Introduction
At a Glance
A case erector design with a high part count can be a hidden source of complexity – for the life of your machine. It makes for potential challenges in 7 key areas:
- Wear parts and failure modes
- Changeover cost
- Machine accessibility
- Cleaning and sanitation risk
- Operator training
- Spare parts inventory
- Line integration
Why does part count have such an effect? Because more parts mean more complexity in each of these areas. That’s why it’s so important that you ask the right questions when purchasing a case erector.
Part count is usually not the first thing buyers ask about, and sometimes it never even enters the conversation. It won’t headline a brochure, and flashier specs like speed, footprint, and flexibility will win more sales.
But part count makes a real quality-of-life difference when it’s been on your floor for a while. Part count is closely tied to complexity. And the more complex a machine, the more downtime, labor, maintenance, and failures drag down line efficiency. So, how significant is part count really? Well, it depends on what you consider significant.
In this article, we’ll cover:
- How part count measures complexity
- The 7 key factors that are affected by part count
- Questions to ask to uncover the real cost of complexity
- The most important factor that part count reflects
What Does Part Count Tell You About a Machine?
Part count tells you how much complexity is built into the machine through mechanical components. And where there are more components, there are more chances for misalignment, wear, and failure. The more the machine runs and becomes integrated into your line, the more that added complexity takes its toll in wear and limits the growth your line can achieve.
A machine that achieves the same result as another, but with fewer parts, often reflects an intentional design approach. More effort on the engineering side usually results in a simpler machine, which results in simpler ownership.
How Does a High Part Count Affect My Line? 7 Key Factors
So, we’ve made it clear that part count does have an affect on your line. But in what ways? A high part count case erector affects more than most buyers think. Here are our top 7 ways that part count affects your line.
1. Wear Parts and Failure Modes
The most direct reason that part count matters, is in mechanical wear. Every part built onto a machine possesses a life cycle. After time, you see bearings wear, belts stretch, sensors drift, etc. That’s expected, and it reflects a normal degree of degradation.
But the place where a high part count comes in, is that when there are more parts, there are more places where parts can wear out. There are more failure points introduced. This shifts your workload by creating more:
- Components to inspect
- Wear patterns to monitor
- Possible causes of failures
This increased maintenance burden can take its toll over time. There will always be more parts wearing and drifting, more parts to maintain and replace.
2. Changeover Costs
For many operations, changeover is a regular part of their everyday. Teams know that the longer changeover takes, the more money is lost. Changeover cost is real, but it’s often underestimated when operations shop for new equipment.
Part count affects changeover in a simple way: more parts mean more adjustments. And more adjustments mean more:
- Steps for operators, in every changeover
- Opportunities for misalignment
- Systems to set correctly at the same time
This leads to a changeover process that is hard to repeat and hard to train for. And high vs. low part count machines work inversely on this point: high part count machines increase changeover complexity; low part count machines decrease changeover complexity.
3. Machine Accessibility
Maintenance goes beyond mere part replacement; it also relates to the accessibility of that part. In other words, can your team easily access parts when they need replacing? And not only can they access it, but can they do so safely and realistically, under normal conditions?
As more parts and more functionality gets built on to the machine, the engineers are tasked with making “more” fit within the same promised footprint. That leads to lubrication points getting tucked behind assemblies, and wear parts buried deep within.
Simple replacements can turn into partial teardowns, with increased time spent in machine construction. This charges in:
- Labor costs
- Downtime
- Delayed routine maintenance
- Ergonomic strain from cramped spaces
Lower part count machines usually have the opposite effect: cleaner access, simpler disassembly, and less time spent in routine service.
4. Cleaning and Sanitation Risk
Especially in food, beverage, or hygiene-sensitive environments, part count can show up once again in cleaning difficulties and inspection risks. Every additional part creates another place for dust to collect, adhesive to stick, and debris to hide.
This results in:
- Slower and more challenging cleaning
- More difficult verification
- Higher audit risks
Depending on the operation, sanitation-ease is a primary concern. Poor cleanliness can go far beyond a begrudged technician, it can turn into safety concerns and legal costs.
5. Operator Training
The more parts a machine contains, the more components your operators and maintenance staff need to understand. That leads to a training burden that’s frequently underestimated during the buying process.
Perhaps you’re thinking about a couple people on your team who you can count on to pick up the mechanics quickly. However, when one of your most accountable operators leaves, goes on vacation, or changes roles, your performance drops. And you’ve placed unfair burden on another stressed-out operator.
Complex machines encourage this reliance on a few specially knowledgeable operators. And it may lead to challenges in training, supporting, and staffing.
6. Spare Parts Inventory
Most buyers account for an initial spare parts package at capital purchase. But fewer fully account for the cost of sustaining that spare parts inventory over time. The parts that fail after six months, will fail again in a year, in two years, in five years – you get the point.
Looking at the long-term burden of an increased spare parts inventory, you see more:
- Money continually tied up
- Need for storage space
- Purchasing and stock management efforts
- Obsolescence concerns
- Long lead times
This is an even greater issue with unique or custom parts. Discontinuation becomes a real risk, and you’ll need to keep a tight eye on lead times. The larger and more specialized your spare parts list, the more dependence you’ll have on the supply chain.
7. Line Integration
Case erectors are only one machine in a larger system. The way your erector performs affects the work of your packer, sealer, and palletizer as well. Complexity doesn’t stop when the case moves on to the conveyor to be packed.
More drive systems, sensors, and handoffs lead to more:
- Controls inputs and outputs
- Pressure for efficiency
- Difficulty in line-level fault isolation
This challenge will become clear during startup and commissioning first, but it will likely continue well after launch. The more complex your erector is, the more complex the handoffs will be between it and the rest of your line.
What Questions Should I Ask When Comparing Case Erectors?
To get a picture of long-term ownership, ask vendors the following questions during your evaluation process:
- Which wear parts are replaced regularly? How often?
- How many adjustment points are there in a typical changeover?
- Can you show me a live changeover under normal operating conditions?
- How accessible is the component that is replaced most often?
- Which spare parts are proprietary? Which are standard?
- How many drive systems, control interfaces, and handoffs are on the machine?
- Which maintenance tasks eat the most time?
- Which parts/assemblies are hardest to reach?
- Where does the machine rely the most on operator judgment?
The way a vendor answers these questions will reveal something about ownership that can’t be found in a brochure. However, the weight each of the answers bears is entirely dependent on your operational specifics.
Part Count: Not the Only Metric, But an Important One
Part count, though important, is not the only metric you should judge a machine by. A high part count shouldn’t automatically sort the machine into your “No” pile. It just warrants a deeper conversation, justifying its parts. There can be legitimate reasons for it:
- Additional systems required for control and reliability in high-speed machines
- Format flexibility requires additional components to aid with adjustment
- Increased part count is possible, because the machine is still excellently built
The most important factor in part count is the design philosophy behind it. Oftentimes an equally capable machine that’s simpler, reflects greater design intention and effort. It takes a certain discipline to make a simple machine a capable one.
Look Beyond the Spec Sheet
We’ve said it before, and we’ll say it again: don’t stop at the spec sheet – look at the machine that lies behind the surface-level numbers.
Part count affects a machine’s reliability, ease, cost, and so much more. Skipping over the part count discussion, reflects a gross underestimation. And it’s one that will have consequences later. Think about how an erector’s part count will challenge your degree of support long-term.
You’re accounting for more than initial investment; you’re accounting for the difficulty of the next decade of your life in ownership.
Looking for a Simpler Case Erector?
Give INSITE a call to receive help evaluating case erectors, and recommendations for the machines that will simplify your operation.
