VDMA Packaging Machinery Association (Translation by VDMA 05/2005)

Food Processing and

Packaging Machinery
Association
DIN 8743: Packaging machines and packaging installations,
time related definitions, reference factors and calculation
fundamentals
Translation not certified by DIN.
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Contents Page
National Preface..................................................................................................................................................3
Introduction.........................................................................................................................................................3
1 Area of application ................................................................................................................................3
2 Normative References...........................................................................................................................4
3 Definitions ..............................................................................................................................................4
3.1 Time definitions .....................................................................................................................................4
3.1.1 Machine working time...........................................................................................................................4
3.1.2 Machine downtime ................................................................................................................................5
3.1.3 Machine operationg time ......................................................................................................................6
3.1.4 Machine running time ...........................................................................................................................6
3.1.5 Breakdown time.....................................................................................................................................6
3.1.6 Empty running time...............................................................................................................................7
3.1.7 Waste running time ...............................................................................................................................7
3.1.8 Quality time ............................................................................................................................................8
3.1.9 Lost time.................................................................................................................................................9
3.2 Reference factors ................................................................................................................................11
3.2.1 General .................................................................................................................................................11
3.2.2 Reference factors for packaging machines......................................................................................11
3.2.3 Reference factors for packaging installations .................................................................................14
3.3 Definitions for the structures of packaging installations................................................................16
3.3.1 Sequential linkage...............................................................................................................................16
3.3.2 Parallel linkage of identical elements................................................................................................17
3.3.3 Parallel linkage of different elements ................................................................................................17
4 Definition of the reference factors .....................................................................................................18
4.1 Definition of the reference factors for packaging machines ..........................................................18
4.2 Definition of the reference factors for packaging installations .....................................................18
4.2.1 General .................................................................................................................................................18
4.2.2 Data collection .....................................................................................................................................18
4.2.3 Calculation ...........................................................................................................................................19
4.2.4 Simulation ............................................................................................................................................20
Appendix A (normative) Formula symbols......................................................................................................21
Appendix B (normative) Types of linkage of packaging installations..........................................................23
B.1 Sequential linkage...............................................................................................................................23
B.2 Parallel linkage of identical elements................................................................................................27
B.3 Parallel linkage of different elements ................................................................................................31
Bibliographical References .............................................................................................................................35
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National Preface
This Norm was compiled in DIN from the specialised packaging machine section of the NAM (Norm
Committee for Machine Manufacture).
Alterations:
The following upgrading has been made to DIN 8743: 1987-2001
a) The introduction of more definitions
b) The defining of more reference factors
c) The compilation of reference factors for packaging installations
Introduction
The operation of packaging machines and whole packaging installations is subject to countless influences
from the machines themselves and associated equipment, from the upstream and downstream units, the
product being packed, the packaging materials, any ancillary packaging means, the production organisation,
the operating and maintenance personnel and the environmental conditions in the packaging area. Because
of this the packaging process does not run uninterruptedly but rather is interrupted by part planned and part
accidental disruptions. During the operation of packaging machines or installations the periods in which
production is carried out efficiently and qualitatively alternate at random with periods in which waste,
downtime and stoppage occur.The characterisation of the performance of a packaging machine or
