2017054 Essentra Packaging Puerto Rico

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Project List RMA List Equipment List Representative List Parts Cost Analysis Service Cost Analysis Essentra 2017054.xlsm Workorders Folder

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Project Scope: The proposed system is for (4) MFT IP 250SLD Industrial Performance Friction Feeders which will separate and feed your products from a stack in the in feed hopper of the feeder. Each feeder will be equipped with a (2) meter Automatic Product Loader for increased loading capacity. The APL's will be mounted at an angle to maximize loading capacity to the system so the leaflets are loaded as vertically as possible on the APL. The feeders will be equipped with an SLD (896mm) long discharge with split discharge opening. The split discharge will allow the MFT 101HSM Label Applicator to fully access the top of the product along the width of the product. Once a leaflet is detected by the start sensor mounted in the discharge of the feeder a labeler will apply a label. The product will then exit the discharge of the feeder and be placed onto the product tray. A lug will then slide the product off the product tray and place onto the bed of the HSC – 1 High Speed Collator. This will allow the back side of the products to be aligned with one another. The labelers can be enabled and disabled from the line by the operator. The products will be secured together with hot melt glue. As the products exit the system they will be collected onto a Shingling Conveyor which will have a Stacker to vertical position the products on their sides as they transfer onto the Shingling Conveyor. Each system will be equipped with a barcode reader to scan the barcode before it exits the discharge of the feeder. If any system has a no barcode or bad barcode read the products will be flagged and tracked through the system where they will be automatically rejected. The reject on error will contain a reject verification sensor which will ensure a product was rejected before it goes into the lock box. If an incorrect barcode is detected the system will stop on error and the system will be locked out (this is an mode they can enable/disable in the software - behind PLC password protected menu). Once locked out the system will require a keyed restart from a manager. The reject on error will allow for MFT and Essentra to activate the reject mechanics. Essentra will mount and integrate their vision inspection system and will activate the reject as needed. As the product is collected on the shingling conveyor a good product count will be verified. Once the good product count has been reached (after the reject assembly) a cylinder will tap a product over so the operator has a visual of where one batch starts and one batch ends. The thickness detection will be a proximity sensor which will measure the height of the stack to an operator set-point. If the stack is too tall or too short it will be flagged for rejection. The labelers will be equipped with a manual splicing table which will consist of a flat work surface with cutter and tape dispenser to provide quick and easy linear splicing. The feeders, labelers and barcode readers will be able to be enabled and disabled individually to allow flexibility with your different job configurations. Optional items: Driven Discharge Assembly with tab folding to allow you to remove one feeder/labeler pocket from the line and feed into this assembly which will fold your labels around the leaflet. This system will be a stand alone conveyor with plow folding on it's own mounting, extended warranty for 2 years of warranty coverage (parts and labor at Multifeeder), extended warranty for 2 years with parts and labor in Manati. Essentra is tax except so MFT won't pay any taxes on the order. Should any arise it will be the responsibility of Essentra to pay the taxes.
