The process at ACG Engineering involves manufacturing of Blister packaging machines according to the Blister design received from their clients. Each machine has to go through various operations viz., Forming, Feeding, Guiding, Sealing Cooling, Main Cam, Indexing, Punching, Embossing, Perforation, Perforation+ Embossing, Scoring, and Printing. The machine parts are categorized as “Format Parts” which change as per the blister design and “Standard Parts” which do not change from machine to machine. An FPDMS (Format Parts Data Management System) solution developed by a third party was in place to capture the data from Sales Inquiry to Layout Design. However, the same was not effective due to lack of support from the vendor.

CASE STUDIES

Knowledge Based Engineering Solution for Pharmaceutical Blister Packaging Machines

Transforming Packaging Machine Design: ACG Engineering's Journey to a Paperless
Factory with Golden Eagle System

Client Background

ACG Engineering, a member of the globally renowned ACG group, specializes in the design and manufacture of various types of packaging machines, including blister packaging and carton packaging machines. They are pioneers in flat bed blister packing technology for thermoformed and cold-formed blisters. Their product line serves the pharmaceutical, nutraceutical, food, confectionery, and personal care segments, offering blister packaging machines, cartoning machines, integrated blister cartoning lines, and tablet thickness sorters.

Pre-implementation Status

The process at ACG Engineering involves manufacturing of Blister packaging machines according to the Blister design received from their clients. Each machine has to go through various operations viz., Forming, Feeding, Guiding, Sealing Cooling, Main Cam, Indexing, Punching, Embossing, Perforation, Perforation+ Embossing, Scoring, and Printing.
The machine parts are categorized as “Format Parts” which change as per the blister design and “Standard Parts” which do not change from machine to machine.
An FPDMS (Format Parts Data Management System) solution developed by a third party was in place to capture the data from Sales Inquiry to Layout Design. However, the same was not effective due to lack of support from the vendor.

Need Analysis

ACG Engineering's Blister Packaging Machine Manufacturing Process involved the following challenges:

Establishing a Foolproof Product Lifecycle Management (PLM) System: Demand for a new system which must comprehensively capture all processes from Sales to QA and assembly while embracing the vision of a paperless organization.
Integration & Automation: Demand for automated processes and advanced integration capabilities where the Format Parts Data Management System (FPDMS) would seamlessly integrate with other business functions. Additionally, the automated design process for Format Parts had to be enhanced to maximize efficiency.
Knowledge Based Engineering (KBE) Approach: The upgraded system should serve as a knowledge-based engineering solution, allowing stakeholders across Sales, Design, Assembly, and QA to derive project learnings for continuous improvements.
Scalability & Future Readiness: The system previously handled automatic drawing generation for one product line, but was required to be structured to accommodate future expansions to other machine types.

PARAM proposed and implemented the Golden Eagle system, an enhanced web version of the FPDMS. This system captures all processes from sales to QA and assembly, aiming for a paperless organization.

Our Solution: GA Layout & Base Frame Drawing Automation

PARAM Developed an integrated ecosystem for Format Parts Data Management System (FPDMS) and automated design process for Format Parts to achieve a synergy effect. This solution was named as “Golden Eagle” by the client.

The System acts as a Knowledge based Engineering Solution for every stakeholder from Sales to Assembly, and also derives Project Learnings for the organization as a whole.

Process Flow:

Database Management: Transition from MySQL to Microsoft SQL Server 2008, with a dot net utility for database transfer.
Project-wise Folder Structure: Ensures a lighter database and smooth user experience.
Engineering Change Management: Incorporates part revisions and change management.
Automated Drawing Generation: Handles automatic generation of drawings for BQS machines, with potential extension to other machines.
Backup Facility: Regular backups of SQL Server database, file structure, source code, and master models.
Support System: Users can raise support tickets with screenshots, generating a token number for each issue.

OUR SUCCESS STORY

The success of the Golden Eagle system has positioned ACG Engineering closer to achieving their vision of a paperless factory, with future enhancements planned to integrate CNC part program generation, further reducing design and manufacturing cycle times.