installation in operation results from reference factors which are constructed from time segments based on
the structural pattern of the machine running time. From this for example the reference factors of total
machine efficiency, total machine availability or operating output can be evaluated as well as stoppages or
loss allocated to their respective causes.
1 Area of operation
This Norm applies to the field of packaging technology. The prescriptions of this norm establish a basis for
the identification of operating performance and for the evaluation of the functionality of technical equipment
designed for the packaging of products. This can be either individual packaging machines or whole
packaging installations consisting of linked packaging machines and in-line ancillary equipment.
This Norm serves to increase the understanding between manufacturers and users of packaging machines
and installations about the efficiency and performance of such equipment.
This Norm does not apply to liquid filling equipment, see DIN 8782 and DIN 8783
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2 Normative references
This Norm contains, through dated or undated references, statements and conclusions from other
publications. These normative references are cited at the respective places in the text and the publications
are listed at the conclusion of this Norm. With dated references later alterations or revisions of these
publications only apply to this Norm in those case where they are inserted through an amendment or
revision. With undated references the latest issue of the mentioned publication applies (including
amendments)
DIN 8728 - Drinks - filling equipment, definitions for filling lines and individual units.
DIN 8783 - Drinks - filling equipment, investigative analysis of filling equipment technology
Norms in the sequence DIN 55405, Definitions for the packaging industry.
DIN EN 415-1 Safety of packaging machines Part 1: Terminology and Classification of the Designation for
packaging machines and ancillary equipment; German Version EN 415-1
3 Definitions
In the use of this Norm the following definitions and those given in DIN 55405-1 to DIN 55405-7 and
DIN EN 415-1 apply.
3.1 Time definitions
Machine working time t
m
Operating time t
btr
Running time t
l
Quality time t
q
Waste running time
t
aus
Empty running time
t
le
Breakdown time t
a
Downtime t
neb
Lost time t
v
Picture 1 Classification of the time definitions
3.1.1 Machine working time
Machine working time of a packaging machine t
m
time which is available for production with the packaging machine or time available for its observation or
investigation
NOTE This is the sum of the operating time of the packaging machine t
btr
(3.1.3.1) and the downtime of the
packaging machine t
neb
(3.1.2.1)
neb btr m
t t t + = (1)
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Machine working time of a packaging installation t
mA
time which is available for production with the packaging installation or time available for its observation or
investigation
NOTE This is the sum of operating time of the packaging installation t
btrA
(3.1.3.2) and the downtime of the
packaging installation t
nebA
(3.1.2.2)
t
mA
=t
btrA
+t
nebA.
(2)
3.1.2 Downtime
3.1.2.1 Downtime of a packaging machine tneb
is the sum of the times which through either prescribed or planned or other agreed activity on the machine
are not available for machine operation
NOTE 1 To these belong
Activities at beginning and end of shift;
Planned preparation and retooling changeover times;
Stoppages for the resupply of product, packaging materials and other resource;
Cleaning and Sterilising;
Preventative repairs, e.g. exchange of wearing parts, correction to the machine controls, insofar as they fall within
the sphere of the machine working time;
Running in phase until the first pack of acceptable quality is produced.
NOTE 2 The definition of an acceptable quality pack is one which complies with the full scope of the specification.
3.1.2.2 Downtime of a packaging installation t
nebA
is the sum of the times which through either prescribed or planned or other agreed activity on the installation
are not available for machine operation.
With packaging installations only those time segments count as downtime in which the entire installation can
not work.
NOTE 1 To these belong
Activities at beginning and end of shift;
Planned preparation and retooling changeover times;
Stoppages for the resupply of product, packaging materials and other resource;
Cleaning and Sterilising;
Preventative repairs , e.g. exchange of wearing parts, correction to the machine controls, insofar as they fall within
the sphere of the installation working time;
Running-in phase until the first pack of acceptable quality is produced.
NOTE 2 Downtime e.g. through change-overs to individual machines within the installation can be absorbed by
means of existing buffers so that the work of the installation itself is not interrupted.
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3.1.3 Operating time
3.1.3.1 Operating time of a packaging machine t
btr
Machine working time of the packaging machine t
m
(3.1.1.1) minus the downtime of the packaging
machine t
neb
(3.1.2.1):
neb m btr
t t t = (3)
3.1.3.2 Operating time of a packaging installation t
btrA
Machine working time of the packaging installation t
mA
(3.1.1.2) ) minus the downtime of the packaging
installation t
nebA
(3.1.2.2):
nebA mA btrA
t t t = (4)
3.1.4 Running time
3.1.4.1 Running time of a packaging machine t
l
Sum of the times in which the packaging machine is running, irrespective of whether it is producing
acceptable quality packs or rejectable waste, whether it is running empty or with reduced operating speed
NOTE The running time is the result of the operating time of the packaging machine t
btr
(3.1.3.1) minus the
breakdown time t
a
(3.1.5.1).
a btr l
t t t = (5)
3.1.4.2 Running time of a packaging installation t
lA
Sum of the times in which the packaging installation is running, irrespective of whether it is producing
acceptable quality packs or rejectable waste, whether it is running empty or with reduced operating speed.
NOTE 1 The running time is the result of the operating time of the packaging installation t
btrA
(3.1.3.2) minus the
breakdown time t
aA
(3.1.5.2):
aA btrA lA
t t t = (6)
NOTE 2 To the running times belong also the times in which for example with parallel organised machines not all
machines are running or stoppages with individual machines are absorbed through buffers..
3.1.5 Breakdown time
3.1.5.1 Breakdown time of a packaging machine t
a
Sum of the times in which the packaging machine is not running because a breakdown criterion arises
NOTE 1 To the breakdown criteria belong for example accidental technical defects, queuing of product or missing
packaging materials. The breakdown time is a component of the lost time, it can have either a technical or
organisational cause..
NOTE 2 The downtime (t
neb
) does not count as lost time.