Notes: Essentra Packaging Puerto Rico W.O. 2017054 PO contains specific shipping materials and instructions. ME to complete engineering by May 19 per Peter 4-17-17 1/3: Install is going very well. Essentra techs are taken ownership of machine. Bernie is going to work on labeler. Two parts shipments. 12/13: Received sign off on FAT. Machine is being packed now. Picked up this afternoon. Still need to finalize install dates when we have better idea when machine will be delivered on site. Tracking information on preshipment payment was sent by client. 12/6: Coming next Tuesday for FAT. (12/11) Cylinders arrived. Need to determine shipping method. 11/29: Waiting on pneumatic cylinders for reject gate. Delivery expected 12/4. Checking with customer on coming to MFT on 12/10. Haven't heard back yet. 11/15: Still working hard on machine. Design for reject is complete. Ordering new clutch. 11/8: Bernie and Steve working on it this week along with Greg B. Making good progress. Mechanical standpoint - everything upstream of reject done by end of day tomorrow. Need to look at clutch. 11/1: Engineering should be complete with reject redesign by 11/9. 10/25: Essentra traveling back today. Made good progress having them on site. Working through slight redesign of reject. Starting early next week. 10/18: customer here this week mounting cameras 10/11: Visit has been pushed back. Miguel and Jose on site 10/17-10/24. Bernie will be back on machine on Monday. 10/4: Visit with Miguel went well. Happy with what he saw. Essentra originally planning on two techs here next week for mounting camera and vision equipment. We have requested to push back to 10/22. Clay waiting for response. 9/27: Miguel here visiting today. 9/20: Bernie back on this next week. Miguel will be here next Thursday for visit. Wants to look at barcode readers and camera and check in on equipment status. 9/13: Bernie will be back on this machine after Larkin is complete. Requested to have Miguel come 9/27 in the afternoon and 9/28 in the morning to look at machine and answer questions. Will find out what the agenda is they want to see. 9/6: Review meeting on 9/4 following a call with customer. All teams on same page. Bernie will start when complete with Becton Dickinson early next week. Steve will help Bernie when done with Elring. 8/30: Call scheduled for 9/4. Final review with EE on 9/5 8/23: Clay and Peter reviewed yesterday. Need to determine who resources are and when we can work on it. 8/16: Had call with them. Issue with understanding the delay. Have another call next Monday morning. Clay will send a revised schedule this week. 8/9: Trying to set up a call but rescheduled to Monday morning. 8/2: Clay in process of re-laying out their schedule. Received money for change order 7/26: Hoping to have payment on upgrade this week. 7/19: Kick off on Monday. Upgrade PO received and invoiced. 5/10: Customer requested Jim to come to Puerto Rico to review proposal. Suggested to come to MFT. 5/3: Waiting for signed layout. 4/26: Sent revised change order yesterday. Responded back with a request for a call (tomorrow AM) 4/19: ME looking at a few things related to samples to determine if change order is needed. 4/12: Building collator. Setting up one feeder/labeler combo 4/5: Still waiting to hear back on layout drawing 3/29: Call with customer on Monday. Client requested a revised layout showing machine as it stands currently. ME finished revised layout. Waiting for info back from client on how to proceed. 