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Automated/Robotic Beverage Packaging
Line
Project Summary
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Our Client: |
Worldwide producer and distributor of malt beverages |
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The Project:
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Installation of $75M high-speed, robotic draught beer keg line and
associated control, utility, and support equipment. |
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APS' Mission: |
During
line construction and startup over a period of 6 months, prepare over 30
operations and maintenance personnel and supervisors to safely and
effectively operate and maintain a complex new automated packaging line
for preparing and filling draught beer kegs, including robotic
depalletizing and palletizing operations. |
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The Challenges: |
No
as-built and very little line-specific technical documentation was
available at the time the training materials had to be prepared in order
to support the line training and startup schedule. Equipment was
manufactured in Europe and was not available for observation, hands-on
research, or photography until after installation. Many documentation
items were not in English. Equipment manufacturer (OEM) provided very
limited technical support, information, or assistance with design
questions. |
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APS' Approach: |
APS
formed a project team with previous first-hand experience with the type
of equipment employed on the new packaging line and also with the OEM.
Sufficient documentation was obtained from various sources to enable
preparation of detailed operation and maintenance training manuals to
support initial training, startup, and OJT. Training documentation was
revised to be line-specific following startup and commencement of
production.
APS designed and developed training materials and
technical documentation for the following:
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Keg destacker |
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Robotic keg
depalletizer |
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Robotic keg
palletizer |
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Pallet and keg
conveying systems |
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Keg external
washer |
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Rotary keg washer
& sterilizer |
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Rotary keg filler |
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Process quality
monitoring and control equipment |
For each of the
above pieces of equipment, APS developed the following documentation:
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Operations
training manuals & instruction materials |
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Maintenance
training manuals & instruction materials |
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Job performance
aids |
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Job qualification
checklists |
The operations
training manuals described the major components, functions, theory of
operation, and routine evolutions such as start-up and shutdown for all
major pieces of line equipment.
The maintenance
training manuals described routine maintenance, lubrication
requirements, equipment troubleshooting, electrical power distribution,
PLC control system network, control system input and output devices,
integrated process management system architecture, and unique control
valves, valve positioners, and flow meters.
APS also delivered
over 200 hours of classroom and hands-on training and assisted the
client with on-the-job training. |
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The Results: |
APS
completed the development of all training materials on time and on
budget. All classroom and OJT was conducted during line startup and
initial operations. The line started up and began production on
schedule. APS continues to assist the client with a variety of training
initiatives. |
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