Every packaging facility manager knows that labor costs can make or break their bottom line, especially in today’s competitive market, where finding and retaining reliable workers is increasingly challenging. How do accumulation tables reduce labor costs in packaging lines?
Accumulation tables reduce labor costs by automatically managing product flow during line stoppages. They eliminate the need for manual product handling and allow facilities to operate with fewer workers per shift. Studies show labor reductions of 15-25% are typical.
While this answer captures the basic concept, it’s worth reading to understand the scenarios where accumulation tables provide the most excellent labor savings and how to calculate the potential return on investment for your facility. This information will help you decide whether implementing accumulation tables is right for your operation.
When Do Accumulation Tables Provide The Greatest Labor Savings?
The most significant labor savings from conveyor accumulation systems occur during planned and unplanned line stoppages. Without an accumulation table, workers must manually remove products from the line and reload them during these events, which is time-consuming and labor-intensive. Typical scenarios include equipment maintenance, downstream machine jams, or product changeovers.
Accumulation tables are valuable in high-speed production environments where even brief stoppages can create significant product backups. They’re also highly effective in facilities that run multiple shifts, as the labor savings multiply across each operational period.
How To Calculate ROI For Accumulation Table Implementation
The return on investment calculation starts by determining the current labor costs associated with manual product handling during line stoppages. Track the frequency and duration of stoppages, multiply by the number of workers involved, and factor in their hourly rates. Then, compare this against the cost of implementing an accumulation table system.
Consider additional factors like reduced product damage, improved line efficiency, and increased throughput capacity. Most facilities find that accumulation tables pay for themselves within 12-18 months through labor savings alone.
What Are The Secondary Benefits Of Installing Accumulation Tables?
Beyond direct labor savings, accumulation tables offer several valuable advantages. They significantly reduce product damage that often occurs during manual handling, leading to less waste and fewer quality control issues.
These systems also improve worker safety by eliminating the need for repeated lifting and carrying of products during line stoppages. Additionally, they help maintain consistent product temperature and handling conditions, which are crucial for food and beverage packaging operations where product integrity is paramount.
Finally, accumulation tables contribute to better overall line efficiency by maintaining steady product flow and reducing the stop-start cycles that impact production targets and equipment performance.
What Type Of Accumulation Table Is Best For My Operation?
The ideal accumulation table depends mainly on your specific product characteristics and production requirements. For lightweight products like empty bottles or small packages, bi-directional alpine tables offer excellent space efficiency by utilizing vertical space. These systems can hold large quantities of products in a relatively small footprint.
Single-level rotary tables or linear accumulation conveyors might be more appropriate for heavier items or products requiring gentle handling. Products with unusual shapes or those prone to tipping often work best with guided rail systems or specialized holding mechanisms.
Factors like product stability, required accumulation time, and available floor space must be considered when selecting an accumulation table system.
How Do I Integrate Accumulation Tables Into Existing Production Lines?
Integration requires careful planning but doesn’t have to disrupt current operations significantly. The first step is identifying the optimal location for the accumulation table—typically before or after critical control points where bottlenecks commonly occur.
Modern accumulation tables come with sophisticated controls that can be synchronized with existing line control systems. This allows for seamless communication between different parts of the production line, ensuring smooth product flow and optimal accumulation timing.
Many manufacturers offer modular designs that can be installed during planned maintenance periods or over weekends, minimizing production downtime. Working with experienced system integrators who can ensure proper installation and training for operators and maintenance staff is essential.
The key to successful integration lies in thorough planning, including consideration of future production needs and potential line modifications. This forward-thinking approach helps ensure the accumulation system remains valuable as production requirements evolve.
Conclusion
Based on the information provided, your first action should be to conduct a detailed analysis of your current line stoppages and associated labor costs over a typical production week. Document how often your line stops and how many workers are involved in manual product handling during these stops, and calculate the total labor hours dedicated to these tasks. This data will form the foundation of your ROI calculation and help determine if an accumulation table is right for your operation.