3/22: Call with customer yesterday. Discussed samples and scheduled follow up call for next Monday. Appears we may be able to use the original design. 3/15: Updated samples are in. Jim working with client to schedule call for Wednesday of next week. 3/8: No change 3/1: Jim and Clay talked to customer on the phone. Will try to get us a couple new samples by Friday. 2/22: Collator is done (drawings and instructions are done) Need to modify parts. 2/15: In burn in. Production working on labeler. 2 need to be totally rebuilt. Replacement belts on order. Will rebuild the base of 3rd labeler. 2/8: Production working on portions of equipment. Re-ordering belts. Client reached out with intention to proceed. We agreed we can build the labelers and collator. 9/7: Still no word from customer 8/24: Client sent email on 8/23 requesting full stop to project. MFT will hold until we hear from Essentra. 8/17: No response from customer on when they want to schedule a time to discuss 8/10: Client was in this week. Went well. Vision system issues are solved. Label orientation issues - presented 3 options to them. Will let us know tomorrow what direction to go. 7/20: Issue with sheet metal for collator. Might need new vendor. 7/13: Done today or tomorrow in ME. First feeder in burn in. Production take Labeler off. 7/6: ME working on it. Meeting tomorrow morning. Call with client at 9:30am. 6/29: ME working on getting it released. Estimated 2 weeks until complete in ME. 6/22: Provided revised schedule. Would like sooner but understand. David working on collator. Believes he can release 6/28. May be able to get sheet medal parts faster. Joel working on Impresso labeler. 6/15: Modified schedule sent to Essentra on Monday. Client confirmed they received. Currently reviewing. Pushing for 6/22 release date. 6/8: ME working on revised layout drawing to be complete end of day. Call with customer tomorrow morning to review layout draft. 6/1: Call this morning discussing layout drawing. Pushed back on us. ME working through options to get rid of drawings then to provide an updated drawing to customer. Conference call will be set up to review drawing after. 5/25: Silence from customer. Need approval. Clay notifying them project is delayed until we get sign off. Engineering release is delayed until 6/9. 5/11: Waiting for signed layout drawing and samples. Sample should be shipped 5/11 or 5/12. Making good progress. Next release APLs and then driven discharge. 5/4: First revised release and kick off 5/5. 4/20: Call this afternoon with client. In ME. Feeder portion is est. 70% done. ECN tomorrow should allow Mark to order more Impresso labelers. Feeder/labeler release should be released at end of week 4/24. Procurement can begin looking at quotes. 4/13: Processing in ME. Two design concepts. Meet 4/14. Try for draft timeline by 4/20 4/6: Meeting 4/7 for review. 3/30: In ME. Need more design review meetings"
Work Done: 12/27/18 Traveled to Manati PR with Steve for install Bernie and Steve 12hrs 12/28/18 Arrived onsite, met with Miguel. Machine was uncrated and in place. got all feeders and conveyor wired up and glue all hooked up. Powered up machine and all things worked as it did when it was shipped, Had to reset up feeders to run 4count pack. Got all feeders working to feed product, after lunch problems occurred feeding had to tweek all feeders to work. Reject timing was off as well as collater to discharge. Simulated the problem and learned that if a feeder faults out PLC does not get a cycle complete and before next product the timing is wrong for three products. Set up a barcode reader created a reader