Success Stories

 

A wide variety of adhesive tapes are used during the manufacturing process for most appliances. Distinguishing between how and where to use these different types of tape is a key decision for Engineers and Production Managers alike. They need to identify specific tapes for every aspect of the process. At the same time, an additional consideration must also be granted for the cost of the tape. With such high volumes of usage, the total costs could have a major impact on the P&L of the company.

START International has been helping companies in the Appliance Industry, specifically by increasing focus on how to generate higher productivity rates and lower cost structures by dispensing tape. Main appliance manufacturers are working with START tape dispensers.

 

 

 

The problems of a Global Manufacturer

 

MABE CELAYA happens to be one of the largest manufacturers of home appliances, with plants in 70 countries.

In this particular case, we partnered with our distributor to assess how we could help to streamline the production on their largest refrigerator plant in Mexico.

 

Initial process

 

In the assembly area numerous pieces of different tapes were being used for protection of the refrigerator door before merging it with the body.

Ten operators were used for this critical operation. Each operator’s work station was equipped with a manual dispenser and estimated the length of the tape before manually pulling, cutting and applying it.

 

Main Problems

 

WASTE: The actual length of the cut was neither controlled nor measured. In 1 out of  5 cuts the operator failed to pull enough tape to cover the target area, resulting in the need to pull additional pieces or they pulled entirely too much. These inefficient methods resulted in more than 20% of the tape being wasted.

TIME INEFFICIENCIES: Pulling tape manually is very slow and cumbersome.

WELFARE AND SAFETY: Pulling tape every 10 seconds results in hundreds of pulls per shift. This repetitive motion can cause pain and long term muscular problems. There is also an elevated risk due to the operator’s constant exposure to sharp blades.

The Solution

 

MABE CELAYA shared samples of their tape. Samples were analyzed by START certified technicians to determine the correct machine for each tape and production environment. A video was produced for the customer to view their tape dispensed in rapid speed. Finally, the START International PREMIUM Distributor installed the machine at the factory for a free two weeks evaluation test. After that MABE CELAYA ordered 10 machines.

The TDA150FM is the ideal industrial-strength dispenser for high volume production lines or operations requiring repetitive taping for wide tapes or multiple rolls together. The machine runs at twice the speed of TDA150 at 13.2”/sec

TDA150 150mm Wide Electronic Industrial Tape Dispenser

Key Benefits

 

High cost savings specifically derived from less product waste.

+80% productivity increase, resulting in the faster speed of the process and in less people needed (half of the operators who were previously dedicated to this process were freed up to pursue other responsibilities).

Sensitive increase in profit margin towards overall plant production.

“During the demo of the TDA150-FM I realized the huge potential we had in our factory by simply reducing some repetitive actions. So we bought 10 machines” 

C.K. Plant Manager

“Before having the machine, this operation was causing huge bottle necks in the line. I had tried

many different home-made solutions. I thought it was due to a lack of organization in the workflows, but when I saw the machine in a trade show I knew it could make a big difference”

A. B. Engineer

“I work better and less tired. Before having the machine this was the worst shift of the line” 

P.M. Operator