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3.1.5.2 Breakdown time of a packaging installation taA
Sum of the times in which the packaging installation is not running because a breakdown criterion arises.
NOTE 1 To the breakdown criteria belong for example accidental technical defects, queuing of product or missing
packaging materials. The breakdown time is a component of the lost time, it can have either a technical or
organisational cause
NOTE 2 Packaging installations could run as well if necessary if several installation elements break down. A break
down of a packaging installation is to be considered as the stoppage of the bottle neck machine.
NOTE 3 The downtime (t
neb
) does not count as lost time.
3.1.6 Empty running time
3.1.6.1 Empty running time of a packaging machine t
le
Sum of the times in which the packaging machine is running but not producing any packs
NOTE 1 Causes of this are for example interrupted product flow and/or packaging material supply
NOTE 2 The empty running time can also be calculated from the number of empty cycles and the target output of the
packaging machine:
est
le
le
q
n
t = (7)
whereby n
le
is the number of empty cycles and q
est
is the target output of the packaging machine (see 3.2.2.1.2)
3.1.6.2 Empty running time of a packaging installation t
leA
Sum of the times in which the packaging installation is running but not producing packs
NOTE 1 Causes of this are for example interrupted product flow and/or packaging material supply.
NOTE 2 The empty running time can also be calculated from the number of empty cycles and the taget output of the
packaging installation:
estA
leA
leA
q
n
t = (8)
whereby n
leA
is the number of empty cycles and q
estA
is the target output of the packaging installation (see 3.2.3.1.2)
3.1.7 Waste running time
3.1.7.1 Waste running time of a packaging machine t
aus
Sum of the times in which the packaging machine is producing waste
NOTE 1 The waste running time can also be calculated from the number of waste packs and the target output of the
packaging machine:
est
aus
aus
q
n
t = (9)
whereby n
aus
is the number of empty packs and q
est
is the target output of the packaging machine ( see 3.2.2.1.2)
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NOTE 2 The running in phase until the first pack of acceptable quality is produced does not belong to the waste
running time.
3.1.7.2 Waste running time of a packaging installation t
ausA
Sum of the times in which the packaging installation is producing waste
NOTE 1 The waste running time can also be calculated from the number of waste packs and the target output of the
packaging installation:
estA
ausA
ausA
q
n
t = (10)
whereby n
ausA
is the number of empty packs and q
estA
is the target output of the packaging installation ( see 3.2.3.1.2)
NOTE 2 For the purposes of comparison, where a packaging installation is performing more than one packaging
process (eg primary packaging, point of sale packaging, collation unit) it is the number of primary packages
which is to be used for this calculation.
NOTE 3 The running in phase until the first pack of acceptable quality is produced does not belong to the waste
running time
3.1.8 Quality time
3.1.8.1 Quality time of a packaging machine t
q
Sum of the times in which the packaging machine produces packs of acceptable quality.
NOTE 1 The quality time is calculated from the actual number of packs of acceptable quality (n
btr
) and the target
output (q
est
) of the packaging machine.
est
btr
q
q
n
t = (11)
whereby n
btr
is the actual number of packs of acceptable quality and q
est
is the target output of the packaging machine
(see 3.2.2.12)
3.1.8.2 Quality time of a packaging installation t
qA
Sum of the times in which the packaging installation produces packs of acceptable quality
NOTE 1 The quality time is calculated from the actual number of packs of acceptable quality (n
btrA
) and the target
output (q
estA
) of the packaging installation.
estA
btrA
qA
q
n
t = (12)
whereby n
btrA
is the actual number of packs of acceptable quality and q
estA
is the target output of the packaging
installation (see 3.2.3.1.2)
NOTE 2 For the purposes of comparison, where a packaging installation is performing more than one packaging
process ( e.g. primary packaging, point of sale packaging, collation unit) it is the number of primary
packages which is to be used for this calculation.
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3.1.9 Lost time
3.1.9.1 Lost time of a packaging machine t
v
Sum of the times in which the packaging machine, through breakdown, empty running or waste production,
does not produce any packs of acceptable quality.
NOTE 1 The losses caused through waste running, empty running or breakdowns can be classified as either
technical (t
vt
) or organisational (t
vo
). The technically caused lost time is subdivided into machine related
(t
vtm
) and machine external(t
vtf
)
3.1.9.1.1 Technically caused lost time of a packaging machine (t
vt
)
3.1.9.1.1.1 Machine related, technically caused lost time (t
vtm
)
Sum of the lost times which arise from breakdowns or faults in the packaging machine (working elements ,
controls, drive, setting up and adjustment systems, transport system, etc.)
NOTE 1 To the machine related breakdowns belong for example:
Interruptions in the the flow of packaging materials and products ( such as blockages and jam ups) which are due to
a failure of the working elements of the machine;
Destruction of packaging materials, product or pack which is due to a failure of the working elements of the machine
and the consequent cleaning operation;
Failure of the controls and the necessary corrective action;
Adjustment and replacement of machine parts during the operating time;
Machine repairs.
3.1.9.1.1.2 Machine external, technically caused lost time t
vtf
Sum of the lost times due to machine breakdowns whose cause lies outside the scope of the packaging
machine, ie such as the product, packaging materials, or packs.
NOTE 1 To the machine external breakdowns belong for example:
Functional disruption due to non conformance with the specification, ie tearing of packaging material due to
inadequate mechanical strength or weak spots, variation in the physical properties of the product;
Blockages due to any deviations in size, shape and location;
Cleaning and maintenance caused by breakdown of an upstream process.
3.1.9.1.2 Organisationally caused lost time of a packaging machine t
vo
Sum of the lost times which arise from disruption in the organisational area (e.g. the production organisation,
upstream and downstream process management, operating and maintenance personnel, supply means,
etc.)
NOTE 1 To the organisational causes belong for example:
Unplanned changeover or conversion times on the machine due to non conformance in the specification of
packaging materials, product or packaging ancillaries;
Unplanned machine stoppage or empty running due to missing product, packaging materials or packaging