fault and all timing worked like it should. All the feeding issues at end of day could have been due rising humidity Bernie and Steve 10hrs onsite 12/29/18 Changed gearing to 50% from 100%, errors from feeder faults went away. Problems with getting 100% gearing pulleys off shafts due to much lock tite being put on set screws. Once glue was melted, the glue heads were timed in, Essentra had specific placement of glue, took some time to dial in. Once in correct place the glue would rub on bottom of upcomeing straps that hold the next product in place waiting for lug creating a big mess. adjusted straps, cleaned up mess and all went well. all the while Essentra was working on the barcode readers. At end of day feeders and glue system were working great. Bernie and Steve 8hrs onsite 12/30/18 Upon arrival Essentra had line powered up and looking thru HMI. Once glue was heated up we started to run, all went well, feeder 4 had a few issues (due to curled product) we made a small adjustment and all was good after that. Had Essentra navigate the HMI while running machine. Changed machine speed from 17mpm to 20mpm and barcode timing was wrong, showed Essentra how to adjust timing and they changed it to correct timing. Did a small run (5min) with no issues. Had to turn off barcode readers because of extremely curled product. Bernie and Steve 4hrs onsite 12/31/18 Feeder 2 was not 100%, raised feeder height and lowered discharge problem solved. Had Essentra employees run machine, they then wanted switch over, they did with the assistance of Steve on one feeder, they did the rest. Showed them a few things in the HMI and now they are doing everything on their own. Bernie and Steve Steve onsite for 3hrs Bernie onsite for 6.5hrs 1/2/19 Worked on getting labeler running, could not run do to no start sensor, works manually. Had Essentra change over to small nexgard, little assistance was needed. Once done all ran good. Bernie 8hrs onsite 1/3/19 Repalced APL box and sensor. Had Essentra ship bad componets back to MFT. Got labeler up and running. Essentra worked on getting vision system up and running. Labeler was not working the way Essentra wanted, moved start sensor to different position, all was good with vision system and labeler, customer seems to be happy with machine. Bernie 8hrs onsite 1/4/19 Essentra changed back to 4 pack combo and set up barcode readers. At end of day Essentra ran machine as they would during production (approx. 1hr) with one issue due to operator pushing the wrong button on HMI. I was there all for support only. Bernie 7hrs onsite Travel from PR to home 9hrs Bernie

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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	28821			ANGLED APL MOUNTING (ESTIMATED AT 20 - 45 DEGREES)	Set Complete		0 hrs	4		$625.00
Edit	28822			AFTER REJECT PRODUCT COUNTER (GOOD PRODUCTS) WITH PRODUCT KICKER	Set Complete		0 hrs	1		$875.00
Edit	28823	7005190		STACKLIGHT TL50 GRY M12 CBL	Set Complete	4 Standard Production Build	4 hrs	4		$439.00			18
Edit	28824	7160100		SENS BGS ML17 PP 50MM FIXED	Set Complete	8 Standard Production Build	8 hrs	8		$398.00			9
Edit	28825			FINAL STACK HEIGHT DETECTION - PROXIMITY DETECTION	Set Complete		0 hrs	1		$1,322.00
Edit	28826			(4) DAYS INSTALLATION AND TRAINING INCLUDING EXPENSES	Set Complete		0 hrs	1		$7,500.00
Edit	28827			LABELER SPLICING TABLES - MANUAL SPLICING TABLE WITH LINEAR CUTTER AND TAPE DISPENSER	Set Complete		0 hrs	4		$425.00
Edit	28828			STOP ON LOW LABEL	Set Complete		0 hrs	4		$229.00
