c. c. Dr. LC.F. 'Blackman
STRATEGY I
Minutes of the Steerinr_ Co-nittee Meetinr! in
Groun R F_ D Centre 10th -1u!--ust 19?9
Those Present: Messrs. D.P.'O'Brien
Dr. L.C.F. Blackman
G.H. Ashurst
D.E. Hu,-hes
H.E.
L. Parel
A.R. Stewart-Cox
1. Matters Arising: From Previous EeetinR
a) The minutes of the last meeting
:, have been distributed to
some Asscciates. A formal disbribution list was
discussed
and agreed (see Appendix A). The minutes of this
and all
subsequent Cormittee meetin-s will be distributed
to this
list. In addition, the note indicatin- the
wo-,ointment of
A.R. Steaart-Cox as Project 1"'ansager, and the
discussion note
Dre-oared for this -neeting will also be included.
All
aocu-in-ents will be classified as 'Restricted' in
order to
maintain the Droject security.
The Committee were aCreed that it was necessary to
ensure
that interested Assoclates were well i-n-formed on
the =oiect
objecti,rcs and develop"Ient progress in order
that they shou-3--l
have the oprortumit,7 ~o make- construct-;ve
contributions.
Represerza~Ives from Associates would C.e, invited
to attend
a presentation, describin- the project a=d
progress, %rith-4-n-
the next six months.
b) The delivery of the Schmermund LYA-77
packer/wrapne=
was schaduled foz- Auaus-~ 2?. (.`1o t t-, rhe
e: oince he =ee,..inFr
deliver,y date has been deferred, by Sch=ermund,
to
Oct;ber 7th 101?9). _--7very effort Is beinc made~
to ensure the
earliest ava-411--a.ility of this equi=ent So
tha+. relevant
project activities zay be commencea.
Since "he Schms=und LF could be seen in o-eration
in
U.K. & :. . the Co=-=J;.ttee ri~?cor_=ended that
B.A.T.rS u _4 3 0- e
should not need -to receive visitors requesting to
see the
Schmer-,-,.L-.d.
c) Arrangements Inave been made for '_~'.A-T.
Suisse to ma'.:-e u--
to 125 MI. cimazettes cn the Stratec I Erou-) in
the remaininCc:>
months of this year. In addition, there will be
considerable-~O
flexibilitY cozen to th-en in the azrangsnent of
the ->roducticrPO
sclicdule. In 10,S0 a productior. quota of 40 :1.
per montla CO
has been or;zanised. CD
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2
2. The Project Plan
In order to formallise the project a note
describing the
objective, motivation and Euidelines was
-presented. This
note was discussed in detail and the amenaed
version, which
fully reflects the views of the Steering
Committee, is attached
(Appendix B).
The numberous loossible activities (sub-projects)
within
Strategy 1 which have been suggested in the past
by The -
Study Group, Steering Committee and Development
Staff within
GrouD R & b Centre were organised and cond-ensed
into a
project plan using computerised Network Analysis
Techniques.
The plan will be continuously updated using an
on-line
computer'facility.
The Droject plan was illustrated by both a bar
chart and
a network diagram to show the sequence and
interdependance of
the Activities. It was emDhasised that the
develo-oment
activities were descri-.)tive of the sDectrum of
work envisaged
for the project, and were not intended to be a
definitive at
this stage. It is ex-pected that other Activities
would be
added as the project proceeded.
3. Prooosals for within-Project Activities
The Steering Committee were "asked to discuss the
relevance
and pricrities of the list of Activities (Appendix
C). Inf o=al
notes describing the objectives and philoso-bhy
behind the
choice and division of the Activities were
provided.
The Steerina Co=ittee endorsed the basic project
scheme
and the majority of Activities as outlined. A
short list
of Activities was, however, deemed to be of low
-Driority in
view of the macnitude of the develonment effort
"Invo ived
in the Major Activities and the limited timescale
- currently
a period of two years - which is desirable. These
low
priority projects may be re-exa=ined at a later
date.
The Informal notes describiniz the Activities
which are
currently to be included in the zroject are -3.Ven
in
0
Appendix D. Those Activities whilch are to be
omitted are
given separately.
