End Manufacturing at Rocky Mountain Metal Container with

End Manufacturing at Rocky Mountain Metal Container, with views on emerging technology Paul Schrock Miller. Coors LLC Rocky Mountain District MBAA Technical Meeting 9/20/2008

What is an End? n n Ends Come in a variety of Sizes and Variations but all are an integral component of the 2 Piece Aluminum Can. The End is seamed on the top of the can and forms the beverage consumption point.

Raw Materials n There are 2 main Direct Raw Materials associated with End Manufacturing n Aluminum n Liquid Latex

Aluminum n The Aluminum comes in 2 Forms n Shell Coil (End Stock) n Tab Coil (Tab Stock)

Latex n Latex or Compound is placed in the curl of the shell as it cures it becomes the gasket as the end is seamed to the filled can.

Raw Material Usage n n Use ~ 1 Million lbs of Aluminum / Week Use ~ 86 Gallons of Latex / Week

End Manufacturing Process n Main processes to produce an End n Blank and Curl the Shell n Line the Curl n Convert the End

Shell Press and Curlers

Shell Press Coil In Feed Manufacturing Process - Blank the Shell

Shell Press Manufacturing Process - Blank the Shell

Single Stroke, Pneumatic Assist Forming Die Manufacturing Process - Blank the Shell

Curler Manufacturing Operation - Curl the Shell

Shell Press / Curler Info • 7 Shell Presses at RMMC • Press Strokes at 560 SPM • 2800 EPM, 4, 032, 000 EPD • Each Consumes ~ 750 LBS Aluminum / HR Curled Shell Work In Process / Machine Info

Stick Feeds Material Handling

Traffic Cop Material Handling

Six head Rotary Liner Manufacturing Process – Line the Curl

Compound Dryer Manufacturing Process – Line the Curl

Lined Shell Liner Info • 14 Liners at RMMC • Liner Runs 1480 RPM • 3 Turns of Lining Manufacturing Process – Line the Curl

Balancer Material Handling

Conversion Press

Tab Stock In feed Manufacturing Process – Convert the End

Form Tab Manufacturing Process – Convert the End

Form Shell Manufacturing Process – Convert the End

Form Shell - Progression Bubble Button Manufacturing Process – Convert the End

Form Shell - Progression Rehit Score Manufacturing Process – Convert the End

Form Shell - Progression Deboss Inserter Manufacturing Process – Convert the End

Form Shell - Progression Tab Ear Wipedown Incise / Emboss Manufacturing Process – Convert the End

Converted End Conversion Info • 9 conversion Presses at RMMC (3 -Sys 7, 6 -Sys 8) • Press Runs 650 SPM • Plant Constraint Operation • Overall Plant Capacity 15, 600 EPM 22, 464, 000 / Day Manufacturing Process – Convert the End

Semi – Auto Bagger Packaging Info • 3 Pack Types • Small Pack – 198, 000 EPP • Secured Pack – 228, 000 EPP • Large Pack – 257, 400 EPP Material Handling

In Line Inspection Systems 100 % Camera Inspection of all ends exiting the Liners Process Quality Control

In Line Inspection Systems 100% Light Testing for Leaks Process Quality Control

In Line Inspection Systems 2% Pressure Test for Leaks Process Quality Control

Off Line Inspection Systems Offline Colt SPC Pressure Check for Leaks Process Quality Control

Off Line Inspection Systems SPC Check for Compound Weights Process Quality Control

Off Line Inspection Systems SPC Check for Tab Strength and Opening Characteristics Process Quality Control

QC Lab Finite End Measurements Process Quality Control

Warehouse / Shipment • 26 Large Pack Pallets / Trailer – 6, 692, 400 Ends Material Handling

Scrap Bailer Supporting Process – Scrap Collection

Palletizer Bailer / Palletizer Info • Briquettes ~ 40 lbs each • 46 Briquettes / Pallet • Generate ~ 3 Pallets / 8 Hour Shift Supporting Process – Scrap Collection

Tab Scrap Overall Scrap Recycling • Total Waste Stream generates ~ $1 Million revenue each month. Supporting Process – Scrap Collection

Emerging Technology in Operations 24 Out Shell Press with Stacked Curlers

Emerging Technology in Operations Advanced Camera System for Finished End Inspection

Emerging Technology in Operations Robot arm for bailed scrap collection

Emerging Technology in Operations Complete Auto End Bagging System

Questions ?