ancillaries;
Unplanned machine stoppage or empty running due to breakdown in the upstream equipment;
Unplanned machine stoppage or empty running due to breakdown in the downstream equipment;
Operating errors;
Missing operating or maintenance personnel;
Disruption of the supply means;
Act of God.
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3.1.9.2 Lost time of a packaging installation t
vA
Sum of the times in which the packaging installation, through breakdown, empty running or waste
production, does not produce any packs of acceptable quality.
NOTE 1 The losses caused through waste running, empty running or breakdowns can be classified as either
technical t
vtA
or organisational t
voA.
The technically caused lost time is subdivided into installation related
t
vtfA
and installation external t
vtfA
3.1.9.2.1 Technically caused lost time of a packaging installation t
vtA
3.1.9.2.1.1 Installation related, technically caused lost time t
vtmA
Sum of the lost times which arise from breakdowns or faults in the packaging installation (working elements,
controls, drive, setting up and adjustment systems, transport system, etc.)
NOTE 1 To the installation related breakdowns belong for example:
Interruptions in the flow of packaging materials and products (such as blockages and jam ups) which are due to a
failure of the working elements of the installation;
Destruction of packaging materials, product or pack which is due to a failure of the working element of the
installation and the consequent cleaning operation;
Failure of the controls and the necessary corrective action;
Adjustment and replacement of installation parts during the operating time.
3.1.9.2.1.2 Installation external, technically caused lost time t
vtfA
Sum of the lost times due to installation breakdowns, whose cause lies outside the scope of the packaging
installation, i.e. such as the packaging materials, product or pack.
NOTE To the installation external breakdowns belong for example:
Functional disruption due to non conformance with the specifiaction, ie tearing of packaging material due to
inadequate mechanical strength or weak spots, variation in the physical properties of the product;
Blockages due to any deviation in size, shape or location;
Cleaning and maintenance caused by breakdown in an upstream process.
3.1.9.2.2 Organisationally caused lost time of a packaging installation t
voA
Sum of the lost times which arise from disruption in the organisational area (e.g. the production organisation,
upstream and downstream process management, operating and maintenance personnel, supply means,
etc.)
NOTE 1 To the organisational causes belong for example:
Unplanned changeover or conversion times on the installation due to non conformance in the specification of the
packaging materials, product or packaging ancillaries;
Unplanned installation stoppage or empty running due to missing product, packaging materials or packaging
ancillaries;
Unplanned installation stoppage or empty running due to breakdown in the upstream equipment;
Unplanned installation stoppage or empty running due to breakdown in the downstream equipment;
Operating errors;
Missing operating or maintenance personnel;
Disruption of the supply means;
Act of God
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3.2 Reference Factors
3.2.1 General
The reference factors serve to characterise and act as an assessment of the operating performance of a
packaging machine or installation under concrete conditions. They are compiled from the recorded times, the
time calculations and from the registered volumes. They facilitate the standardised and measureable
assessment of a packaging machine or installation in contracts or agreements, the proving of fulfillment of
claimed performance and the comparison in performance of packaging machines or installations.
3.2.1.1 Output
Produced or produceable number of packs per time unit
NOTE Quantity based reference factor, synonymous with the terms productivity, throughput, and production
efficiency
3.2.1.2 Availability
Proportion of time in which the packaging machine or installation is available, measured against the
appropriate total time.
NOTE Time based reference factor
3.2.1.3 Efficiency rate
Relationship between the produced and produceable number of packs
NOTE 1 dimensionless reference factor
NOTE 2 with constant target output the value for machine availability and for efficiency rate is the same.
3.2.2 Reference factors for packaging machines
3.2.2.1 Output of a packaging machine q
3.2.2.1.1 Nominal rated output of a packaging machine q
n
The maximum number of acceptable quality packs (n
max
) per time unit for which the packaging machine,
under the assumption of defined ideal conditions regarding machine condition, packaging materials,
packaging ancillaries, product and operating personnel, was designed:
t
n
q
n
max
= (13)
whereby n
max
is the maximum number of acceptable quality packs from the packaging machine and t the time unit.
NOTE 1 The nominal output is a theoretical value
NOTE 2 Packaging machines which for example can produce several pack sizes have correspondingly several
nominal outputs.
NOTE 3 The time unit t can be for example a shift, an hour or a minute.
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3.2.2.1.2 Target output of a packaging machine q
est
mathematical number of acceptable quality packs (n
est
) per time unit which the packaging machine at the set
working speed and with uninterrupted running and disruption free production produces:
t
n
q
est
est
= (14)
whereby n
est
nest is the mathematical number of acceptable quality packs from the packaging machine and t
the time unit.
NOTE 1 The nominal output is the upper limiting value for the target output.
NOTE 2 The target output is dependent on the package type and size, the packaging materials and ancillaries, the
product and the system of pack closure.
NOTE 3 The time unit t can for example be a shift, hour or a minute.
3.2.2.1.3 Operating output of a packaging machine q
btr
actual number of acceptable quality packs (n
btr
) which are produced by the packaging machine within the
operating time (t
btr
):
btr
btr
btr
t
n
q = (15)
Whereby n
btr
is the actual number of acceptable quality packs from the packaging machine and t
btr
is the
operating time ( 3.1.3.1)
NOTE 1 It takes into account all lost times ( 3.1.9.1)
NOTE 2 It is an empirical value
NOTE 3 By definition is q
btr <
q
est
3.2.2.1.4 Running time output of a packaging machine q
l
actual number of acceptable quality packs (n
btr
), ) which are produced by the packaging machine during
running time (t
l
):
l
btr
l
t
n
q = (16)
NOTE By definition is q
est >
q
l >
q
btr
3.2.2.1.5 Effective output of a packaging machine q
eff
actual number of acceptable quality packs (n
btr
) which are produced by the packaging machine based on the
operating time (t
vtf
) after reduction for machine external (t
btr
) and organisationally caused (t
vo
) lost times:
vo vtf btr
btr
eff
t t t
n
q