4. Resources
It was recognised that some of the project
Activities
were sufficiently Eelf-contained to be contracted
out 41"o
Engineering and Desi-n Consultants. Consultants
will be
used wherever -practicable in order to enhance the
-resources
of the project ' In the discussion of the
Tnfornation and Cz:)
Control System, it was arreed that the Holins
MAID:,' distributed -0
micro-processor sz-~stem could fo= a .,e=y useful
basis for CX:)
develop=ent. Messrs. O'Brien, Hur-hes and Willis
will investicat-jPo
Z.: X__D
the possibilit7 of -)lacinr a development contract
with ,.olins. r~,)
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Since there are other Activities within the
project which
were judged to be particularly suitable for
aevelopment
through holins, the contract basis in the
discussions with
them would be wider than the KAIDN system alone.
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PUP P EEN D I XA
Distribution of Stratery I information
Associate Comnan7 Countr-r
RJ1. Herdard Brown & Williamson Tobacco U.S.A.
Dr. R.A. Sandford Corporation Limited
R.M. Gibb Imperial Tobacco Division of Canada
C. Warren Imasco Limited
P.M. Denton W.D. & H.O. Wills (Australia)
Australia
R.G. Nichols Limited
E. Rittershaus B.A.T. Cigaretten-Fabriken German.7
F. Seehofer G.m.b.H.
T.G. Kendrick-Jones B. A. T. (UK & Export) Limited
United Kine-don
W. Fankhauser.. B.A.T. Suisse S.A. Switzerland
M.E. Crawshaw Cia. Souza Cruz Industria E Brasil
Dr. C.J.P. de Siguera Comercio.
A.B. Clements Cigarrera La Moderna. S.A. de Mexico
C.V.
A. Lov Malaysian Tobacco Co. Berhad Malaysia
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APPEIMIX B
NOTE FOR STEEIRING COMITTEE
AUGUST 10 1979
(with amendments)
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STRATEGY I
A G E N D A
STEERING COK'HITTEE- r_EETIN~,, GROUP R & D CENTRE
10 TH AUGUST 1979
1. Matters aris ing from the previous meeting.
a) The distribution of information to Associates.
b) The Schmermund Delivery schedule.
c) The Production Situation.
d) Other.
2. The. Project Plan.
3. Proposals for within-Project Activities.
4. Resources.
5. Any other business.
Distribution-.
Messrs. G.H. Ashurst C=)
Dr. L.C.F. Black-man %-0
D.E. Hughes c0
D.P. O"Brien c0
L. Parel
N.E. Willis
A.R. Stewart-Cox NO
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THE STRATEGY I PROJECT
The Project Objective is summarised as follows:-
To develop current high-speed secondary machinery
into
a semi-automated sin~zle Drocess line, having a
high efficiency
and with significantly reduced operator
intervention when in
normal production.
The motivation to B.A.T. to conduct such a project
derives
from the recognition of several points:-
1. That new generation secondary machinery is now
to be
classed as sophisticated both mechanically and
electronically.
2. That the techniques of automation are essential
for maximising
the pro'duction potential of the secondary
manufacturing
proces.s.
3. That trained operators for such machinery are
expensive
and their cost will cvn"'inue to rise as a
proportion of
direct manufacturing costs.
4. That the machinery manufacturers do not
necessarily have
the same economic motivation (as suppliers) as
B.A.T.
*(as manufacturers) in machinery desi,-'n. it is
necessary
for B.A.T. to direct machinery d,~sign towards its
own
objectives - such as the efficient use of skilled
operating
staff.
5. That there is a potential advantage over
competitors by
achievina souhisiication in zroduction techni-ques
at the
earliest possible time.
The project requires a substantial allocation of
resourco-s
and it is seen a s a broad spectrum of
sub-DroJects (Activities)
within severU defined areas of work.
A project plan proposall J. - -
of Activit4es has been prenared
by Net-work Analysis technioues in ordcr to
provide a ~aslls
for the Steering Co=ittee to assess the re-Jevance
an-d priority
of the numerous possible Activities urhich have so
far been
suggested by the Study Group, the Committee itself
and
Development engineers in GR-& D Centre.
Before a more detailed Dresentation of the
proposed plan
and pro-'ect Activities, it is worth notinc the
Guideiines
1)
which are considered necessary to achieve-a
realistic and
successful conclusion to the exercise.
Guidelines
1. There must be a true integration of mechanical
and
electronic develoo=.ents with both the basic
rachinery
and all other develonments. It is valuable to
recuire c0
that standardisation of materi-els and components
~e c0
observed.
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2. As far as is possible, in the development of
so-Phisticated
machinery, outward simD.licit;y of operation must
be held
as important.
3. Wherever Dossible, Development Activities
should be
directed ~o the removal of the root causes of the
operating
problem rather than to ameliorisation of effects.
