House of Kits Spare parts for all life-cycle phases www.boschpackaging.com Explore our new range of products for the entire life-cycle of your Bosch Packaging Technology equipment
Your needs our solutions House of Kits House of Kits List of content The main focus of Bosch as a single-source provider is to ensure suitability and high equipment availability. Your needs are our priority. To fulfill these needs, we have developed a new range of parts packages (kits), using expert knowledge. For each machine life-cycle phase (commissioning, ramp-up, operation, modernization) we can offer a suitable kit solution, which is tailored specifically for your packaging machine and maintenance needs: Commissioning & Ramp-up Phase Basic/Extended Assortment Kit Operating Phase Standardized PM Kit Customized PM Kit Introduction Maintenance Strategies 3 House of Kits 4 House of Kits Portfolio Assortment Kit Basic and Extended Assortment Kit 7 Preventive Maintenance (PM) Standardized PM Kit 9 Customized PM Kit 10 Customized PM Kit Variant: Rebuild Kit 11 Exchange Unit Add-on Service: Bosch in-house overhaul 12 Add-on Service: E-Portal Memo 13 Modernization Control Upgrades 15 Variant: Rebuild Kit Exchange Unit Modernization Phase Control Upgrades /Software Updates We would like to show you on the following page the possible maintenance solutions, tailored to your needs. The corresponding products can be found in the House of Kits. Please get in contact with your local partner to discuss your possible kit solutions. 2
Maintenance Strategies We offer the following Bosch solutions based on your different maintenance needs. Condition-based strategy (CB): You are looking for a high level of reliability, regular observation and feedback loops of your packaging equipment. You strive for high production reliability and qualified condition. You want to eliminate risks, which affect the production output or product quality at all times. Bosch solution: Regular condition monitoring and maintenance. 100 % Reliability 0 % Operating phase in years Preventive strategy (PM): You are striving for a smooth and ongoing production and select a preventive maintenance approach. You know your required TCO (Total cost of ownership) budget due to planned downtime cost. Based on this, the shift plans and resource planning are in focus. Bosch solution: Planned maintenance. 100 % Reliability 0 % Operating phase in years Corrective strategy (Corrective): You are having a high production pressure and less budget for maintenance costs. This approach bears the highest risk (delayed time-to-market, etc.) and requires ad-hoc reactions in case of unforeseen machine stops. Bosch solution: Management of recommended parts stock. 100 % Reliability 0 % Operating phase in years Risk Matrix* High Medium Low CB Total cost of ownership PM Corrective Low Medium High Risk *Assumption: High production capacity 24/7 (un)-planned downtime Legend Downtime Machine check up by a technician Planned downtime and Maintenance Inspection (optional) Identification of failure Repair Unplanned downtime: Parts Management 3
House of Kits For each machine life-cycle phase we can offer a suitable kit, which is tailored specifically for y packaging machine and maintenance needs. Assortment Preventive Maintenance Application Support the commissioning of the new packaging system in critical phases during production ramp-up Support of the regular, planned maintenance during operating phase Benefits Safe and smooth ramp-up in the critical phase Quick re-start of production Understanding of the general spare parts demand Increased production safety Optimized planned maintenance Reduced storage costs Reduced production downtime costs Less preparation time Products Basic Extended Standardized Customized Rebuild Exchange Unit Machine Life-Cycle Commissioning & Ramp-up Phase Operating Phase 4
our Modernization Support throughout technical solutions by having retrofits and state-of-the-art technologies Assist in case of discontinuation of OEM parts Extended lifetime of equipment Increase efficiency Optimized production Control Upgrades Modernization Phase 5
Assortment
