Team Dade Behring Mechanical Modifications to a Vibratory Tablet Feeder Prepared by: Craig Livingston Andrew Snodgrass Jordan Weinstein Aaron Winn

Agenda Executive Summary Executive Summary Mission Statement Mission Statement Context Context Problem Description Problem Description Concepts Concepts Testing and Results Testing and Results Recommendations Recommendations Acknowledgements Acknowledgements

Executive Summary Project Recap Project Recap Dade Behring needs to improve tablet throughput Dade Behring needs to improve tablet throughput Investigated feeder subsystems (vibration, pneumatics) Investigated feeder subsystems (vibration, pneumatics) Pneumatic subsystem targets key feeding problems Pneumatic subsystem targets key feeding problems Clumping and jamming caused by tablet feed angle Clumping and jamming caused by tablet feed angle Lane starvation increases camera inspection time Lane starvation increases camera inspection time Two-pronged solution Two-pronged solution Modified Track Cover Modified Track Cover Modified Puffer Modified Puffer Justified design details through air flow and friction analysis Justified design details through air flow and friction analysis Air concept can be easily implemented into Dade Behring’s production line Air concept can be easily implemented into Dade Behring’s production line

Executive Summary Current Position Current Position Modified Puffer and Modified Track Cover Modified Puffer and Modified Track Cover Finalization of design specifics Finalization of design specifics Fabrication of Modified Puffer and Modified Track Cover Fabrication of Modified Puffer and Modified Track Cover Testing was conducted through a Design of Experiment (DOE) that compared current system vs. prototype Testing was conducted through a Design of Experiment (DOE) that compared current system vs. prototype Final statistical analysis concluded that we exceeded our goal of a ten percent increase in throughput Final statistical analysis concluded that we exceeded our goal of a ten percent increase in throughput Secondary Suggestions Secondary Suggestions Through testing and research we found other areas that need improvement Through testing and research we found other areas that need improvement Base material suggestions for improved vibration control Base material suggestions for improved vibration control Counterweight influences tablet feed angle Counterweight influences tablet feed angle

Mission Statement Our goal is to design cost effective mechanical modifications to an existing vibratory tablet feeder which will increase through- put by a minimum of ten (10) percent.

Context Impending product release (new tablet lines) Impending product release (new tablet lines) Current feeder cannot achieve necessary throughput Current feeder cannot achieve necessary throughput Failure to increase feeder performance will result in purchase of new production line, costing $2-4 million Failure to increase feeder performance will result in purchase of new production line, costing $2-4 million

The System: How’s It Work? Components Rumble Plate – moves tablets Track Cover – guides tablets into lanes Puffer – breaks up tablet clumps with air Channel Plate – guides tablets to package

Problem Description Specific Problem Areas 1.Feeding to one side 2.Clumping and jamming 3.Slow advancement and feed lane starving

Original vs. Modified System Additional tubes in through-put direction Air tubes fed via puffer Milled grooves provide air to push tablets Modified PufferModified Track Cover 6.25”

Function and Description Modified Puffer Made from polycarbonate Made from polycarbonate Channels in both feed and throughput directions Channels in both feed and throughput directions Air jets Air jets 1.Break up clumps in feed direction 2.Expedite tablet advancement in throughput direction Supplies Modified Track Cover with air Supplies Modified Track Cover with air Modified Track Cover Made from polycarbonate Maintains original contour Channels tablets into feed lanes Milled grooves 1.Located underneath plate 2.Provide light airflow along feed edges to discourage clumping 3.Spaced according to puffer channels 4.Location minimizes dust

New System in Action

Validation Strategy Testing Plan Study how various parameters effect throughput under ideal conditions (no feed angle) Study how various parameters effect throughput under ideal conditions (no feed angle) Study effect of airflow on throughput under ideal conditions Study effect of airflow on throughput under ideal conditions Compare modified system to original system under production conditions Compare modified system to original system under production conditions Design of Experiments (DoE) 3x2x2 Duplicated 250 Tablets/Run Zero Feed Angle (Ideal) Varied Parameters Line Pressure Vibration Amplitude Puff Frequency

DoE  Performed under ideal conditions  Vibration amplitude setting had greatest effect on throughput  Not practical to exceed amplitude setting of 35  Air did not have anticipated influence  Modified system less variable ~ GOOD  Applied amplitude conditions to further experiments

Ideal Conditions Experiment Conditions Conditions Zero feed angle Zero feed angle 35 Amplitude Setting 35 Amplitude Setting Puff frequency 2s Puff frequency 2s 250 Tablets 250 Tablets Modified System Modified System Varied air pressure Varied air pressure Greatest influence 9.3% faster Greatest influence 9.3% faster Modified ControlOriginal Control

Validation: Process Conditions Experimental Conditions 8-10 degree feed angle 8-10 degree feed angle Air pressure 0-80psi Air pressure 0-80psi 250 tablets/run 250 tablets/run Amplitude setting 35 Amplitude setting 35 Puff frequency 2s Puff frequency 2s Under Production Conditions: 40% Increase in Throughput!

Cost Analysis Prototype Modified Puffer Modified Puffer Polycarbonate block $39.85 Polycarbonate block $39.85 Pneumatic flow control valve $15.00 Pneumatic flow control valve $15.00 Track Cover Track Cover Polycarbonate block $23.79 Polycarbonate block $23.79 Prototype Cost:$78.64 Implementation 3 Modified Puffers Material and machining$ Track Covers Material and machining$5, Personnel Costs Design modification and testing, 3 full time engineers working for two weeks $9, Implementation Cost: $15, Total Cost: $15, Total Savings: $2-4 million

Recommendations Design and test track covers for 27 methods Design and test track covers for 27 methods Fabricate a modified puffer for each feeder (3) Fabricate a modified puffer for each feeder (3) Idealize manifold channel diameters using computational fluid dynamic software (CFD) Idealize manifold channel diameters using computational fluid dynamic software (CFD) Our testing revealed zero feed angle as ideal Our testing revealed zero feed angle as ideal Large component of problem: Vibratory Isolation Large component of problem: Vibratory Isolation Change base plate material from aluminum to cast iron Change base plate material from aluminum to cast iron Explore support structure for further damping possibilities Explore support structure for further damping possibilities

Acknowledgements We gratefully acknowledge: Jim Kegelman and Peter Truitt of Dade Behring Jim Kegelman and Peter Truitt of Dade Behring Dr. Dick J. Wilkins Dr. Dick J. Wilkins Tim Keene of Dade Behring Tim Keene of Dade Behring Steve Beard Steve Beard Christine Dierickx and Nicolette Blubaugh Christine Dierickx and Nicolette Blubaugh This has been a challenging and ultimately rewarding experience for our entire team. Thanks to everyone who made it possible.

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