4. Activity justification must derive from a
recognition of
likely reduction of operator intervention, an
improve=ent
in tL-rms of automation, and the provision of.
essential
information to the operator.
5. The creative innut and develoDment
contributions should
not rest solely with GR & D centre. Every effort
must
be made to seek direct contributions from 11
interested
Associates. it is, however, realistic to de"ine
that all
develonments should Dass throuGh GR & D Centre, to
ensure
integration with all other relevant Activities.
6. It is imperative that manufacturers
developments, -pertinent
to the precise project objective, are incorporated
in the
linked machinery group.
7. Security is regarded as necessary-in terms only
of
obtaining a lead time of, say, Uwo years in the
specific
availability of the complete developed group to
B~.T Associates.
This does not necessariiy preclude close liaison
or joint
develoDment Activities with Suppliers but requires
adequate
patent cover of inventicns and appropriate
confidentiality
agreements and contracts.
8. The operation of the developed machinery will.
require some
this
new concepts in day-to-day maintenance policy.
should be planned and :ncorporated as new
develoDments are
installed.
9. It is imperative that the machinery retain the
facility
for manual oDeratlion in the event of =alfunction
of
electronic control and COODUting equipment.
10. The principles of develoDment activities =ust*
.encompas
s the
-
requirements of other secondary machinery which
may w&l1 be
used in alternative group configurations.
11. Ergonomic principles =ust be aDDlied to
'%-,-he integration
and indiviaual design of the various machinery
developments.
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The Areas of develODment work have been determined
arbitrarily but are inteiided to identify the
major aspects
of this project.
1. The Making 'Machine Garniture.
2. Automatic Materials Supply.
3- Automatic cleansing and waste removal.
L3
(Objective: to reduce the interference of
redundant material
with machine operation and to remove operator
involvment);.
4. Product Quality Assurance.
5. Machine Reliability.
6. A Comp7ehansive.Information and Control System.
For each of these areas of work, several
Activities are
suggested in the Project Plan and are briefly
described in
this.document.
The Plan is taken forward in time to the Doint at
which initial tests after installation have bee-n
completed
for all the suggested Activities. It is
anticipated that,
concurrent with the -installation -Dhase for eacEL
Activity,
the task of securing commerc--al. pro-duction of
developments
will be started.
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APPENDIX C
STRATEGY I - PROJECT ACTIVITI-ES
02 Machinery installation/Suisse
03 Intervention survey (maker + packer)/Suisse
04 Data acluisition system/GR & DC
05 Install data acquisition system/Suisse
06 Further projects + steering committee
07 Run data acquisition system/Suisse
08 Projectz from data acquisition + steering
committee
10 Intervention survey (maker) + steering
committee
11 Intervention survey (packer) + steering
committee
12 Auto diameter control (maker)/GR & DC
13 Calibrated garniture (maker)/G.R & DC
14 Lap sean system (maker)/GR F- DC
15 Rod breakout control (maker)/GR & DC
16 Automatic materials supply adhesives (maker)/GR
DC
17 *A.M.S. ldhesives (packer)/GR & DO
18 .*A.M.S. ink + print development (maker)/GR &
DC
19 *A.rI.S. Reel Xed materials (maker)/GR & DC
20 *A.M.S. Reel fed materials (packer)/GR & DC
21 *A.H.S. Stack fed materials (packer)/GR & DC
22 Automatic cleansing and waste removal (maker +
ascar)/GR & DC
23 Auto.at--;. cleansine and waste removal
(packer)/GR & DC
24 Control print quality (maker)/GR & DC
25 Auto paper trans-Dort (maker)/GR & DC
26 Tobacco feed control (maker)/GR & DC
27 Chimney blockage control (maker)/GR & DC
28 Filter inspect/reject (maker)/GR & DC
29 Matched diameter control (maker)/C-.i & DC
30 Control reel faults (maker + packer)/GR & DC
31 Crossed cigarette control (oscar)/GR & DC
32 Cigarette inspect/reject (packer)/GR & DC
33 Materials tolerance (naker)AIR & DC
34 Hateria2s tolerance (packer)/GR & DC
35 ImDrove exDendable items (maker + packer)/GR DC
36 Information 1/GR & DC
37 Information 2/GR & DC
38 Inf ormat --On 3/GR & DC
39 Infor--at--:on 4/1,11Z & DC
40 Control I/G-.i &. DC
41 Control 2/G.1 8.- BC
Automatic materials supple- is abbreviated to
A.M.S.