Assortment Basic & Extended Assortment Kit Product description The Basic Assortment Kit consists of all relevant wear parts for new machinery The Extended Kit consists of the Basic Kit, complemented with all relevant spare parts categories like electrical, reserve and customized parts Intended use To support the commissioning of the new packaging system during a critical initial phase Initial stock of spare parts is available at your site Sufficiently prepared for possible, unforeseen machine stops in the initial phase Benefits You receive a mutually agreed spare parts list of all necessary parts categories Storage cost reduction only the relevant (wear) parts in the required quantity are available Smooth ramp-up during the commissioning of the packaging system Support the setup of spare parts stock Understanding of the general spare parts demand for the packaging equipment Knowledge of maintenance requirements and identification of all critical parts Application Usable for the following maintenance strategies Corrective Preventive Condition based Characteristics Structure of the Assortment Kit Machine no., offer no., order no. Machine type Material description Image of the material Material no. Assembly group Sub-assembly Unit Number of installed parts within the machine Recommended parts for storage/stocking Price per item and total price Delivery time Specification of spare parts category: consumables, wear parts and spare parts Packaging line Machine Facts Quotation leadtime: 2 weeks E-Portal: online information and ordering On request Your offered parts are visible and can be ordered through your own E-Portal You can check the current lead time and availability of spare parts 7
Preventive Maintenance
Preventive Maintenance Standardized PM Kit Product description Bundling of wear parts for main assembly groups (partially pre-assembled parts included) Designed for standardized packaging machines Exchanged at the recommended maintenance intervals (operating hours or years) Application Intended use To support your preventive maintenance at your packaging plant during the production phase Usable for the following maintenance strategies Corrective Preventive Condition based Characteristics Standardized PM Kits are marked by: Pre-defined wear parts list per assembly Can be ordered directly with a fixed material number On demand additional information available (required tools, installation time, etc.) Details on the recommended maintenance intervals in operating hours or years Expert know-how (technician experience, suppliers) tested/reflected PM Kit documentation supplied Assembly group Machine Facts Quotation leadtime: 1 week E-Portal: online information and ordering On request Your offered Kits are visible and can be ordered through your own E-Portal You can check the current lead time of the Kits Bosch service technician recommended Benefits Cost savings Less inspection cost Reducing storage cost Optimization of planned downtime Reducing supply chain costs Time savings Partially pre-assembled parts Less preparation time Quicker re-commissioning Easy installation and instruction Defined PM Bill of Material (BOM) Drawings with marked sub materials of the Kit 9
Preventive Maintenance Customized PM Kit Product description Bundling of wear parts for main assembly groups (partially pre-assembled parts included) Individually designed for your specific packaging machine Exchanged at the recommended maintenance intervals (operating hours or years) Optional on request: «consumables» e. g. belts, knives, etc. Time savings Partially pre-assembled parts Less preparation time Quicker re-commissioning Easy installation and instruction Defined PM Bill of Material (BOM) Drawings with marked sub materials of the kit Intended use To support your preventive maintenance at your packaging plant during the production phase Application Usable for the following maintenance strategies Corrective Preventive Condition based Characteristics Customized PM Kits are marked by Have your individual PM Kits Bill of Material (PM Kit BOM) Can be ordered with your specific PM Kit material numbers Details on the recommended maintenance intervals in operating hours or years Assembled based on expert know-how Customized PM Kit documentation supplied, designed according to your preventive maintenance time frame On demand: additional information available (for example required tools, installation time, etc.) Benefits Cost savings Less inspection cost Reducing storage cost Optimization of planned downtime Reducing supply chain costs Packaging line Machine Packaging leg Assembly group Facts Quotation leadtime/ Development time: 8 10 weeks E-Portal: online information and ordering On request Your offered kits are visible and can be (re)-ordered through your own E-Portal Provision of your PM Kit documentation Bosch service technician recommended 10
