Bespoke solution cuts component loss

The team worked with the company and other stakeholders to conduct detailed analysis of its current system to reduce factors that were leading to component loss and machines over-producing – both costly scenarios.

A UK company, Essentra Components has offices across the globe and, as the company has built a reputation for supplying small, high volume components, its production system is crucial to products being delivered to high standards and on time.

UPM Conveyors designed a bespoke solution and installed it on site in Kidlington. Working with the site's production engineers, UPM conducted extensive root cause analysis to identify loss zones for components, and discovered conveyors unfit for purpose, and units where static was created from the moulding process.

With these issues established, it evaluated each belt type and flight combination to ensure optimisation across all combinations; this is a significant number as over 35,000 products are offered on site by EC. This was a challenge as three systems – the conveyor, component chute, and anti-static equipment – all needed integration and mating.

Throughout this process, UPM worked with Fraser Anti Static and fabricator TDI Solutions. After six months of trials, research and development, the system was ready to benefit the business. It included a custom designed chute using a dock designed by UPM’s Sean Martin, which deposits all components onto the centre of customised UPM swan necked conveyors. At discharge point, de-ionising equipment designed by Fraser Anti Static removes all static from components to ensure a clean drop to the inspection tables.

Scott Miller, lead engineer for engineering and facilities for the business, states: “UPM Conveyors work in conjunction with TDI Design & Production towards the integration of our component chutes with conveyor systems has been amazing. I look forward to seeing more outstanding bespoke solutions arriving shortly from the team, hopefully with many more to come from them.”

Chris Butler, process developer manager at EC Kidlington, adds: “We are lucky enough to be playing a part in a period of change and development, and working with colleagues such as those from UPM, who have the same energy for change as ourselves, enables significant progress.

"Their attitude towards delivery, safety and the open exchange of ideas matches our own, and is a key component in driving essential improvements.”