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APPENDIX D
GEN-zRALLY MIDOIRSEED PROJECT ACTIVITIES
INFORLIJALL DESCRIPTION
Activity C2 rNSTAILAT.1011
Objective: to define, specify, order and install
the
secondary machinery for the prioject in B.A.T.
Suisse.
This a=tivity extends to the installation and
testing of all
but the case filler. At this stage, there is a
limit caused by
uirements of the ciGarette brand to be
the case 1-~-er re
produced - Z & H U.X. & E. offshore canufacture).
Case filler
~
machinery P-d developments will be considered for
addition to the
project plan at a laier date.
Activity Oa DATA ACQUISITIMT SYSTF11
Object-_Ire: to specify, order and test within
G.R. & D.C.
a computer based Data acquisition system.
Details: S::ecify D.A. System Completed
Order - C.I.L. Chandlers Ford May 79
Install in G.R. & D.C. Sept/Oct. 79
1--e-pare Transducers and Started
Sensors (14.k. 9/PA8)
P-repare Sensors (Oscar)
?---Pare Sensors/Transducers 01FILV)
P---pare Simulator Started
R & D Trials
Transfer to B.A.". Suisse (Activity 05)
P-n-pare D.A. information room in B.A.T. Suisse -
with
p--Iovision of the later installation of the
Infor=ation
and Control System.
P--epare Data Analysis techniques (main-frame
software).
T - A
Activit, 07 USE OF DATA "CrXISITIGN SYSTEM
it is Suggested that this project should be used
specificall.-~- to define and generate information
for the
following Act-ivri 'ties:-
15. The control of Rod Brealkouts (by elimination)
27. The Control of Chimney Blockages.
38 and ',~q. The provision X valuable guidance
information
for the operator - vis: Early warning system,
stoppage
cause annunciation.
41. The transducers and sensors for the provision
of
cemtralised control of: start-u-i
machine stoD
production quantity etc.
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In addition, it should work in parallel with other
of
the info=--ation and control project phases. There
will be
value -4-- the detailed k-nowledge of the
electrical and electronics
design of the machinery that this project must
generate.
Proiect Ga4dance throurh Knowledre of the level of
C-Derator
Intervention
There is a sequence of survey activities designed
to yield
sub-prcject proposals with a quantification of the
likely reduction
of operator intervention. The consideration of
these prODOSalS
by the Steering Committee is included.
Activit-7 10: Initial surveys of older k1k9/PA8
machinery operated
in a hazh efficiency production environment.
Sub-project or
Activity ~roDosals related to the MO-5PA85
development
and also -Generar Activity proposals related to
the Information
system.
Activit-7 11: Initial survey of soft-cup packing
machinery
kthe G.:,11) ODerated in a high efficiency
environment.
Activit-7 C6: A survey of the operator
intervention requirements
on. the newly installed Group of machinery for
this project. This
activit-7 requires that the machinery has been
brought to an
accepta'-l-z- high efficiency/operational state.
The period of
two 130=~.h~s only has currently been Drovided in
the machinery
A installation activity for B.A.T. Suisse to
achieve this state.
There must be further group surveys. Two are
considered
necessa=7: The first after the installation of
500% of the
B. sub-project activities. The second a' the end
of the project
plan (sa-~ mid-19815. These are unpro'rrammed 3t
the mo-ment.-
They'w--11'be added to the proCra=me_wh_e'n the
sub-project proposals
are more fully determined.
Activities shoi-m in the project Dian are eiven
below.
They follow an arbitrary grouping. Ail are areas
of work
suggested by either the Stud7'GroUD, the Steering
Com=ittee,
formal discussions between develoD:-7,ent
engineering staff in
G.R. & D.C. or are derived from conclusions which
may be reached
by consideration of the Intervention Survey
work-which has
been rerformed.to date.
Area I- - The Total Garniture ConceDt:
The following Activities are substantially
inter-related,
due in part,to the limited space available.
Activity 12 Automatic control of tobacco rod
diameter.
This is a Product quality assurance Droject;
considered
valuable in autona-Eing-- one of the few'
garniture adjustmenza
that are legiti=ately-made by the operator.
(Current
operator activity rate, one/hour). -Automation
could
aiso i=prove oualit7 and relieve stoppares due to
mismatch, of filter and tobacco rod
circu-'=ferenc; and
two further project activities cater for this
(Act4
-vities
28 and 29).
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Activitv 13 Calibrated Garniture:
Fixed or calibrated, reproducible garniture
settings are
considered essential. ZObserved operator
intervention rate
2/hour including those quoted for Activity 12).
