3R's of PACKAGING MACHINERY OVERHAULS

Retrofit, Rebuild or Replace? It’s a question that your Operations staff constantly ponder as they face the new reality of global competition, new SKUs, faster rates, and more change-overs, especially when investment capital is tight.

Edson’s long established competencies in our own proprietary machine design and manufacturing also provides the competency of re-building and overhauling Edson and non-Edson packaging machines.

The primary advantage of Retrofitting machines in situ are enhanced capabilities and short downtime while the retrofit is underway, from a few hours to a few days.

A Rebuild / Overhaul can be done either In-Situ or at the Edson factory, depending upon your resources, available space and allowable downtime. Factory Rebuilds & Overhauls take from 4 weeks to 12 weeks, and is a primary factor when choosing Rebuild or Replace. A Rebuild can provide superior performance and reliability from the original specifications, when upgrading with current technology & materials. The price ranges from 30% to 75% of a new machine of similar performance – if its beyond that, then the long term Rebuild ROI benefits diminish.

Each situation is unique and needs to be evaluated on its own merits. Major factors for consideration are:

• Safety Compliance
• Reliability
• Ease of Change-Over
• Flexibility
• Maintainability
• Speed
• Delivery Interval

Determining Retrofit / Rebuild Viability

Edson has long experience in Rebuilding / Overhauling its own and other OEM’s packaging machinery, and we can help you understand the benefits and challenges that your situations presents. This begins with a thorough Machine Audit and Consultation with an experienced Edson Technician, preferably while your machine is operational to minimize the unexpected surprises.

A Machine Audit Report is provided, along with a priced quotation offering various alternatives for consideration (in situ vs Edson factory; desired level of upgrades; arrangement of dismantle & re-installation; training).

Factors for a Successful Rebuild / Overhaul Program

Our experience has been that all Rebuild & Overhaul programs change along the way, due to unforeseen issues, change to the scope or delivery; commercial considerations. Key factors in achieving the goals, even when the goals change, are:

Minimize Surprises – Frequent client meetings with all key staff to monitor progress; pictures, pictures, pictures.

Deal with the Surprises Quickly – communicate the unexpected situation immediately and select from the possible solutions provided by both Rebuilder & End User;

Instill Familiar Operating Methods & Feel, just like the machine’s around it – operators can adapt quicker with a machine they are familiar with;

Make it Look Good – while the machine’s appearance doesn’t affect its performance, it affects the acceptance by the operators, and puts pride of ownership into the plant.

Installation Service & Training – with the machine’s enhanced performance, operators will want to understand the changes to their machine and quickly develop Standard Procedures for Operations & Maintenance. On-Site Support by a Factory Trained Technician is essential for a fast start up, and establishing reliable operation.

#1 Success Factor – Work as a Team & Rely on the Other’s Expertise – Overhauls are challenging because no one can identify / anticipate all the issues ahead of time. Your Rebuilder will be better able to meet / exceed your expectations when able to openly communicate issues, and rely on your expertise to make the best decisions.