= (17)
NOTE The effective output takes into consideration only the machine related lost times (3.1.9.1)
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3.2.2.2 Availability of a packaging machine v
3.2.2.2.1 Total availability of a packaging machine v
g
Relationship of the time in which the packaging machine is producing to an acceptable quality to the
operating time (quality time t
q
), to the operating time (t
btr
) expressed as a percentage:
100 =
btr
q
g
t
t
v (18)
3.2.2.2.2 Technical availability of a packaging machine v
t
Relationship of the time in which the packaging machine is producing to an acceptable quality (quality time
t
q
), to the operating time after reduction for the organisationally caused lost times expressed as a
percentage:
100

=
vo btr
q
t
t t
t
v (19)
3.2.2.2.3 Machine technical availability v
m
Relationship of the time in which the packaging machine is producing to an acceptable quality (quality time
t
q
) to the operating time after reduction for machine external and organisationally caused lost times,
expressed as a percentage
100

=
vo
vtf btr
q
m
t t t
t
v (20)
3.2.2.3 Efficiency rate of a packaging machine
3.2.2.3.1 Total efficiency rate of a packaging machine
g
Relationship of the operating output (q
btr
) to the maximum possible output at the set working speed (target
output q
est
), expressed as a percentage:
100 =
est
btr
g
q
q
(21)
3.2.2.3.2 Technical efficiency rate of a packaging machine
t
Relationship of the operating output (q
btr
) to the target output (q
est
) after reduction for restorative losses
occasioned in the organisationally caused lost time (t
vo
), expressed as a percentage:
( )
100
) / ( 1


=
btr vo est
btr
t
t t q
q
(22)
3.2.2.3.3 Machine technical efficiency rate
m
Relationship of the effective acceptable quality output (q
eff
) to the produceable production quantity (q
est
) at
the set working speed and with uninterrupted running and disruption free production, expressed as a
percentage:
100 =
est
eff
m
q
q
(23)
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3.2.3 Reference factors for packaging installations
3.2.3.1 Output of a packaging installation q
A
3.2.3.1.1 Nominal rated output of a packaging installation q
nA
maximum number of acceptable quality packs (n
maxA
) per time unit for which the packaging installation, under
the assumption of defined ideal conditions with regard to the condition of the installation, the packaging
materials and ancillaries, the product and the operating personnel, was designed:
t
n
q
A
nA
max
= (24)
whereby n
maxA
is the maximum number of acceptable quality packs from the packaging installation and t is the time unit
NOTE 1 The nominal output is a theoretical value
NOTE 2 Packaging machines which for example can produce several pack sizes have correspondingly several
nominal outputs
NOTE 3 with sequentially linked elements of the packaging installation q
nA
is equal to the nominal output of the
machine with the lowest nominal output in the packaging installation (bottle neck machine)
NOTE 4 The time unit t can be for example a shift, an hour or a minute
3.2.3.1.2 Target output of a packaging installation q
estA
mathematical number of acceptable quality packs (n
estA
) per time unit which the packaging installation at the
set working speed and with uninterrupted running and disruption free production produces:
t
n
q
estA
estA
= (25)
whereby n
estA
is the mathematical number of acceptable quality packs from the packaging installation and t is the time
unit
NOTE 1 The nominal output is the upper limiting value for the target output.
NOTE 2 The target output is dependent on the package type and size, the packaging materials and packaging
ancillaries, the product and the system of pack closure
NOTE 3 The time unit t can be for example a shift, an hour or a minute
NOTE 4 With all packaging installations of loose linkage the individual elements of the installation are generally set
to different working speeds. The target output of the packaging installation with sequential linkage is
therefore the same as that of the individual packaging installation element with the lowest target output.
With packaging installations with parallel linkage the target ouput is the same as that of the smallest sum
of the target output of the parallel linked elements of the packaging installation.
NOTE 5 With packaging installations with control over the working speed of the individual installation elements the
working speed can alter according to the process. The target output in this case can not be extracted
through a preset figure but only on the basis of the actual running cycles completed within the period of
observation
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3.2.3.1.3 Operating output of a packaging installation q
btrA
actual number of acceptable quality packs (n
btrA
) which are produced by the packaging installation within the
operating time (t
btrA
):
btrA
btrA
btrA
t
n
q = (26)
whereby n
btrA
is the actual number of acceptable quality packs from the packaging installation and t
btrA
is the operating
time (3.1.3.2)
NOTE 1 It takes into account all lost times ( 3.1.9.2)
NOTE 2 It is an empirical value
NOTE 3 By definition is q
btrA <
q
estA

