5S in the Foam Plant

A few years ago, Commodore undertook an initiative to implement 5S in both of our divisions.  Looking back on the process, it is interesting to see how the changes that 5S brought have become routine here at Commodore.

5S, for those not familiar, is a method of workplace organization.  Originating in Japan, each of the five S’s relate to a part of the organization process.  Here is a brief summary of the 5S’s:

• Sort:  Removing all nonessential items from the work place.
• Straighten:  Arranging all tools and equipment in a manner that promotes work flow.
• Shine:  Keeping the workplace clean; and more importantly, putting things back in designated places so they can be found when needed.
• Standardize:  Consistent work practices; operating in a consistent fashion.
• Sustain:  Maintaining focus on the previous four S’s.  

While we use 5S here at Commodore Technology, our sister company, Commodore Plastics, has benefitted greatly from the use of 5S.  Most noticeably, we have had measureable improvements in downtime reduction, and the cleanliness of the plant is outstanding.

One key area where 5S was first implemented was the foam roll storage area.  Before 5S, foam rolls were set in the warehouse for aging in whatever order they were produced.  While this would not be a problem if all of the rolls were the same, our multiple sheet types meant that it could become very difficult to locate the correct rolls for any given thermoformer run.  Today there is a system in place that keeps the foam in a dedicated space (sort) where it is arranged by sheet type (straighten).  Maintaining the warehouse in an orderly fashion (shine) and always following the procedures for storing the foam (standardize) means no more downtime while our operators are waiting for the correct material.  As this system has become a normal part of our routine, we are aware of the need to keep at it (sustain).

Although implementing 5S can be challenging, in some ways the most difficult part of the 5S method is sustain.  Human nature tends towards reverting back to old methods and practices.  One useful tool that is a part of our routine is the 5S Checklist.  Performing daily and weekly audits using checklists ensures that all of the elements of 5S are being consistently applied.  Here is a copy of the daily checklist for the foam warehouse:

As you can see, there are numerous items that get reviewed each day.  Thanks to the checklist, any deviation from the 5S standards can be quickly identified and corrected.  Problems are documented, and over time we can see if there is a particular issue that needs futher evaluation or a change in procedure.  Another aspect of the 5S and the use of the audit checklist is that we can score the performance of the plant personnel against the 5S standard.  We have not only created a cleaner, safer, and more productive work environment, but we have the tools to measure our employees' performance against the standard.

In a future post I will discuss some details about how we use the 5S performance data as a part of our employee incentive program.  In the meantime, let us know if we can help you in any way, whether with your 5S initative, or any other aspect of your plant operation.

Implementing NX CAM Software

In our last post, we told you about our recent success in delivering a tooling order to a customer in record time. While there are many reasons that we were able to exceed our customer’s expectations, without a doubt the biggest factor was our recent CAD/CAM software upgrade. While the whole process is fairly complicated, we thought we might share some of the developments on the manufacturing side, and demonstrate how they have helped us reduce tooling delivery times.

Commodore’s recent investment in new 3D modeling software from Siemens PLM has been a major step forward for our tooling design department. The implementation of the NX (formerly called UniGraphics) software has delivered increased productivity and accuracy in our tooling design process. Now that we have made our way through the learning curve on the design side, we have begun to realize some benefits on the manufacturing side.

Our CNC programmers have transformed their NC programming and machining processes, reducing waste and increasing productivity. Utilizing feature based machining, NX automatically creates the CNC programs directly from part design models. Process templates and wizards ensure the use of preferred and proven tooling and machining methods. According to our senior programmer, Dave Simmons, “The programming of tool paths to be used on the CNC equipment has become more efficient. We are saving time on programming, and at the machine.”

Another great feature of NX that helps our productivity is machining simulation. Once the program is complete, NX gives us the ability to take it and immediately replay the tool path to simulate material removal. This allows the programmer to verify that the machine tool will be creating the exact part required before the program is actually run. This feature all but eliminates costly damage that can occur when there are errors in the program.

All of these time savings are beneficial in providing thermoformer tooling to our customers at competitive prices, within a very small delivery window.

Custom Tooling in Seven Days

Commodore recently completed what we believe to be our fastest delivery to date on a custom meat tray mold and trim tool - seven working days!

Yes, seven days from concept to delivery of platen-ready tooling for a Comco 730-28 Thermoformer. It took a coordinated effort and lots of hard work, but we managed to do what for most would not be possible. Although this project went extremely well, the ability to pull off this feat certainly did not happen overnight.

