Check Weigher

Checkweigher
Design Concept
All-Fill Inc.
Dan MacGuigan, Matt
Griffith,
Phil Mitchell, Richard Maurer
Introduction of Project
Weighs
Products
Rejects out-of-spec
Products
Quality
Up to 200
Improvement Objectives
(Wants)
Decrease Cost
Material
Manufacturing/Machin
ing Time
Assembly Time
Fewer Parts
Fewer Required Tools
Increase
Marketability
Easier Maintenance
Tool-less Belt Changes
Drive Belt
Conveyor Belt
Faster Order
Turnaround
Design Constraints
Safety
Protection From Moving Parts
Design Against Catastrophic Failure
Weight
Footprint
Cannot Increase Overall Weight

Cannot Change Current Footprint
Life
Service Life Cannot Decrease
Improvement Metrics
Metric
Material Cost
Current
Target Achieved
$290/$74 $230/$59 $220/$18
0
0
4
Manufacturing Time 18.5 hrs

Assembly Time
17 min
Number of Parts
86/208
# of Rollers
1
# of Tools Required
for Belt Change
14 hrs
14 min
75/100
2
10 hrs
14 min
80/99
2
How to Meet Wants

Divide
Checkweigher into
Subsystems
Each Subsystem Offers Benefits
Some Subsystems Interrelated
Compounded Improvements
Identification of
Motor Mount Subsystems
Roller Attachment
Knife-Edge
Sidebars & Tie
Bars
Current
Design
Motor Mount
Wants
Lower Cost (Benefits Sponsor)
Fewer Small Parts (Nuts, Washers,

etc.)
Less Costly Manufacturing
Faster Assembly
Increase Marketability (Benefits

Customer)
Easy Tensioning of Timing Belt

Tool-less / Fast Belt Change
Metric
Time to Change Belt
Time to Properly
Tension belt
# of Tools to Change
Curre Targ Achieve

nt
et
d
7.3
min
5
min
3.3 min
2 min
1
min
0.5 min
Motor Mount - Current
Motor Mount - New
Thumb
Screw
Roller Integration
Wants
Lower Cost (Benefits

Sponsor)
Lower Manufacturing Cost
Increased Marketability
(Benefits Customer)
Tool-less Belt Change

More Versatile
Metric
Curre Targ Achiev

nt
et
ed
Time to Assemble
17
min
13
min
14 min
# of Rollers Types
# of Tools to
Change Belt
Roller Integration
Current
Roller
Current
AttachmentAttachment
Points
Points of Rollers
Roller Integration New

End Caps
Drive End Cap
Knife-Edge End
Cap
Conventional Idler
End Cap
End Cap Integration

Snap Ring and
Pliers
Concept Roller
Attachment
Cotter Pin
Points
Knife-Edge
Wants

Sponsor)
Lower Cost
Simpler
(Benefits Customer)
Less Vibration
Less Belt Wear
Shorter Transition Distance
Metric
Curre Targ Achiev

nt
et
ed
Time to
Manufacture
7 hr
5 hr
3.7 hr
Material Cost
$740
$590
$184
208
100
99
# of Parts
Knife-Edge - Current
Nylon Spacer
Bearing
Problems
Many Small Parts
Expensive
Difficult to Assemble
Knife-Edge - New
Material PTFE (Teflon)
Low Coefficient of Friction

High Melting Temperature
Inexpensive
Few Parts
Sidebars & Tie Bars
Wants

Sponsor)
Lower Material Cost

Shorter Manufacturing Time
End Cap Integration

(Benefits Customer)
FDA Approved
Lighter
Metric
Current
Target
Achieve
d
Material Cost
(per pair)
$20
$10
$6
Mass/Length
0.05
lbm/in
0.03
lbm/in
0.03
lbm/in
Sidebars - New
Polycarbonate
Lighter
Less Expensive
Easily Machined
Sufficient Mechanical
Properties
FDA Approved
Available
End Cap Integration
Tie Bars - New
Redesigned for
Compatibility with
Polycarbonate Sidebars
Single Attachment to
Sidebar
Material Change
From Aluminum to
Polycarbonate
Less Costly
Lighter
Assembled Prototype
Testing
Weight
Assembly Time
Maintenance Time
Drive Belt Change
Conveyor Belt Change
Accuracy & Precision
Product Weight
Measurements
Weight
Current Weight
New Weight
7lbs 4 ounces
6lbs 3ounces
Current
17.4% Weight
Reduction
Prototype
Assembly Time
Current
Current Assembly
Prototype
17 Minutes
4 Tools Needed
New Assembly
14 minutes
2 Tools Needed
18% Reduction In Assembly Time
Maintenance Time
Conveyor Belt Change Time