3.2.3.1.4 Effective output of a packaging installation qeffA
actual number of acceptable quality packs (n
btrA
) which are produced by the packaging installation based on
the operating time (t
btrA
) after reduction for machine external (t
vtfA
) and organisationally caused (t
voA
) lost
times:
voA vtfA btrA
btrA
effA
t t t
n
q

= (27)
NOTE The effective output takes into account all the lost times ( 3.1.9.2)
3.2.3.2 Availability of a packaging installation v
A
3.2.3.2.1 Total availability of a packaging installation v
gA
Relationship of the time in which the packaging installation is producing to an acceptable quality (quality time
t
qA
) to the operating time (t
btrA
) expressed as a percentage:
100 =
btrA
qA
gA
t
t
v (28)
3.2.3.2.2 Technical availability of a packaging installation v
tA
Relationship of the time in which the packaging installation is producing to an acceptable quality ( quality
time t
qA
) to the operating time (t
btrA
) after reduction for the organisationally caused lost times (t
voA
) , expressed
as a percentage:
100

=
voA btrA
qA
tA
t t
t
v (29)
3.2.3.3 Efficiency rate of a packaging installation
A
3.2.3.3.1 Total efficiency rate of a packaging installation
gA
Relationship of the operating output (q
btrA
) to the maximum possible output at the set working speed (target
output q
estA
) expressed as a percentage:
100 =
estA
btrA
gA
q
q
(30)
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 16 -
3.2.3.3.2 Technical efficiency rate of a packaging installation
tA
Relationship of the operating output (q
btrA
) to the target output (q
estA
) after reduction for restorative losses
occasioned in the organisationally caused lost time (t
voA
), expressed as a percentage.
( )
100
) / ( 1