Edit	28829			PLC TRACKING CONTROLLER - BAD BARCODE/NO BARCODE PRODUCTS WILL STOP REST OF DOWNSTREAM FROM PRODUCIN	Set Complete		0 hrs	1		$15,995.00
Edit	28830			(6) CHANNEL HOT MELT GLUE SYSTEM INCLUDING (6) HOSES/HEADS AND PATTERN CONTROLLER	Set Complete		0 hrs	1		$31,200.00
Edit	28831	4051000		O-RING BRIDGE BELT TRACK	Set Complete	8 Standard Production Build	8 hrs	8		$385.00			0
Edit	28832	CUSTOM		DUAL 220V QUADPLEX ASSY	Set Complete		0 hrs	2		$819.00	0.00	$1,638.00
Edit	28833	8238000		SAFETY CONTROLLER CAT3 5 OUT	Set Complete	0 Electrical Engineering 12 Electrical Technician	12 hrs	1		$4,431.00			1
Edit	28834	9108540	1727-09629	FEEDER 350 SLD SPLIT HCP3	Set Complete		0 hrs	1		$17,008.00	0.00	$17,008.00	0
Edit	28835	7160000		SENS BGS MLV12 PNP 250MM ADJ	Set Complete	1 Standard Production Build	1 hrs	1		$687.00	0.00	$687.00	0
Edit	28836	CUSTOM		PRODUCT TRANSFER TRAYS	Set Complete		0 hrs	3		$795.00	0.00	$2,385.00
Edit	28837	CUSTOM		CONV STRADDLE MNT	Set Complete	0 Standard Production Build 0 Integration and Testing	0 hrs	4		$2,115.00	0.00	$8,460.00
Edit	28839	4603500		FEEDER LABELER MOUNT RLC	Set Complete	12 Standard Production Build 8 Integration and Testing	20 hrs	4		$3,985.00			0
Edit	28840	9279400		ACCUTIPPING W/ENCODER	Set Complete	4 Integration and Testing	4 hrs	1		$5,345.00	0.00	$5,345.00	1
Edit	28841	7160000		SENS BGS MLV12 PNP 250MM ADJ	Set Complete	4 Standard Production Build	4 hrs	4		$687.00			0
Edit	28842	CUSTOM		350SLD SPLIT DISCH	Set Complete		0 hrs	4		$1,895.00	0.00	$7,580.00
Edit	28843	9238500	1805-13924	LUGGED_CONVEYOR	Set Complete	0 Standard Production Build 0 Electrical Engineering	0 hrs	1		$18,185.00	0.00	$18,185.00	0
Edit	28844			SYSTEM INTEGRATION SETUP AND TESTING	Set Complete		0 hrs	1		$85,076.00	0.00	$85,076.00
Edit	28845			PRODUCT TRANSFER DEVICE FROM HORIZONTAL TO VERTICAL AS IT TRANSFERS FROM 90 DEGREE DOWN DD 450/350 T	Set Complete		0 hrs	1		$7,995.00
Edit	28846	9212600	1728-13851	SC 2000 350 RR STD CONFIG	Set Complete	14 Standard Production Build 1 Pre-Production	1 hrs	1		$4,489.00	0.00	$4,489.00	0
Edit	28847	CUSTOM		KEYENCE READER KIT DCC FEEDER	Set Complete	0 Electrical Engineering	0 hrs	4		$6,590.00	0.00	$26,360.00
Edit	28848			PACKAGING AND HANDLING	Set Complete		0 hrs	1		$3,574.00
Edit	28849			AIR SHIPPING	Set Complete		0 hrs	1		$22,870.00
Edit	28850			REJECT ON ERROR WITH LOCK BOX (INCLUDES VERIFICATION SENSOR)	Set Complete		0 hrs	1		$6,995.00
Edit	28851			LOCK OUT BOX - FOR WRONG BARCODE	Set Complete		0 hrs	1		$495.00
Edit	28852			DUAL INPUTS FOR REJECT SOLENOID - ONE FOR MFT AND ONE FOR ESSENTRA	Set Complete		0 hrs	1		$125.00
Edit	28853	9186290	1729-13852	APL 2000 190 ANGLE STAND ASM	Set Complete	0 Standard Production Build	0 hrs	1		$7,804.00	0.00	$7,804.00	0
Edit	28854			SHIPMENT INSURANCE	Set Complete		0 hrs	1		$3,500.00
Edit	29627	9108540	1727-09630	FEEDER 350 SLD SPLIT HCP3	Set Complete		0 hrs	1		$17,008.00	0.00	$17,008.00	0
Edit	29628	9108540	1727-09631	FEEDER 350 SLD SPLIT HCP3	Set Complete		0 hrs	1		$17,008.00	0.00	$17,008.00	0
Edit	29629	9108540	1727-09632	FEEDER 350 SLD SPLIT HCP3	Set Complete		0 hrs	1		$17,008.00	0.00	$17,008.00	0
Edit	29715	9186290	1729-13853	APL 2000 190 ANGLE STAND ASSY	Set Complete		0 hrs	1		$7,804.00	0.00	$7,804.00	0
Edit	29716	9186290	1729-13854	APL 2000 190 ANGLE STAND ASSY	Set Complete		0 hrs	1		$7,804.00	0.00	$7,804.00	0
Edit	29717	9186290	1729-13855	APL 2000 190 ANGLE STAND ASSY	Set Complete		0 hrs	1		$7,804.00	0.00	$7,804.00	0
Edit	29722	9427651	1732-03124	IMPRESSO LABELER ASSY LH 4"	Set Complete	22 Standard Production Build	22 hrs	1		$14,995.00	0.00	$14,995.00	1
