The Packaging Line That Jammed (Boxes Mismatched)
We built a packaging line (the product goes into a box, the box is taped, the box is palletized). On the floor, the line jammed (the box size didn’t match the product). The product was a variant (a different size). The box former (the machine that folds the box) was set for the standard box. The variant product was too big (it didn’t fit). The line jammed. We either added a box former that adjusts (for the variant), or a separate box (a second box size). We added an adjustable former (it changes the box size, for the variant). The line ran. The mistake was not planning for the variants (the line was set for one size, not the variants).
Packaging line handles the variants (box size, product size). This article covers the design.
The Packaging Line
A packaging line has:
- The product: The finished part (from the assembly).
- The box former: Folds the box (from a flat blank).
- The packer: Places the product in the box (manual, or robot, article 191).
- The taper: Tapes the box (top and bottom).
- The palletizer (article 192): Stacks the boxes.
Step 1: The Variants
The product has variants (different sizes). The box must match (the variant product fits the box). A line that’s set for one size (one box) jams on a variant. Plan the variants (which sizes? which boxes?). Use an adjustable former (it changes for the variant), or a second box (a second magazine).
The packaging rule: Plan the variants. The line that jammed was set for one box (not the variant). Use an adjustable former (or a second magazine). The line handles the variants (without a jam).
Step 2: The Box Former
The box former takes a flat blank (a folded cardboard) and forms it into a box. For a standard box, the former is fixed. For a variant, the former adjusts (the width, the depth). Set the former (for the variant, before the run).
Step 3: The Taper (Tape)
The taper tapes the box (top and bottom). A standard taper (hot melt, or pressure-sensitive tape). The tape is consumable (a roll). Change the roll (when it’s empty). The taper applies the tape (consistent).
Step 4: The Label (Article 196)
The box is labeled (the shipping label, article 196). The label (the address, the barcode, article 197) is applied (after the taper). The label is scannable (the warehouse reads it).
| Step | Machine |
|---|---|
| Form the box | Box former (adjustable?) |
| Pack the product | Manual, or robot (article 191) |
| Tape the box | Taper |
| Label the box | Labeler (article 196) |
| Palletize | Palletizer (article 192) |
A Packaging Checklist
- What are the variants? (Sizes?)
- Is the box former adjustable? (For the variant?)
- Is the packer right? (Manual? Robot?)
- Is the taper working? (Tape roll?)
- Is the label applied? (Article 196?)
- Is the palletizer right? (Article 192?)
- Does it jam? (Variant? Test?)
- Is the consumable stocked? (Tape? Boxes?)
- Is the traceability? (Article 197?)
- Is the cycle OK? (Takt? Article 130?)
The Bottom Line
Packaging line handles the variants. The line that jammed was set for one box. Plan the variants (adjustable former). Tape, label, palletize. The line that ran all variants wasn’t the fastest one — it was adjustable.