=
btrA voA estA
btrA
tA
t t q
q
(31)
3.2.3.3.3 Installation technical efficiency rate
aA
Relationship of the effective acceptable quality output (q
effA
) to the produceable production quantity (q
estA
) at
the set working speed and with uninterrupted running and disruption free production, expressed as a
percentage:
100 =
estA
effA
aA
q
q
(32)
3.3 Definitions for the structures of packaging installations
The types of installation structures listed below differ in the methodoloy by which the reference factors for the
packaging installations are calculated from the data and reference factors of the individual elements of the
installation.
In order that those packaging installations which perform multi-stage packaging processes have comparibility
of reference factors the number of primary packs produced is taken in these cases as the basis.
3.3.1 Sequential linkage
3.3.1.1 Uncontrolled rigid sequential linkage
Sequential linkage in which the in-line machines and linked elements are directly connected to each other as
part of a material flow process, where there is no buffer effect, where they work with the same operating
method (continuous or discontinuous) and same operating speed and where the working speed is not
controlled.
3.3.1.2 Controlled rigid sequential linkage
Sequential linkage in which the in-line machines and linked elements are directly connected to each other as
part of a material flow process, where there is no buffer effect, where they work with the same operating
method (continuous or discontinuous) and same operating speed and where the working speed is controlled.
3.3.1.3 Uncontrolled loose sequential linkage
Sequential linkage in which the working speed is not controlled and in which one or more of the individual
installation elements within the line have a buffer effect by which the sequentially following machine or
installation sections are decoupled from each other as regards the material flow at that specific time.
3.3.1.4 Controlled loose sequential linkage
Sequential linkage in which the working speed is controlled and in which one or more of the individual
installation elements within the line have a buffer effect by which the sequentially following machine or
installation sections are decoupled from each other as regards the material flow at that specific time.
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 17 -
3.3.2 Parallel linkage of identical elements
3.3.2.1 Uncontrolled parallel linkage of identical elements, without buffer
Parallel linkage where the installations have sections in which the same machines or linked elements are
connected parallel to each other, in which a material flow is split into several channels or several material
flow channels converged into one, where the machines and linked elements have the same working speed
which is not controlled and where there is no buffer.
3.3.2.2 Controlled parallel linkage of identical elements, without buffer
Parallel linkage where the installations have sections in which the same machines or linked elements are
connected parallel to each other, in which a material flow is split into several channels or several material
flow channels converged into one, where the machines and linked elements have the same working speed
which is controlled and where there is no buffer.
3.3.2.3 Uncontrolled parallel linkage of identical elements, with buffer
Parallel linkage where the installations have sections in which the same machines or linked elements are
connected parallel to each other, in which material flow is split into several channels or several material flow
channels converged into one, where the machines and linked elements have the same working speed which
is not controlled and where within the installation buffers are available.
3.3.2.4 Controlled parallel linkage of identical elements, with buffer
Parallel linkage where the installations have sections in which the same machine or linked elements are
connected parallel to each other, in which the material flow is split into several channels or several material
flow channels converged into one, where the machines and linked elements have the same working speed
which is controlled and where within the installation buffers are available.
3.3.3 Parallel linkage of different elements
3.3.3.1 Uncontrolled parallel linkage of different elements, without buffer
Parallel linkage where the installations have sections in which different machines or linked elements are
connected parallel to each other, in which the material flow is split into several channels or several material
flow channels converged into one, where the machines and linked elements can work at differing speeds,
which are not controlled, and where there is no buffer.
3.3.3.2 Controlled parallel linkage of different elements, without buffer
Parallel linkage where the installations have sections in which different machines or linked elements are
connected parallel to each other, in which the material flow is split into several channels or several material
flow channels converged into one, where the machines and linked elements can work at differing speeds,
which on some or all of the installation elements can be controlled and where there is no buffer.
3.3.3.3 Uncontrolled parallel linkage of different elements, with buffer
Parallel linkage where the installations have sections in which different machines or linked elements are
connected parallel to each other, in which the material flow is split into several channels or several material
flow channels converged into one, where the machines and linked elements can work at differing speeds,
which are not controlled, and where within the installation buffers are available
3.3.3.4 Controlled parallel linkage of different elements, with buffer
Parallel linkage where the installations have sections in which different machines or linked elements are
connected parallel to each other, in which the material flow is split into several channels or several material
flow channels converged into one, where the machines and linked elements can work at differing speeds,
which on some or all of installation elements can be controlled, and where within the installation buffers are
available.
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 18 -
4 Definition of the reference factors
4.1 Definition of the reference factors for packaging machines
The definition of the reference factors of packaging machines serves as a validation of their performance
capacity. This can, other than by these theoretical reference factors, only be verified in the appropriate
working environment. The verification of the reference factors during machine acceptance or functional
validation must always take place under the agreed conditions appropriate for the application with regard to
machine condition, packaging materials, packaging ancillary materials, product, operating personnel,
production organisation and working environment. During this process the operating time normally begins
when the installation is in stationary operation and ends before the installation is run empty. The compilation
of the data for the definition of the reference factors on the packaging machine can either be carried out
manually or with technical assistence (BDE/MDE). The aim is to ensure that adequate, mutually agreeable
statistical reliabilty of the results is achieved.Apart from the data relating to production and breakdowns it is
also important to record the influences from the operating personnel and the environmental conditions.
Prior to the start of the data acquisition it is always necessary to:
- establish the duration of the observation/investigation time ( =machine working time)
- segregate technically and organisationally the packaging system under review
- establish and define the conditions and circumstances of a breakdown, and
- if a causal analysis is to be made then the allocation of the breakdowns to the cause according to
illustration 1 needs to be made.
4.2 Definition of the reference factors for packaging installations
4.2.1 General
With packaging installations the definition of the reference factors can be made with three possible methods:
a) Data acquisition at the packaging machine installation and calculation of the reference factors from that
data.
b) Calculation of the reference factors from the known data and reference factors from the installation
elements
c) Simulation of the operating process of the installation
For the pursuance of the the differing objectives on which the calculation of the reference factors is based
there are different definition processes which apply. The suitable usage is a follows:
Acquisition: optimisation of the process and installation assessment, machine acceptance, appraisal
Calculation: planning, project management or process optimisation
Simulation: planning, project management, process or installation optimisation.
4.2.2 Data acquisition
Manual or automatic acquisition of the operating and lost data at the packaging installation according to
section 4.1
This method assumes the presence of the packaging installation in a fit for purpose functionality. It demands
mostly a high level of application in terms of personnel and time, but does deliver precise results for the
areas under investigation and is theoretically uncomplicated.The consequent results are not transferable to
other situations.
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 19 -
4.2.3 Calculation
The calculation of the reference factors for the packaging installation from the known data and reference
factors from the installation derives from the basis of approximation process and from the gradual reduction
of the actual installation structure to simplified structures. This method is in practice only really applicable to
very simple structures, eg rigid sequential linkage and uncontrolled parallel linkage of identical elemenst
without buffer, see 3.3.1.1, 3.3.1.2, 3.3.2.1). As the size and complexity of the packaging installation grows
so does the required level of effort grow disproportionally, the results become increasingly unreliable and
there is a large increase in the theoretical demands on the mathematical representation of the installation.
The calculations deliver increasingly median reference factors.
For the following cases the practical calculation is sensible:
a) Uncontrolled and controlled rigid sequential linkage (3.3.1.1, 3.3.1.2):
( )min
ni nA
q q = (33)
( )min
esti estA
q q = (34)
( ) ( ) [ ]

=
i btr v btr estA btrA
t t t q q / 1 (35)
( ) ( ) [ ]

=
i
btr vtf btr estA effA
t t t q q / 1 (36)
( )
% 100
/ 1
1
in
t t
v
i
q v
gA

+
=

(37)
% 100
) / ( 1
1
in
t t
v
i q vt
tA

+
=

(38)
gi gA
= (39)
ti tA
= (40)
mi aA
= (41)
b) Uncontrolled parallel linkage of identical elements without buffer (3.3.2.1):