Activit7 14 LaD Seam System:
It is necessary to examine the lap seam adhesive
system
and the resistance to adhesive contaminaticn of
the
garniture components. Essentially, a preci-se,
extremely
consistent, application system without depo-sition
of
adhesive debris is required. Self-cleaninc
garniture
com'Donents and Scanning Unit Passtube may wZ_ll
be vital
to iong ru-n times between stoppages. (See
Activity 15).
The starch paste/whehl. adhesive system on an
older M-.9
leads tp operator intervention at the rate of
6/hour.
Possible Activities: 1. Nozzle aDDlication
essential
(alreaay fitted).
2. Adhesives investization
(relatively cold setting to
remove need for heated iron).
pre-start up procedure
3. Standard
(automatic?) to ensure initial
cleanliness.
4. The use of non-stick surfaces to
'ture components.
garni
CU_re
fiCtivit7 1c, Rod Breakouts ntly account for about
ing 11";achine. Although
50 clo of all stoppares of the Kak-
such stoppages are typically of very short
duration
(12-24 s'ec-s.) they cause operator intervention
at the
Tate of 3 sto-ares (12 ev-ents)/hour on averac-e.
This
is reasonably tevere restriction on run durations.
An
in machine time efficiency of, say 255, might be
directly
estimated. Ho-,.,ever, the indirect benefits in
reduction of
operator intervention are likely to be substantial
if ru-n
durations can be doubled to say forty minutes
because of the
enhanced ecuilibrium status of the machine. The
elimination
of Rod Breakouts is considered essential.
Possible Activities: 1. The provision of rod
support
between the garniture and the
Scanning Unit Pass-Tube.
2. The application of the mrinciple
that rod traction musi be -4=13--oveA
and/or nrovided over the whole
distance between last Carniture
tape traction roint and rod
cut-off. (Direictional surface air
flows to reduce or remove surface
friction).
3. Automatic controlled break-in,
breakout of the rod.
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4. Automatic, pneumatic or
mechanical clearance is reauired
when stop ages do occur to
P
prevent the need for clearance
by the operator of solid,
bunched,~roken rod.
The Data Acquisition System is exmected to provide
substantial information about the causes of
rod-breakouts.
Obviously the la-D seam adhesive system is heavily
involved
and the work in ihat area will take the effect of
the
system on breakouts into account.
Area 2 Aut~omated Materials SuDDLY (A.M.S.)
A concept which has been much discussed as a major
feature of this project. The grand objective which
is applied at present is of a sufficient supply of
all
materials at tiie machine for uninterupted sin-gle
shift
operation. In addition, the loading and running of
bobbins and stack-fed materials should be
automatic
and operator independent. This area currently
requires
a high degree of operator intervention. For the
I-Pe.9/PA8
alone it amounts to some 23 events per hour.
For the purpose of the project plan, the exercise
has been sub-divided.
ActiVit7 19 A.M.S. Bobbin Materials (tTr9.5P_A8.5)
The objective of this Activity must be to provide,
at
the machinery, a continuous or near continuous
single
shift supply of the bobbin materials (Paper and
Cork).
Total auiomation may be th3 goai, but ii may well
be
worthwhile to seek initially -a 3ystem .ilhich
minimises,
but still requires, operator intervention. Floor
sDace
requirements for full shift sun-olies of all
bobbin
materials - in automatic d4stributors - will be
substantial.
There is much value in the concept of similar
systems
for all reel-fed materials for tiie group.
Possible Activities: 1. Centralised supply (from
lower floor?).
2. Cassette packaged, splice
prepared bobbins.
3- Multiple bobbin, splice
prepared units.
4. Continuously (spirally?) wound,
extra long lengih bobbins.
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The Activity is, to some extent, to be integrated
with
Activity 25 - Auto Paper Transport System - and
Activity 30
Auto Cotrtrol of Bobbin Faults.
Activitv 20 A.M.S. of Bobbin Material (sc,~,.
~rzltv, ~Hz)
See Activity 19. This activity 20 is considered th
be
consequent on the direction. and development of
work on
the PaDer and Cork supply systems.
Activity 21 A.M.S. of Stack-Fed Materials
(Sch.N-F)
There are two courses of action available. The
first
is to convert the riaterial sunply to reel form
and then
combine this activity with Ac~ivity 20. The second
is to
provide a suitable autonatic storare and conveyor
system
for prepared stacks of blanks (and-labels) to the
point o,~ use.
Area 3 Autoratic CleansinR: and Waste Dis-)osal
(A.C.W.D.)
Y.
