How Butler Automatic uses metrics to help our customers increase the output of their packaging lines

By Chip Johns, CEO

Butler Automatic builds automatic roll splicers for packaging applications. Butler splicers eliminate roll change downtime, which is the largest contributor to bagging, pouching, or thermoform line output loss. 

Our job is to deliver a new machine to our customer on time, facilitate a vertical start up, and ensure the machine serves our customer for many years in continuous operation with minimal maintenance. Butler uses several standard operational metrics to constantly improve our ability to execute on the mission stated above. It is critical to not just measure our performance, but also analyze variances from our performance to improve performance over time.

Chip Johns Butler Automatic CEO

Butler measures simple things like on time delivery, first time installation success, and parts shipping turn-around times. These are important “final” metrics. But it is also important to go a little deeper on the customer side by measuring whether Butler solutions are operating as the customer expects, 6 and 12 weeks after installation. Butler monitors our after-market business by measuring our time to ship parts orders (80% of our packaging splicer parts orders are shipped on the same day that we receive the order). On the engineering side, we measure how long it takes to release a set of specifications, how many engineering changes are made (ECOs) and the cause of those changes. Our measurements apply on the financial side as well. We measure our vendor payment days, customer collections, and we produce our financial results within one or two days of the end of each month. We try to measure everything that will contribute to a successful delivery, installation, integration, and long-term performance in the field. 

How does this data help us deliver better machines, on time to our customers? Having this data allows us to run our business better. If we can run all aspects of our business better, Butler, our vendors, employees, and technical partners will all be able to support our customers when needed.

Measuring the data is not what provides the results. Looking at the variances from the expected results, analyzing those variances, continuously improving processes and checking the results of those process changes are what provide the results. At Butler Automatic we are measuring our results and continuously tweaking our processes to design, build and support better solutions for our customers.

Chip Johns is the CEO of Butler Automatic. He has spent the last 7 years leading Butler Automatic and learning about the packaging industry. Prior to Butler, Chip built a business in the marine industry building about 50% of all the sailboats in North America.

Five Step Plan to Boost OEE with Automatic Roll Splicing

Butler Automatic offers top five tips to get the maximum Overall Equipment Effectiveness from reliable Butler Automatic splicers

Backed by the experience of delivering more than 17,000 automatic splicing solutions worldwide over the past 65 years, Butler Automatic has published a Five Step Plan To Boost OEE With Automatic Roll Splicing, which results in customers gaining several points of increased Overall Equipment Effectiveness (Availability x Productivity x Quality) for roll fed packaging lines. 

The first step is to involve Butler Automatic in discussions with roll fed applications equipment providers from the beginning of the project.  When the Butler team is directly involved on-site at installation and ramp-up, Butler achieves successful implementation quickly, 99% of the time.  The second and third tips are to utilize Butler’s One Point Lesson Plans (OPL’s), and Clean-Inspect-Lubricate instructions (CIL’s). With these documents Butler customers are able to train and maintain for top performance of Butler solutions, consistently achieving increased output by eliminating 100% of line stoppages for roll changes.  The fourth step includes having a short list of essential wear parts on-hand since Butler solutions consume very few wear parts. The fifth and perhaps most vital, is to establish a solid connection with our team. Butler service and parts teams support our applications 24/7.

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Butler Automatic Reveals SP1 Splicer Enhancement

New ‘WAVE’ bar feature ensures optimal vacuum coverage

Middleboro, MA - Butler Automatic announces a recent innovation to their SP1 Automatic Splicer.

Upgraded vacuum bars featuring Width Adaptive Vacuum Effectivity (WAVE) technology, eliminate edge curl which creates issues on certain films. The new wave bar is an improvement over previous vacuum bars because it includes strategically-placed vacuum holes in conjunction with wave-shaped vacuum slots. This enhancement means that SP1 users consistently have adequate vacuum coverage for their splices, regardless of the width of the film being used. This innovation allows customers the flexibility to change format widths of plastic films without the worry of covering holes on vacuum bars. The innovative design also ensures minimal vacuum loss (i.e. maximum Vacuum Effectivity) regardless of film width. To view a video of the new wave bar design, please click here.

Mike Mucci, Vice President of Engineering at Butler Automatic, states that this enhancement “allows our automatic roll splicing solutions to be more reliable and drive higher OEE (Overall Equipment Effectiveness) on roll-fed packaging lines.”

The upgraded WAVE bars are currently featured on certain SP1 orders and can be added to existing machines on a per case basis.

Butler Automatic Wave Bar for SP1 Splicer