Increased
Due to Sidebar Material Change

Introduce Helicoils in Next Prototype
Drive Belt Change Time

Decreased
Old Time: 7:30

New Time: 3:30
47% Decrease in Time Required
Tool-less
Less Hardware Required
Accuracy and Precision

Testing
Sample Products Run on Actual Machine
Three Different Products

Representative of a Range of Weights
Three Conveyor Units Tested
Old Design
Conventional Prototype
Knife-Edge Prototype
Accuracy Results
49
Average Online Mass - Tube in Box
49
Offline Mass
374
48
48
47.5
47.5
47
Old Design
372
Mass (g)
48.5
Mass (g)
Average Online Mass - Canister
48.5
370
Prototype
368
Knife Edge
366
364
46.5
100
200
Conveyor Speed (fpm)
47
362
100
200
46.5
Average Online Mass - Weight in Box
Offline Mass Compared to Data

From:
2250
Old Design
Prototype of New Design
Prototype of New Design with
Knife-edge
Mass (g)
2240
2230
2220
2210
2200
100
Precision Results
At Least 1 New Design

Outperformed Current
Checkweigher in Every Test
Overall Benefits
Tool-less Belt Change
Motor Mount
Cotter Pin
Versatile
Lighter
Sidebars
Tie Bars
Fewer Parts
Knife-Edge
Motor Mount
End Caps
Knife-Edge
Sidebars
Less Expensive
Component
Money
Saved
Motor Mount
$11
Knife-Edge
$480
Sidebar (2)
$14
Tie Bar (3)
$21
Manufacturing $510
SAVED: Time
$1036
TOTAL
(60% of Current Checkweigher Cost)
(~33% of
Conclusion
Design
Prototyping
Lighter
More Versatile
Easier Maintenance
Less Expensive
Fully Functional Prototype

100% Scale
Testing
18% Assembly Time

Reduction
Tool-Less Belt Changes
More Accurate
More Precise
Implementation Plan
Provide to All-Fill:
Bill of Materials
Complete Electronic Drawing Package
Checkweigher Prototypes
Manufacture Three Complete

Improved Checkweigher Designs
Run Mock Production Line
Questions
Acknowledgements
Nate
Cloud
Ha Dinh
Ed
White
Dave Kendell
Steve Beard
BoM - Conventional
Conventional Roller
Quantity
Hardware
1/4-20x1/2" Hex Socket Bolt
N/A
5-40x1/4" Flat Head Screw
Motor Plate
MM1
1/4-20x1" Hex Socket Bolt
Spacer
MM2
1/4-20 Washer
Motor Mount
MM3
1/4-20 Lock Washer
Tie Bar
S1
1/4-20 Thumb Wheel
Sidebar
S2
10-32x1" Hex Bolt
Drive End Cap
EC1
10-32 Washer
Idler End Cap
EC2
Idler Roller with Bearings
N/A
10-32 Lock Washer
10-32x1" Wing Bolt
Drive Roller with Bearings

and Sprocket
N/A
10-32 Thumb Wheel
Roller Shaft
S3
10-32x1/2" Hex Socket Bolt
Table Top
S4
Brass Washer (ID 3/8", OD .75")
Drive Belt
N/A
4
Hairpin Cotter Pin (Wire

