RML Automation
Project Specific Knowledge
As part of the Safety Compliance all hazards had to be fully marked, such as compressed air
Communication with an off-shore client was a distinctive part of this case study. While it was a compliment that Nestlé chose off-shore RML to contract, it also presented several very real problems. Due to the fact the Nestlé engineering team were so particular about what they wanted, they needed to be constantly liaised with. This problem was solved with little difficulty by means of telephone conferences and frequent e-mail contact. This worked well until drawings and the actual workings of the machine needed to be discussed. After some consideration, this was resolved by the Solid Works software which allowed for a three dimensional interactive model to be sent digitally. This allowed for the Nestlé team to check certain parts, virtually being able to see inside the planned machine. Before the s540 could be shipped over for installation in the Melbourne factory, it needed to be finally checked by Nestlé for it function and safety. This was done by taking a high definition digital video of the collator in operation from different vantage points; this was then sent in digital format to Nestlé who could then review it before agreeing for the installation to commence.
Safety, Laws and Legislation were all factors which had to be considered very carefully in the design of the s540 collator. Not only did the product have to comply with the familiar New Zealand regulation but also with those in Australia, where it would be installed. These standards were unfamiliar to the RML team and required them to research into how they could ensure their machine would comply without reducing its functionality.
The specific standard they had to work with the most was the AS4024.1. This standard contains the many regulations concerning the safety of the machine when it is running. The requirements it contains range from the position of hazard stickers to the strength and types of metal acceptable for use in guards covering moving parts. The factor which was of largest concern with the design was the position of these guards. Nestlé required that the containers of ice cream would be accessible while on the machine, the problem was achieving this while staying in compliance with AS4024.1. The designers were briefed on the issue and managed to form a solution by extending out the sides and fully enclosing the internals of the machine, leaving only the belts open. The safety compliance of the machine was fully checked by both RML and Nestlé before installation in the factory.
In addition to the safety standards, care had to be taken for customs. This required that all the parts be accessible for checking around to ensure nothing illegal or hazardous was included in the shipping container.
Before installation the circled area was identified as a hazard, as a hand could get caught
Trouble shooting is something which RML commit to when guaranteeing their product and is also considered a good way to improve their knowledge. In this case study it had to occur in two places. The first of these was picked up in the video check sent to Nestlé. During their safety analysis, they identified that there was a possibility that an operators hand could get caught in the area circled in the picture. They contacted RML regarding this, to which they responded by removing the outlet feed further back into the machine, and by changing the drop feed rate.
With this issue addressed the machine was disassembled, packed and shipped. Both an automation engineer and a mechanical engineer were flown over to install and commission the machine while training the Nestlé engineers. However once the machine was installed and running they discovered another significant problem. The two belts which carried the cartons out from the machine, were slipping beneath them for a second before it gripped them enough to carry them out. This was due to condensation forming on the outside of the containers. The result of this was a dramatic reduction in the speed of the machine. The issue had not been picked up in past testing as all the cartons had been dry of condensation. The two engineers resolved the problem by changing the type of belts to ones with a rougher surface to increase the friction of them. The information gained from these problems is considered valuable as it will help prevent similar problems in future products.
Patents are usually taken out on machines created by RML, however in this case it was decided that it was not worth the cost. The reason behind this is similar to that of Sharp Concepts with the Skorpian Skate, Matthew's second product development case study for this acievement standard. Due to the fact that the s540 collator is a one off product for a very specific use, in the unlikely event that another company would require such a machine, they would come to RML as they are the best at making them. Due to the large amount of tacit knowledge that they contain they remain the head of their field.
