All in One
Pearson Packaging's GTL-AN1 Case-Tray Packer is a fully automatic pick-and-place case or tray forming, packing and sealing system. It can be changed over to different case sizes and pack patterns in less than 10 minutes.Over time the company's machines also shifted from 100% pushbutton-operated to almost every machine now operating through an HMI. They have the ability to be connected to each other and to an MES, a function that is increasingly in demand, Senske notes.
Senske has been with the company for about 15 years. It was when he took over as president and CEO in 2003 that Pearson also began a shift to Lean Manufacturing principles and various modes of standardization.
The machine builder has focused on designing more modular machines, standardizing code, and standardizing interfaces, Robertson notes. "This is our biggest selling point," he says. "It's why you'd buy a machine from us."
Standardizing software included a switch in 2007 to Packaging Machinery Language (PackML), a software methodology that creates data standardization across all of Pearson's machines. To learn more about Pearson's approach to PackML, see "The Case for PackML."
"If it's all PackML-compliant, you can use the same code to get data out of the machine," Senske says. "We use that code on every machine. It doesn't take us as long to deliver the equipment; it's easier to service in the field; there's a standardized way we're programming the equipment."
Standardization — PackML and otherwise — even applies to recent acquisitions Pearson has made. Pearson acquired Goodman Packaging Equipment, based in the Chicago area, in late 2008, incorporating its gantry top-load case packing equipment into its own line. Just in October, Pearson acquired Moen Industries, a Los Angeles-based manufacturer of packaging equipment and corrugated packaging designs.
In both cases, Pearson is working to bring production together with its own manufacturing. Manufacturing will be combined, and Pearson will bring Goodman and Moen lines into line with Pearson standards.
"We're not just buying them and operating them independently," Senske says. "We're moving manufacturing and assembly to Spokane, although we do retain skilled employees in the remote locations."
Speaking when the Moen acquisition was brand new, Pearson pointed to plans to apply PackML to the Moen machines. "That will allow us to integrate the machines easier," he says.
Robertson adds that modularization efforts will be a part of the melding process of the companies. "As we go to integrate the Moen product line, we'll use our own building blocks," he says.
"As time goes on, we'll apply our technology on the new machines. Then we'll be able to integrate them as part of a larger line," Senske says. "We still will write to customer specifications, but it will happen less and less."
Pearson usually finds that its standard control set is sufficient as well. "We're a complete Rockwell shop," Senske says.
In fact, Rockwell was instrumental in helping Pearson make its move to PackML, which came at a time when Rockwell was incorporating the standard into its Power Programming template.
Pearson also worked closely with Rockwell as the supplier developed its linear servo drive. This has been a major shift away from having to transfer rotary motion into linear motion. "Our old servo-driven system took 25–30 parts to drive the linear motion," Senske says. "This has five parts."
Not only is the motion fast, it's easier to convert the motion, Robertson adds. "It's not just high speed. The speed becomes highly scalable. If production drops in half, we can drop the speed in half. The wear on the machines is also cut in half."