Diameter = 0.1")
1/8"x1" Steel Dowel
Quantity
Part
Drawing Number
Motor with Sprocket
Conveyor Belt
N/A
Sidebar
Right End Cap (KnifeEdge)
Left End Cap (KnifeEdge)
Lateral Support
Knife-Edge Support
End Cap Drive
End Cap - Idler
Motor Mount
Motor Plate
Spacers
Tie Bars
Table Top
Roller Shaft
Sidebar
Deflection
Analysis
Assumptions:
Height = 1.15
Length (support to support) = 4.5
Width (plastics) = .5
Width (Aluminum) = .5
Package weight = 12 Lb.
Elastic Moduli =
Aluminum - 57,000 ksi
UHMW PE - 100 ksi
Nylon 66 200 ksi
Polycarbonate 392 ksi
Schematic
Sidebar side view

Package
weight
Support from
below
checkweigher
Support from
below
checkweigher
Sidebar Deflection
Analysis
Iplastic = .063 in4

IAluminum = .048 in4
Max deflection at center of sidebar:
Aluminum .0000084
UHMW PE .0036
Nylon 66 .0018
Polycarbonate - .00092
Worst Case Scenario
Sidebar Deflection Analysis

Standard loading
Assume 2 equally loaded sidebars

Deflections:
UHMW PE
.0018
Nylon 66 .0009
Polycarbonate .00046
Aluminum .0000042
Machining precision is .0005, greater

than potential deflection of
Polycarbonate.
Raw Data Tube (Slow

Speed)
Raw Data Tube (Fast

Speed)
Raw Data Box (Slow

Speed)
Raw Data Canister (Slow

Speed)
Raw Data Canister

(Fast Speed)
Suggested Improvements
Introduce helicoils for easier

threading
Hole in Motor Mount to allow access
to screw covered by Motor Mount
Screws through Knife-edge end caps
into knife-edge lateral support
Consider replacing more aluminum
parts with polymer
Material Cost
Material
Vendor
Height (in.)
Width (in.)
FDA-Approved?
Cost per ft.
Aluminum (anodized)
McMaster-Carr
1.5
0.375
no
$9.07
Aluminum (non-anodized)
McMaster-Carr
1.25
0.375
no
$4.35
Aluminum (non-anodized)
Metals Depot (MetalsDepot.com)
1.25
0.375
no
$2.75
Polycarbonate
McMaster-Carr
1.5
0.5
no
$3.23
Polycarbonate
San Diego Plastics (www.sdplastics.com)
1.5
0.5
yes
$3.00
UHMW Polyethylene
McMaster-Carr
1.5
0.5
yes
$3.16
UHMW Polyethylene
Modern Plastics (www.modernplastics.com)
1.5
0.5
yes
$2.50
Nylon 66
McMaster-Carr
1.5
0.5
yes
$6.30

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Checkweigher

Tool-less Belt Changes

Cannot Increase Overall Weight

Service Life Cannot Decrease

Manufacturing Time 18.5 hrs

How to Meet Wants

Fewer Small Parts (Nuts, Washers,

Increase Marketability (Benefits

Easy Tensioning of Timing Belt

Curre Targ Achieve

Motor Mount - Current

Motor Mount - New

Lower Cost (Benefits

Lower Manufacturing Cost

Tool-less Belt Change

Curre Targ Achiev

Roller Integration New

End Cap Integration

Lower Cost (Benefits

Curre Targ Achiev

Material PTFE (Teflon)

Low Coefficient of Friction

Sidebars & Tie Bars

Lower Cost (Benefits

Lower Material Cost

End Cap Integration

End Cap Integration

Tie Bars - New

Accuracy & Precision

18% Reduction In Assembly Time

Conveyor Belt Change Time

Due to Sidebar Material Change

Drive Belt Change Time

Old Time: 7:30

Accuracy and Precision

Sample Products Run on Actual Machine

Three Different Products

Three Conveyor Units Tested

Average Online Mass - Canister

Offline Mass Compared to Data

Conveyor Speed (fpm)

At Least 1 New Design

Tool-less Belt Change

Tie Bar (3)

Fully Functional Prototype

18% Assembly Time

Manufacture Three Complete

1/4-20x1/2" Hex Socket Bolt

5-40x1/4" Flat Head Screw

1/4-20x1" Hex Socket Bolt

1/4-20 Lock Washer

1/4-20 Thumb Wheel

10-32x1" Hex Bolt

Drive End Cap

Idler End Cap

Idler Roller with Bearings

10-32 Lock Washer

10-32x1" Wing Bolt

Drive Roller with Bearings