Justifying the costs to upgrade the controls in an old capacitor winding machine, that's a hard one isn't it? Not with KR International's winder retrofits!
ME's, Maintenance Personnel & Others, PLEASE Contact finance before you contact me, please run this by the finance manager first. None of it is BS. It's usually in the budget after considering these points. This can pay for itself in a big hurry.
Hopefully you have read the page about the Winding Machine Mechanical Refurbishment Cost Justification. Where are those hundred dollar bills shown at the left? What you save over buying a new winding machine! Another reference link, Winding Machine Controls, for a brief list of what we do.
How to Justify the Expense? I ran a Manufacturing Engineering position at GE, and it made sense to them!
Finance People this one is for you! You say we are making product, we are meeting expectations and there's no budget for this. Well, since I have run a product line at General Electric I have run into this before. Well, all I can tell you if things keep getting done the same way all the time, you're absolutely right.
Maybe you are not familiar enough or can't find a company with the concept of taking a machine which is near junk, doesn't have all those new capabilities and quite frankly doesn't run fast enough or doesn't run at all, and giving it a new productive life. Furthermore, the impression is that the old stuff can't possibly be outfitted to remember your product line setups, and can't be made efficient enough to take a huge burden off the engineering staff, manufacturing staff and production workers. So you go out and price new equipment, only to find out you can't afford it. You tell everybody maybe next year business will get better, and know in your heart full well without a huge capital investment that's a pipe dream. Everybody looks at you like the enemy, but you really aren't because the right solution hasn't been in front of you, until now. As far as I know, KR International is the only qualified retrofitter in the USA.
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Fiction: Old E W Barton Company winders have no hope and should be scrapped. After all they're old, and an E W Barton is an E W Barton. Fact: Don't make me laugh out loud. Just look on this site and find out you're wrong. Maybe you have a capacitor winder of European Manufacture, and it's sitting there with dead controls. Been there, seen that. Nobody deals with these, right?
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Fact: KRI Controls remember every last thing about the winding setup. Recipe control is standard. Setup time is dramatically reduced. New part recipes can be saved instantaneously. Any part recipe can be called up (last setup on that part) and you are off and running. This can save about a half hour or more per changeover.
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Fact: If you have an old relay control chassis, you will amazed at how much quicker the capacitor winding machine can run. And if you have a dead Euro machine, it's sitting there collecting dust. New controls run at least 100 - 10,000 times faster (not necessarily the machine), depending on the control model. What does that equate to in production? For example, an old Barton Machine on a 15 turn product will take about 30 seconds to produce. Take out all the delays, get the good controls that we offer and the time drops to 5 seconds, maybe faster. Some say on small parts it runs like a rattlesnake. Even those of you with one of the faster running Euro winders won't be disappointed.
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Now, it can depend on part parameters, but it's like having somewhere between 2 - 6 capacitor machines running at once, don't have to buy a new machine & hire new labor & train. Outstanding! And if you get my point, we know how to make them run much faster than that.
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Even if you don't have an old Barton Machine, the complaint we hear every time is electronic parts, knowledge and service of the European Controls. No, we don't troubleshoot these, why? The computer control we use is about the cost of 1 single board for the Euro winders. So we gut these and start over. Of course, the brain isn't all that's involved. Many of the Euro controls are obsolete and don't have an upgrade path (proprietary stuff by others, I can't change those). Worse yet, try to find somebody to repair these! So many sit idle while dreams of getting them running fade away. It might just cost as much to troubleshoot the system as elimination of the entire problem completely.
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Try buying a new capacitor winder that encompasses all your needs. Truth is, if your product doesn't fit the cookie cutter theory, maybe for an exorbitant price you'll get what you need.
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We can program & upgrade to make a myriad of options, new product introductions become more painless, without buying new equipment. Get everything including the kitchen sink. None of the controls I have installed years ago have died yet. All of my work can be ported to newer controls with very little effort. Your technology investment doesn't drain away. It isn't like the expense of upgrading MS "Windows®", all your computer software and hardware for each release. Promise!
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Dream up stuff & make it personal. Oftentimes,we can make it do many more things, while looking over my shoulder some dreams can be completed and tested in as little as 5 minutes. I make it your way, try to beat that.
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Compared to the old stuff, these run the exact same precise cycle each time, there is absolutely no variation (except your raw material). Tired of spending money on labor and get a low yield of 1% or 2% parts anyway? That's going to change.
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Even the smaller companies see a quick return on investment.
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Controls are self diagnostic, they can actually tell your maintenance personnel or operators there's a problem, what it is, and a course of action. Sure saves a lot of downtime.
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There's more to it than that, can you afford not to act? You finally become a hero and your non-existent budget to grow just got easier.
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Now, isn't that all BS? I get respect, fulfill promises & get continual repeat business. It's real, and available now. None of my customers waste money on expensive new stuff. Get out of the end of the month overtime blue's while shipping more product, with less expense. Get your ROI, that is the bottom line, NO BULL.