1		$29,995.00
Edit	22865	4650300		AIR INJECTION ASSEMBLY - WITH REGULATOR	Set Complete	2 Standard Production Build	2 hrs	1		$1,065.00			0
Edit	24236	7034150		I/O BOARD KIT GEN3	Set Complete	2 Standard Production Build	2 hrs	1		$2,242.00			1
Edit	24237			CAMERA CABLE ASSEMBLY (NORMALLY CLOSED)	Set Complete		0 hrs	1		$395.00
Edit	24238			INTEGRATION, INSTALLATION, AND TESTING AT MULTIFEEDER	Set Complete		0 hrs	1		$2,495.00

+ denotes that software settings are available for this piece of equipment.

Labor Hours
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	Department	Quoted Hours	Est. Hours	Hours Remaining	Billed Hours	xid
Edit	Mechanical Eng.	100	100	-1	101	3077
Edit	Electrical Eng.	34	34	20.5	13.5	3078
Edit	Software Eng.	0	0	0	0	3079
Edit	Integration	220	220	-65.75	285.75	3080
Edit	Machine Shop	0	0	-29	29	3081
Edit	Management	0	0	0	0	3082
Edit	Additional Production	0	0	-300	300	3083

Purchase orders for this Work Order

Edit	XID	Description	PO	Partial	Cost
Edit	2517	POWERMATION - SERVO DR, PANEL 12 X 10 X 8	23166	yes	($735.09)
Edit	2520	MCMASTER - CUSTOM LABELS	23178	yes	($22.50)
Edit	2696	MCMASTER-CARR - ANTISLIP TAPE 4" X 30' LG,	24111	yes	($26.40)
Edit	2729	MIDWEST CRATING - 200" L X 54" W X 66" H ID, 120" L X 72" W X 54" H ID,	24312	yes	($1,320.00)


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			**ALL ITEMS BELOW ARE INCLUDED IN COSTING & PRICING PN 9740001**