Edit	37321			EXTRA FREIGHT BILLING - INVOICE 29419	Set Complete		0 hrs	-1	$13,793.00	$0.00	0.00	$0.00

+ 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	Assignment	History
Edit	Mechanical Eng.	280	600	-317.75	917.75	1754	Sequential	we know we need additional hours to complete (350 hrs)-MFT\peternordling per design review we have 3 additional weeks effort with 2 resources (600 hrs)-MFT\peternordling
Edit	Electrical Eng.	174	360	-84.5	444.5	1755	Sequential	additional programming and hardware changes (360 hrs)-MFT\peternordling
Edit	Software Eng.	0	0	0	0	1756
Edit	Integration	240	600	62.75	537.25	1757	Sequential	Place holder waiting on project review (600 hrs)-MFT\hunterludwig
Edit	Machine Shop	0	0	-142.25	142.25	1758
Edit	Management	0	0	0	0	1759
Edit	Additional Production	60	60	-212.5	272.5	1760	Sequential	All lot of time missing for this W.O. (60 hrs)-MFT\PennyPeterson

Purchase orders for this Work Order

Edit	XID	Description	PO	Partial	Cost
Edit	3384	FACTORYMATION - WEG 2 POS MOM SWITCH, WEG GREEN 22MM PB, WEG RED 22MM PB, WEG BLACK 22MM PB, MERSON DISCON SHAFT HANDLE	27805		($42.50)
Edit	3385	KEYENCE CORP OF AMERICA - 2D CODE READER, CVONTROL CABLE 5M UL, ETHERNET CABLE 5M UL	27806		($5,199.00)
Edit	3386	BECKHOFF AUTOMATION - PANEL 12" 800X600 ULV827E, TWINXAT 2 PLC RUNTIME COMP7, TWINCATPLC HMI CE WIN RUNTIME, ETHERCAT TERM 2 CHANNEL	27807		($3,229.95)
Edit	3387	HALLOCK COMPANY, INC. - CIRC BREAKER 2 POLE 10A	27808		($64.82)
Edit	3389	POWER/MATION DIVISION INC - RITTAL ENCL 400X400X120,	27810	yes	($113.93)
Edit	3421	NORDSON CORPORATION - MELTER PROBLU 10,6 H/G, HOSE BLUE SERIES, CONTROLLER SPECTRA 30 ENCODER, SENSOR DIFFUSE MODE, ENCODER QUAD ASSY W/BRKT	27923	yes	($14,056.00)
Edit	3437	ECO FINISHING COMPANY - EN+ HI PHOS W/BAKE REMOVE HYDROGEN	27998		($105.00)
Edit	3436	ECO FINISHING COMPANY - ELECTROLESS NICKEL,	27999	yes	($45.00)
Edit	3440	BECKHOFF AUTOMATION - 2 CH ANALOG TERM 4...20MA	28015		($129.20)
Edit	3463	ECO FINISHING COMPANY - CLEAR ANODIZE	28080	yes	($40.00)
Edit	3470	PEPPERL+FUCHS. INC - ULTRASONIC SEN 20-250MM M8,	28171	yes	($348.92)
Edit	3479	AIR ENGINEERING & SUPPLY - 8020 15 SERIERS PIVOT STD 0 DEGREE,	28216	yes	($96.30)
Edit	3481	ECO FINISHING COMPANY - BLACK ANODIZE	28262	yes	($40.00)
Edit	3488	ECO FINISHING COMPANY - BLACK ANODIZE	28313		($80.00)
Edit	3489	ECO FINISHING COMPANY - BLACK ANODIZE	28313		($80.00)
Edit	3490	ECO FINISHING COMPANY - BLACK ANODIZE	28314	yes	($26.66)
Edit	3491	ECO FINISHING COMPANY - HARD ANODIZE NON DYED, MASK	28315	yes	($67.50)
Edit	3509	ECO FINISHING COMPANY - HARD ANODIZE NON DYED	28392		($95.00)
Edit	3508	ECO FINISHING COMPANY - CLEAR ANODIZE	28393	yes	($26.66)
Edit	3507	ECO FINISHING COMPANY - ELECTROLEES NICKEL, MASK 16MM HOLE & KEYWY	28394	yes	($45.00)
Edit	3523	ECO FINISHING COMPANY - CLEAR ANODIZE	28438	yes	($26.66)
Edit	3839	ECO FINISHING COMPANY - CLEAR ANODIZE	29688	yes	($40.00)
Edit	3840	ECO FINISHING COMPANY - ELECTROLESS NICKEL	29689	yes	($45.00)
Edit	3869	MCMASTER-CARR - SQ PLUG SNAP IN,	29779	yes	($6.60)
Edit	3890	POBCO, INC. - LUGD COLL BELT TRACK RAW 10'	29916		($125.00)
Edit	3895	ECO FINISHING COMPANY - CLEAR ANODIZE,	29946	yes	($40.00)
Edit	4071	ECO FINISHING COMPANY - ELECTROLESS NICKEL, MASK	30778	yes	($44.00)
Edit	4128	FACTORYMATION - WEG BLU 22MM NON-METALIC KEY,	31046	yes	($24.00)
Edit	4133	DIGI-KEY CORPORATION - PWR CORD IEC 320-C14-C13 9.84',	31072	yes	($129.60)
Edit	4253	MIDWEST CRATING - 144"L X 46"W X 80"H, 150"L X 58"W X 64"H, 150"L X 54"W X 78"H, 150"L X 86"W X 64"H	31506		($2,110.00)


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