The operator is heavily involved in cleaning,
clearin.- and
collecting waste within the machinery, using
various tools
air hose, long-nosed tweezers - and movinG uards
etc.
MakerAl'i-iner alone The objective
(Some 13 eventsAour in
of this Activity should be to provide automatic
and com-Dlete
removal of waste (tobacco, paper, filters) from
the grou'D.
It is necessary, however, to maintain aaste levels
at a minimum.
Whether or not the materials are Drocessed and the
tobacco
is automatically returned to the ;aker is a
secondary question.
In addit5on, since general environmental
cl-anliness can
account for about 6 events Der hour for the
oT)erator on a
Mk.9/PAB, it is reasonable to include within this
area of vrork
precautionary measures to reduce the escape of
waste and dust
to the local environment.
For the Durvose of the project plan, this area of
work has
been sub:.d-iv'ided:-
Activit7 22 A.C.I.-I.D. (rT<9.r~/'_vA8.5 OSCA-IR)
An integrated system for the whole maker/tipper
unit
is required. in the garniture area, the work must
be
integrated with the Eeneral garniture develozment
- Activities
12-15, since there is limited machine space
available in the
crucial locations.
Activit7 23 A.C.W.D. (Sch. I-IF/tV, 7-FZ)
Techniques used in Activity 22 nay well be
subsequently
applied to the packer, wrazper. The Packer
intervention
survey - Activiiies 11 and_~2 are clearly
important to control
the direction of this activity.
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Area 4 'Product Oualit:7 Assurance
In order to reduce some as-oects of the ODerators
task
at the machinery, it is necessary to select the
core
important of his discretionary duties, which are
relevant
to product quality, for automation.
.7 25 Auto Paner. Transnort and Positioninz
Activit:
The clearance of obstructed paper runs and the re-
threading operation requires subst-antial operator
dexterity.
Automatic threading paths with self-clearinE
properties
can offer a useful facitlity. In addition, autoL
positioning of the paDer and Carniture tape
relative to
the laD seam adhesive-a-onlicator could
be'included.
This would link the Activity with Activity 14 -
Lap
Seam Adhesive system.
The principle could be extended to other reel-fed
materials - in particular cork and foil.
Activity 26 Control of Tobacco Feed Rate
This is not considered to be an Activity of high
priority.
However, it is believed that to control the
ecretage
returns at a stable, constant level could be of
value
to the maker's weight performance, also itir.
likely
that the control facility will be useful in the
subsequent Activity 27 - Control of Chimney
Blockages.
Certainly, the sensor, transducer information for
control
of tobacco feed rate is likely to ac,~rue from the
Activity 02 - Data Acquisition System.
Activity 28 The Control of Filter 'Quality by I/R
at
the YA8.5
Since filter quality in terms of length, shape and
diameter in rarticular, can be the cause of Tipper
i
i
ts/lhour),
n
stoppages requiring operator attention (0.5 eve
there is soce value in rejectinr the abnormal
filters
to prevent disruption of the tipping process.
Circumference (diameter) measurement could well be
by
the same technioue as that used in Activity 12 -
Auto
diameter control of tobacco rod - but optical
techniques
seem most likely. In addition Activity 29 - the
control
system for matched tobacco rod and filter diameter
-
would require the measurement of incoming filter
diameter.
Activity 29 Vatched Diameter Control
See Activity 28 above.
Activit7 30 The Control of 3obbin Material Faults
With Activities such as 19 and 25 providin.-
automatic
material supply, it is possible to consider the
extension
of on-machine ins,:~ection of reel-fed material
faults with
the objective of preventing production loss caused
by
paDer breaks etc.
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Possible Activities: 1. In-line inspection - with
controlled machine stoD and
operator information.
2.-In-line inspection with
automatic strengthening of
defective area - with subsequent
rejection.
3. Automatic bobbin rejection and
replacement.
Activitv ~-2 Cigarette InsDection and Relection at
Facker InDut
The excessive wastage caused by pack rejection due
to~a-single missing or faulty cigarette detected
at
the bundling stage can be avoided. Single
cigarette
inspection - particularly in terms of ends quality
-
and missing tip - with consequent single cigarette
rejection needs to be further developed and made
more
efficient.
Area Machine Reliabilit7
Activit7 27 Chimney Blockame Control
The use of the Data Acquisition System Activity 07
is intended to provide a background description of
the
machanisms which generate chi=ney blockages. The
aim of this Activit7 is then to eliminate the
-oroblem
by prevention techniques (not by automatic
metfiods of
clearinG blocked chimney and 'rails etc.). The
Activity
may effectively become an c-:ercise in broadening
the
machine tolerance to variations in the physical
characteristics of the tobacco.