Preventive Maintenance Customized PM Kit Variant: Rebuild Kit Product description The Rebuild Kit consists of all necessary wear and spare parts, to maintain your worn-out assembly group Options Option 1: Our service technician maintains the worn-out assembly group at your site with the Rebuild Kit Intended use For the efficient maintenance of the worn-out assembly group ideal in combination with the Exchange Unit (see page 12) Bosch service technician Rebuild Kit and worn-out assembly group Updated assembly group Usable for the following maintenance strategies Corrective Preventive Condition based Option 2: You maintain your worn-out assembly group with the Rebuild Kit Benefits Convenient and easy re-ordering with a customized material number for your Rebuild Kit Customer Rebuild Kit and worn-out assembly group Updated assembly group Facts Quotation leadtime/ Development time: 2 weeks Roller Feed Rebuild Kit: consists of green marked parts Application E-Portal: online information and ordering On request Your offered Kits are visible and can be (re)-ordered through your own E-Portal Provision of your PM Kit documentation Assembly group 11
Preventive Maintenance Exchange Unit Product description Completely new Exchange Unit, which directly replaces the worn-out assembly Application Intended use Assembly is changeable at any time in case of possible fault Ideal if this assembly is installed in several packaging machines Usable for the following maintenance strategies Corrective Preventive Condition based Benefits Planned downtimes for maintenance are shortened Exchange Unit can be installed immediately during a failure Less downtime due to quicker changeover Assembly Group Assembly group Tip Ideal in combination with a Rebuild- Kit (see page 11): The production can be run with the newly installed Exchange Unit while you can maintain your worn-out assembly group Benefit: you can use the updated assembly group immediately during a failure Add-on service: in-house overhaul You send the worn-out assembly group to Bosch to get an updated assembly group Benefit: you have no maintenance efforts customer sends worn-out assembly group updated assembly group Facts Quotation leadtime: 1 week E-Portal: online information and ordering On request: Your offered Exchange Units are visible and can be (re)-ordered through your own E-Portal You can check the current lead time of the Exchange Unit Bosch service technician recommended 12
Preventive Maintenance Add-on Service: E-Portal Memo Product description You can add your required wear parts/kits in your own E-Portal to your shopping basket, save as a memo and you can (re)-order it Memo Example Intended use The created memos can be used for planned maintenance Tip The memos can be created by using a recommended spare parts list (transfer quote as memo) Usable for the following maintenance strategies Corrective Preventive Condition based Characteristics You have access to your personal E-Portal Flexible customization of your memo (add or delete items, change quantity, give a memo name and change it) Supports the maintenance preparation managed by you Benefits Detailed spare parts information Online information and easy ordering 24/7 Transparency on cost and availability Electrical Interface Connections Open Catalog Interface (OCI) with Punchout: You reach the E-Portal website via a link from the catalog system (e.g. SAP). There you can use the E-Portal, search parts, create memos and add items to the shopping basket. The selected data is returned to your ERP system via OCI Punchout. Coupa or ARIBA with Punchout: You reach the E-Portal website via a link from Coupa or ARIBA. There you can use the E-Portal like a catalogue and search parts, create memos and add items to the shopping basket. You can send the created shopping basket or memo via Punchout to ARIBA or Coupa and order there with your system. E-Portal: www.boschpackagingservices.com/ eportal 13
Modernization
Modernization Control Upgrades Product description Replace obsolete controls or discontinued components with newer state of the art solutions (focus on electronic components) Examples Intended use Mainly for older machines or systems which require new replacement components Ensuring compatibility with available components for extended machine life Electric Cabinet before Electric Cabinet afterwards Usable for the following maintenance strategies Corrective Preventive Condition based Benefits Ensure spare parts availability Ensure long-term availability of your machine Sophisticated replacement solutions for a reliable and safe operation Servo Drive Controller HMI Additional Service Software update E-Portal: online information and ordering On request: You will be informed about obsolete parts and available technical solutions Control Panel Application Bosch service technician recommended Packaging line Machine Packaging leg Assembly group 15
E-Portal Access link www.boschpackagingservices.com/eportal Bosch Packaging Services Contact www.boschpackaging.com You will find your local partner at: www.boschpackaging.com House of Kits 04/2017 (V2) PA-FCS/PRM Bosch Packaging Services (subject to alterations)