One of our customers was looking for help to improve the efficiency of their Ultra-Low Temperature (ULT) freezer line. They were performing a lean transformation of the line. The demand for ULT freezers doubled in 2020 because manufacturers used these freezers to store COVID-19 vaccines.. Pfizer recommended that their vaccine be stored at -70 Celsius, while Moderna and Johnson & Johnson recommended storage temperatures of -20 to 8 Celsius. One of the Manufacturing Engineers was leading a mission-based team to streamline the ULT line.
Ultra-low temperature (ULT) freezers are essential to any lab environment, as they play a critical role in helping to ensure the safe storage of precious samples. ULT freezers operate within the −50°C to −80°C range and store a wide range of analytes and products, from biospecimen samples to enzymes and drugs
The engineer requested Newell Automation’s support to improve the throughput of the foaming process. One of our Senior Controls Engineer and our Account Manager reviewed the operation of the foaming jigs. They determined that we could improve the process by replacing the two-hand machine control with a momentary push button control and upgraded safety devices. We proposed installing vertical light curtains on the loading side of the three foaming jigs. We also reprogrammed the PLCs to sequence the machine with a single momentary push button press. The customer accepted our proposal. We scheduled and completed the work over two Saturdays to avoid disrupting their production schedule.
This upgrade has improved Takt time by allowing the operator to perform other tasks while the machine is cycling. The upgrade has also improved machine safety. The light curtains act as an emergency stop and ensure that no one, including another operator, enters the hazardous area while the machine is actuating.