Possible Activities: 1. -Increase the depth of the
chimney.
2. Redesi-n of rail s/garni-ure
entry.
3- Chimney seal development.
4. HiGh-speed control of overfeed.
5- Improved, increased air--flow
and vacuum.
6. On-machine control of tobacco
moisture content and
temperature.
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Area 6 The Information and Control Function
The essential feature of the information system
built into
a StrateCy I group must be to -provide specific
valid information
for the onerator's guidance at the time when and
the location
where it 'is useful. In addition, progress and
quality information
should be available to him at-a central location,
which he
may interro7ate at his discretion. There should be
a strong
emDhasis on restricting the amount of continuously
displayed
inkormation related to obligatory duties. The
information
system should also Droduce concise, limited
management information
reports.
The Information function necessarily requires the
use of
computing facilities and all electronic equipment
for the
group which is fitted during the project MusD be
compatible
and integrated where necessary. But it is
essential that the
group machinery re=ains operational during a
failure of any
grou- cord-outing facility.-
p
In terms of the com-outing equipment available
currently the
71 most likely system confiGuration is that of
distributed
micro-processor based units linked by a data
highway to a
small groUD computer. The Group computer should
provide
superior computing power to indlividuail
micro-Drocessor units
but principally provide control and the data
organisation and
reduction required to inform the operator of the
operating
status and progress of the whole p.-rouD. It is
believed that
the visual presentation of information is of prime
importance,
printed information should be limited and concise.
Since, in general, t1ae measurement information
used by closed
control loons within the Croup will also be
useful, at some
time or other, to the operator, it is probable
that these
control activities will be integrated completely
with the
r information s7stem.
A base for the grou-p information system is seen
to be either
of the Molins ~~kIDN or Acculla7 C?OCO s-,stems.
It is nolentiall-.
valuable to acce--,)t the use of this commercially
available ecuizzen,;
rather than to consider "he e-xiensive develonment
of a hir:!:fy
intricate new s7ste= with BAT. (Note: It is no",
ex-Dected .
that the com.
puting facility of the Data Acquisition system
will
form nart of the final information system. There
are 'Iwo
reasons:-
The system desirn is snecific to the hirh speed
acquisition,
with minimal nrocessing, of data to describe croup
operating status - which is not appropriate to the
enviseZed
group computer fitriction.
ii) The direct use of the Data Acquisition system
is planned
to extend over the bulk of the project period).
The development is seen in four phases for the
Information
function and in tao phases for the Control
function.
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Activit7 36 Information Phase I
1. The purchase and evaluation of a base system
for
extension into a group syste=.
This will provide'weight control, weight
information and local nroduction data for
Hk9.5/PAe.5.
Additionally, the special functions develoDment
within the base system to provide weight
performance
analysis is expected.
2. The design and purchase of suitable television
camera and monitor equipment to provide improved
group visibility for the operator.
Activit7 37 Information Phase II
1. The extension of the base system to provide
nroduction
data and monitoring of the packing maclainery.
2. The system design, specification and purchase
of
the group computer and peripherals.
Software deveionment to suii the system to the
Strategy 1 information system objective.
3. The design of sensors and interfacing equipment
to
provide 'Low material' alarms and others.
4. The design and unification within ar operators
console of a re-oeater gauge system of essential
-mechanical status information (air pressures,
machine
speed, temperatures etc.).
5. Quality information from on-=achine
transducers.
(FrintAllumber and ty-pe of defects etc.).
6. Sampling systems to provide cigarettes, packs
etc.
for off-line Quality Control tests. The input of
off-line Quality Control information.
Actirit:7 40 Control Phase 1
1. Determine machine speed control strategy.
2. Pit or other-etise modify machine drives for
variable sDeed control.
3. Establish control to maximise packed output
against
reservoir stock levels.
Activit7 38 Info=ation Phase III
1. Establish Stoppage Alarms and cause display.
2. Develop Early Warning System.
3. M-anacement information of averaSe quality
characteristics.
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Activity 41 Control phase I,
1. Establish centralised control of group speeds,
start and Stop and of production quantity.
2. Establish centralised control over various
closed
loop control systerns.
Activit7 39 Information Phase IV
1. Generate Stoppage cause log for ODerator and
possible management information.
2. Develop system fault diagnostics.
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In the project plan the installation activities
have been
numbered as the development activity number plus
one hundred.
e.g. Activity 12 - Auto diameter control will
Cenerate
equipment which is installed in BAT Suisse in
Activity 112.
