TOOL AND DIE ENGINEERING

TO : Mr. G.R. ABELLA J.V. Maximo EVALUATION OF ESS PROPOSAL NO. 76-492-99-0031 Date: April 17, 2000 cc: RCSantos DCSantillan DMBartolome File

FROM : RE :

TITLE OF PROPOSAL :

Multi-Spindle Rolling Machine for Continuous Thread Caps

BACKGROUND : Rolling operation, a critical process of forming the closure profile, requires machine stability and precision tools to meet dimensional requirements of caps. Important aspects of closures, specifically for Continuous Thread caps are the height of cap, knurl diameter, internal thread diameter and bead diameter.

EXISTING CONDITION : Prior to this project, 18-400 Continuous Thread caps are rolled on Threader machine. Threader machine is a single-spindle rolling machine with a capacity of 80 caps per minute. The existing Threader machine has the following disadvantages: Low production capacity High variation in ovality of caps Complex design of machine parts Large backlash of mating gears Requires frequent resetting of rolling tools due to unstable condition of machine Requires frequent machine maintenance

PROPOSAL : With these disadvantages, Tool and Die Engineering envisioned to have a better rolling machine. The cost of buying a new machine however, entails a big capital expenditure. Thus, TDE proposed to develop an In-house fabrication of a multi-spindle rolling machine for Continuous Thread caps.

DEVELOPMENT : In 1992, through the ESS, we started the concept of a multi-spindle rolling machine for Continuous Thread caps due to the obvious advantages it will generate compared to a single-spindle rolling machine. In 1995, a prototype was assembled for 18-400 C/T caps. The first prototype, produced inconsistent rolled caps. Results of inconsistencies were based on the following observations: Overlapping of knurls Presence of scratches on thread Inconsistent height and bead diameter of rolled caps

From these observations, we were able to trace the cause to the following: The alignment of the upper assembly and lower assembly is not consistent The ratio of gears is not the same as the ratio of knurls and ratio of thread The base and main shaft of the machine are not stable

With these, we identified critical parameters to be addressed in the new design, namely: Alignment of gear holder with respect to tool holder requires both perpendicularity and concentricity To establish relationship of gear ratio, knurling die ratio and thread ratio There should be precision in fabrication of tools and machine parts

With these in mind, new design was prepared with the critical parameters: Working equations were established for the computation of the following: 1. Gear ratio

2. Design computation of knurl of cap with respect to knurl of tool 3. Design computation of thread of cap with respect to thread of tool To maintain alignment, we have provided four (4) leader pins which assure perpendicularity and concentricity Error in fabrication was limited to within 2 microns (0.002 mm). And once assembled, accumulated error of 0.02 millimeter maximum

Finally in September 1999, employing new design, we developed the multispindle rolling machine which we named as ZFX-2000.

ZFX-2000 MULTI-SPINDLE ROLLING MACHINE : ZFX-2000 is a six-spindle rolling machine initially designed for 18-400 C/T caps. Its rated capacity is 700 caps per minute or 42,000 caps per hour. ZFX-2000 provides stability of rolling tools to sustain long production run. It is equipped with PLC (Programmable Logic Control), sensors, and pneumatic control system and requires low maintenance. It is also designed such that it can be converted to other sizes of C/T caps. For a more stable setup, it has a fixed outer rolling tools, back center and timing gear. The ZFX-2000 rolling machine includes accessories necessary to facilitate the faster manufacture of C/T caps namely: hopper, magazine, stainless chutes, control switchboard and appropriate sensors. The total cost of ZFX-2000 is PhP 750,000.00.

RESULTS : The main advantage of ZFX-2000 as against the Threader machine is its high production output and its excellent quality of caps produced. Based on test results, the caps are within manufacturing and customer specifications. Standard deviation on rolled caps was improved by 50%. With its output of 700 caps per minute, it is 8.75 times faster than the output of one (1) Threader machine (80 caps per minute). As a result, standard deviation on knurl diameter of cap was improved by 50%, bead diameter was improved by 58%, rolled height deviation was improved by 50% while internal thread diameter was improved by 56%. Moreover, a saving of 4.25 Million Pesos was brought about compared to buying a brand new machine.

To date, we have just completed the 2nd ZFX-2000 multi-spindle rolling machine for 20-400 Continuous Thread caps.

COMPUTATION OF SAVINGS : Items Cost : Proposed No. of units : Total Cost : *Imported machine @ 10 yrs economic life 5,000,000.00 3 15,000,000.00 ZFX-2000 @ 10 yrs economic life 750,000.00 3 2,250,000.00 Savings 4,250,000.00 x3 12,750,000.00

*Matocapco-1995 price

RECOMMENDATION : With this milestone achievement, being an entirely new concept, it is therefore recommended for Level 3 of our Employee Suggestion System. Moreover, since 10% of the savings generated is higher than the maximum monetary award, it is recommended that we award the maximum amount of PhP 130,000.00 for Level 3. Also, in pursuant to the guidelines of ESS, it is recommended that we award first the project under Level 2 with the maximum monetary award of PhP 65,000.00. For your approval. __Original Signed__ Jerome V. Maximo Noted by : Original Signed FB Baytan

Endorsed by: Original Signed DC Santillan