Commodore is constantly looking for, and investing in, ways to improve our processes. From our recent Unigraphics CAD/CAM upgrade, to our 5S implementation on the shop floor, from the improved internal communication to outstanding relationships with our key vendors, we are always looking for ways to create the products you need as efficiently as possible. While it is very satisfying to see the results of our efforts, we will never be satisfied with the status quo.

Congratulations to the entire team for coming together and delivering!

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Commodore Plastics Receives "Superior" Plant Rating from AIB!

Commodore Technology's sister company, Commodore Plastics, recently earned a "Superior" plant rating from the AIB International Consolidated Standard for Food-Contact Packaging Facilities Program.

AIB International is committed to protecting the safety of the food supply chain. Through rigorous inspections, superior audits and training, and shared expertise AIB empowers clients to lower their business risk and strengthen their reputations. Learn more about AIB here: www.aibonline.org

Congratulations to the entire team here at Commodore for your efforts in making Commodore a world-class facility that we can all be proud of!

Fadal VMC 6030 Renovation

When it comes to making tooling for the EPS foam industry, Commodore excels at creating detailed designs so our customers can make the highest quality products possible. As we complete the engineering phase and begin with manufacturing, accuracy is among the most important factors in regard to creating a productive tooling set.

Keeping our machine tools in good working condition is an ongoing commitment for Commodore Technology. In fact, just last month we spent a considerable amount of time servicing one of our Fadal CNC machines, a VMC6030.

After the 1991 fire that devastated our facility, we recognized that we had a major task ahead of us in rebuilding our foam plant. One of the biggest challenges that we anticipated was replacing all of the foam tray tooling that was lost in the fire. Commodore bought the VMC6030 from Mid-Atlantic CNC and moved it into our newly rebuilt shop. Needless to say, our Fadal performed as expected and was instrumental in our efforts to get back in to the foam business. However, after tens of thousands of machine hours, it was becoming apparent that the machine was no longer running to its original accuracy of +/- 0.0005". Recently we had been reduced to limiting the use of this machine to making parts that do not require a high degree of accuracy. As mold making was no longer possible, the decision to renovate the machine was made.

Over a three week period, our employees and a technician from Machine Tool and Research tore apart, serviced, painted, and rebuilt the Fadal. We replaced bearings, scrapers, installed a new lubrication system, and replaced the bearing surfaces on the table and saddle. We even replaced the polycarbonate windows in the doors. Although it may need an updated machine control in the future, the maintenance extended the life of the machine, and better yet, our old VMC 6030 is now more accurate than when it was new!

Eric Vogel running the newly refurbished VMC6030

Comco SX-28 Thermoformer

Summer has turned to fall, and things have been busy at Commodore. Sorry for the lack of updates, I am guilty of procrastination...until now.

If you have been following my posts, you know about our newest thermoformer, the SX-44. In the last few months we have been working on the design of the next SX generation machine, the SX-28. This former fills out our product line with a machine that offers high production rates at an affordable price.

All of the specifications have been defined, and design work has begun. Here is a preliminary view of the machine from our Unigraphics design software.



This machine promises to be the next step in combining simplicity, reliability and value in a foam thermoformer. Check back soon for more information.

Fritz

It's Been Awhile...

Sorry for the lack of updates lately. After all of the details that were involved in sending out the new SX-44, and then the final prep for NPE 2009, it was an awfully busy time. Once all of that was behind us, a little break was called for.

At any rate, despite the lack of blog posts, things have continued to move along here in Bloomfield. Since my last post, we have shipped out another SX-16 thermoformer, done the lion's share of a rebuilding job on a customer's older Comco 730-28 former, and continued work on some tooling orders.

Thanks to those of you that visited us at NPE in Chicago last month. It was great to see some familiar faces, as well as make some new friends. The booth looked great, and our video of the SX-44 was a hit. I'm not sure what was more impressive, the thermoformer itself, or the overall quality of the video production. Special thanks to Doug at Blackbird Son Production Service for the outstanding job on the video. If you have not had a chance to see it, you can view it below, or take a look here. We had an enjoyable show, and despite the obvious light attendance, we consider it a success.



The most exciting development of the past month is that we will be rounding out the SX line of thermoformers, bringing the much-anticipated SX-28 to fruition. This former will offer high-end perfomance and features at a low-end price. Stay tuned for updates on our progress through the summer and fall.

That's all for now, thanks for reading!

Fritz