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APPENDIX D (continued)
REJECTED /DEFERRE D PROJECT ACTIVITIES
Area 2
Activity 16 A.r.S. Adhesive (Dlk9.5, PA8.5)
Machine adhesive capacity currently meets the
above requirements,
however, there are -a range of small problems
associated with the
application of adhesive to pa-oet (See Activity
14), and to cork
which can conveniently be included in this
exercise.
Activit:7 17 A.M.S. Adhesive (Sch. LF, MV and
FHZ).
Comments as for Activity 16.
Activity 18 A.M.S. Ink and Print Develonment 0"..
.5, PAe.5)
There is no Droblem envisaged in ensuring a
shift's supply of
ink at the printer. However, the activity is
extended to include
the development of the printer - preferably by
simplification -
since the printer receives operator attention at
the rate of 2-4
events/hr. The work on the printer must be
integrated with Activity
25 - Automated Daper transport (self threading)
and Activity 24 -
Control of Print Quality.
Possible Activities: 1. New printing techniques
allowing a much
simpler paperpath eg. Ink. Jet Printing.
2. Automatic threading and/or cleaz~mce of
paper after break.
There are manny sound arguments for the complete
removal of the
printer from the machine leading to the use of
nre-Drinted
tipping. In particular, the simplification of the
-!.,aper run, -the
elimination of print quality adjustments and all
other cperator
activities concerned with the oDeration of the
-orinter. 'It may
well be a reasonable objective of this Activity to
test the
value - in machinery operation terms of the use of
pre-printed
tipping for the Strategy 1 group.
Area 4
Activit7 2L The Control Of Print (ZUB1it7
Althou-,Ii denendant on the course of action
adopted in Actl ity 18,
-Y
this Activity is seen as essential if on-machine
printing is
retained.
Automatic inspection of two-colour print position
and print
intensity is required, together with the Drovision
of si=Dle
report information to the operator.
Activit-,- -Z1 Crossed Citzerette Control in OSCAR
% The Rate Feed Forward facility offered by Molins
to overcome
the Droblem of crossed ciGarettes on the OSCAR
conveyors is to be
installed and tried. It is possible that
mechanical means may C=>
still be necessary to remove crossed cirarette
'bridges' in the I'D
packer do-.-m-drop. The Control Systems 7ctivities
40 and 41 may CXD
well be used to further chan~-e the olieratinC
strateCy of the CDO
OSCAR reservoir, bearing this problem in mind.
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Deferred
Area
Activit-7 '~3 Extension of Machire Tolerance to
Variability of
Materials
This and the following Activity is included to
indicate the
conceDt of reducing the sensitivity of the
machinery to
variaiions in the rphysical characteristics, ie.
quality,
of tobacco, filters, paper a-nd cork in
particular. Various
aspects of tolerance ~ro-adening may be considered
within,
for example, Activities 15, 27, 28 and 70.
Tt is necessary to view such an exercise as
agressive -
le. correcting the source of faults rather than
applying
corrections to the effects wherever possible,
and'it is
expebted that this Activity should complement the
work in
other activities to ensure that there 'is
increased tolerance
rather than h;ishtened sensitivity in the
developed machinery.
Possible Activities: 1. Quality inspection of
supplied
materials.
2. On-machine control of tobacco
moisture.
;,-Deferred Act-:-,rit7 ~LL Extension of Machine
Tolerance to Variabilit7 Of
Materials (Sch I-Li/JV ~~iZ)
See Activity 33. The packer, in particular, is
held to
be highly sensitive to materials quality and in
particular
to the dimensions of -jack blanks. Further
exmerimental
information is required before it will be DoskUe
to define
the possible methods of improving the machine
tolerance to
material variations. This Activity is thu3
consecuent of
the results ;f the intervention suirrey on packing
-r-ach--nes
(Activity 11) probabl7, also, a snecific iniltial
investigation
similar to the Pira, survey made in WK & F..
Activit7 75 The Im-orovement of Exmendable Items.
It should not be necessary to replace or change
exmendable
machine items (eg. knives, garniiure tape)
duz---;rZ the
production shift, and measures should be taken to
concentbrate
and organise releva-nt operator activities prior
to and
subsequent to the production -period. In addition,
some
of the exT)endable items could well be improved in
terns
of operating life or in terms of mainta;n'ing
their stability
of dimensional or other physical characteristics -
thus
reducing operator intervention.
Possible Activities: 1. Garniture tape
development.
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