Weighing scales to be used at each machine on the shop floor

M

Metal_Maniac

#1
Hi,
I needed some opinion on this matter to check if it is a feasible option or if it is a common industrial practice.

We are into selling aluminum circles & sheets. Our processing involves cutting bigger circles into smaller ones. The processed amount does not always match the customer requirements that are stated on the job ticket. The problem is with the piece counts. We do not count the pieces for selling and ordering, but there is an estimated piece count on the job ticket. The operators use that piece count as a target, but they are seldom correct. The piece count could be anywhere from 200 to 4,000. We also track the productivity based on the pieces processed as currently there is no other alternative.

The management has decided to install scales at each machine that will help the operators by eliminating the need to count the pieces and also to make sure that the correct quantity is sent to the customer.

Anybody has some idea about the feasibility of this option? We are looking for scales that could be mounted on top of a table and the size of 4ft x 4ft if possible. Is the option of movable scales that can be shared between machines appropriate? Any feedback about this and the kind of scales is highly appreciated.

Thank you.
Regards.
 
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ScottK

Not out of the crisis
Staff member
Super Moderator
#2
Hi,
I needed some opinion on this matter to check if it is a feasible option or if it is a common industrial practice.

We are into selling aluminum circles & sheets. Our processing involves cutting bigger circles into smaller ones. The processed amount does not always match the customer requirements that are stated on the job ticket. The problem is with the piece counts. We do not count the pieces for selling and ordering, but there is an estimated piece count on the job ticket. The operators use that piece count as a target, but they are seldom correct. The piece count could be anywhere from 200 to 4,000. We also track the productivity based on the pieces processed as currently there is no other alternative.

The management has decided to install scales at each machine that will help the operators by eliminating the need to count the pieces and also to make sure that the correct quantity is sent to the customer.

Anybody has some idea about the feasibility of this option? We are looking for scales that could be mounted on top of a table and the size of 4ft x 4ft if possible. Is the option of movable scales that can be shared between machines appropriate? Any feedback about this and the kind of scales is highly appreciated.

Thank you.
Regards.
I've done this in plastic molding and in contract packaging (bottle filling). It's a very common thing that can take out a lot of operator counting error, as long as the scales are maintained and not abused.
4' x 4' is not a big deal. I've done 3' x 3'.
You can go basic with just a counting scale, or you can get automated with bar code scanner, built in roller conveyor, and and a mechanism to push out full containers. Depends on how much you want to spend.

Just search Thomas Register http://www.thomasnet.com/ for materials handling specialists in your area.
 

BradM

Staff member
Admin
#3
Not sure how much these circles/sheets weigh. That may be a lot of weight on a scale.

Say each sheet weights 500 grams. 1000 sheets will weight approximately 500 kg. So 4000 sheets will weigh 2000 kg. Thus you will need a scale and a table that can withstand that weight. Too, unless you spend some money, your scale may not have the sensitivity to pick up the weight difference like you might want. I am just guessing at some numbers here; your situation may be totally different.

If the weight thing works out, then yes you could use this scenario. You would need to have them calibrated by an acceptable outside vendor. Too, you may consider purchasing calibrated weights so that performance checks could be performed on the scales/balances prior to use. If you decide to move the scale/balance, perform a performance check before it is moved, and after. That way, if there is any unacceptable error, you will know when this error occurred.
 
M

Metal_Maniac

#4
I looked up some industrial bench scales to begin with. The pieces that we are using can range from anywhere between 1 lbs to 10 lbs. The main aim is to match the processed lbs with the customer request. The operator will be using the scale as an intermediate table and can keep recording the total lbs (which will only be required a couple of times in a 2-3 hr job).

There were some Acculab scales that I liked and am trying to get some reviews on those. They have a capacity of 300- 400 lbs. Getting a calibrated set is a good idea, thanks for that Brad!

Don't wanna spend a lot on those, but still it will be helpful for the operators and eliminate the counting!
 
C

crendfrey

#5
Greetings Metal,

Yes, Scales are used in all manner of applications.
I would also suggest you contact a local scale company for advice.
Try to get someone who represents several manufacturers.
This way you can get the correct tool for the job.
While it may be distasteful to some people to speak with a “salesman”
you will find may are application engineers who will be able to sort through
all of the different types and varieties of scales to find a few for you to choose from that will serve your particular purpose. This is never a waste of time.
Please remember, “you get what you pay for” in durability, reliability and resolution.
As to calibration, a good scale house will be able to offer you several types of calibration schedules. You will need to actually use the scales in a specific application to determine how often they need calibration especially if you have never implemented this system before. Try to start around 90 day intervals. You can always adjust frequency as you see how the scale performs. A credible scale company will help you with this.:notme:
 
M

Metal_Maniac

#6
Greetings Metal,

Yes, Scales are used in all manner of applications.
I would also suggest you contact a local scale company for advice.
Try to get someone who represents several manufacturers.
This way you can get the correct tool for the job.
While it may be distasteful to some people to speak with a “salesman”
you will find may are application engineers who will be able to sort through
all of the different types and varieties of scales to find a few for you to choose from that will serve your particular purpose. This is never a waste of time.
Please remember, “you get what you pay for” in durability, reliability and resolution.
As to calibration, a good scale house will be able to offer you several types of calibration schedules. You will need to actually use the scales in a specific application to determine how often they need calibration especially if you have never implemented this system before. Try to start around 90 day intervals. You can always adjust frequency as you see how the scale performs. A credible scale company will help you with this.:notme:
Hi Crendfrey,
I completely agree with you about working with a partner to implement the new system. I am getting one scale for one machine now and working with a scale company to set it up, since it is much more than just installing it. I need the right stand for it and to make sure it is properly connected and not interfering in the movement of the operator. Once we have successfully finished our trail run, it will be easier to just let them know how many of the same we need.

Talking to the salespeople is always a learning experience, at least that's what I think ;) , maybe not useful, but can be learning, right? :yes:

Regards.
 

gpainter

Quite Involved in Discussions
#7
We had scales at each of our barwells they weighed up to 15-20 lbs had them on their own leveling stands and had then surrounded by plexiglass. They were calibrated every 6 months by an outsource. I believe that we had approximately 50 of these throughout the plant.
 
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