=
ni nA
q q (42)

=
esti estA
q q (43)

=
btri btrA
q q (44)

=
effi effA
q q (45)
( ) ( ) 1 ,..., 1 , 0 1 = =

i k v v v
k
gi
k i
gi
k
i
gA
(46)
( ) ( )
k
ti
k i
ti
k
i
tA
v v v
=

1
(47)
( ) ( )
k
gi
k i
gi
k
i
gA
=

1 (48)
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 20 -
( ) ( )

=
k
ti
k i
ti
k
i
tA
1 (49)
( ) ( )

=
k
mi
k i
mi
k
i
aA
1 (50)
with k=0,1,....,i-1
i=number of installation elements
k=number of the installation elements out of operation
With all other types of linked installation the calculation method is too imprecise or too laborious and
therefore not possible or practical.
4.2.4 Simulation
For the simulation of the operating performance of the packaging installation a PC with a simulation system
is used to display the target installation and the packaging process is projected as near as possible to
reality.This method is very quick and flexible to changing conditions. The simulation delivers considerable
information over and above the reference factors relating to the performance of the target installation.
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 21 -
Appendix A (normative)
Table A.1 Formula symbols
Formula symbols Designation Section
Efficiency rate of a packaging machine 3.2.2.3

A
Efficiency rate of a packaging installation 3.2.3.3

aA
Installation technical efficiency rate 3.2.3.3.3

g
Total efficiency rate of a packaging machine 3.2.2.3.1

gA
Total efficiency rate of a packaging installation 3.2.3.3.1

m
Machine technical efficiency rate 3.2.2.3.3

t
Technical efficiency rate of a packaging machine 3.2.2.3.2

tA
Technical efficiency rate of a packaging installation 3.2.3.3.2
n
aus
Number of waste packs from a packaging machine 3.1.7.1
n
ausA
Number of waste packs from a packaging installation 3.1.7.2
n
btr
Actual number of acceptable quality packs relating
to the operating time of the packaging machine
3.1.8.1
3.2.2.1.3
n
btrA
Actual number of acceptable quality packs relating to the
operating time of the packaging installation
3.1.8.2
3.2.3.1.3
n
est
Mathematical number of acceptable quality packs
at a set working speed of the packaging machine
3.2.2.1.2
n
estA
Mathematical number of acceptable quality packs
at a set working speed of the packaging installation
3.2.3.1.2
n
le
Number of empty cycles 3.1.6.1, 3.1.6.2
n
max
Maximum number of acceptable quality packs of a
packaging machine
3.2.2.1.1
n
maxA
Maximum number of acceptable quality packs of
a packaging installation
3.2.3.1.1
q Output of a packaging machine 3.2.2.1
q
A
Output of a packaging installation 3.2.3.1
q
btr
Operating output of a packaging machine 3.2.2.1.3
q
btrA
Operating output of a packaging installation 3.2.3.1.3
q
eff
Effective output of a packaging machine 3.2.2.1.5
q
effA
Effective output of a packaging installation 3.2.3.1.4
q
est
Target output of a packaging machine 3.2.2.1.2
q
estA
Target output of a packaging installation 3.2.3.1.2
q
l
Running time output of a packaging machine 3.2.2.1.4
q
n
Nominal rated output of a packaging machine 3.2.2.1.1
q
nA
Nominal rated output of a packaging installation 3.2.3.1.1
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 22 -
Table A.1 (complete)
Formula symbols Designation Section
t Time unit 3.2.2.1.1
t
a
Breakdown time of a packaging machine 3.1.5.1
t
aA
Breakdown time of a packaging installation 3.1.5.2
t
aus
Waste running time of a packaging machine 3.1.7.1
t
ausA
Waste running time of a packaging installation 3.1.7.2
t
btr
Operating time of a packaging machine 3.1.3.1
t
btrA
Operating time of a packaging installation 3.1.3.2
t
l
Running time of a packaging machine 3.1.4.1
t
lA
Running time of a packaging installation 3.1.4.2
t
le
Empty running time of a packaging machine 3.1.6.1
t
leA
Empty running time of a packaging installation 3.1.6.2
t
m
Machine working time of a packaging machine 3.1.1.1
t
mA
Machine working time of a packaging installation 3.1.1.2
t
neb
Downtime of a packaging machine 3.1.2.1
t
nebA
Downtime of a packaging installation 3.1.2.2
t
q
Quality time of a packaging machine 3.1.8.1
t
qA
Quality time of a packaging installation 3.1.8.2
t
v
Lost time of a packaging machine 3.1.9.1
t
vA
Lost time of a packaging installation 3.1.9.2
t
vo
Organisationally caused lost time of a packaging machine 3.1.9.1.2
t
voA
Organisationally caused lost time of a packaging
installation
3.1.9.2.2
t
vt
Technically caused lost time of a packaging machine 3.1.9.1.1
t
vtA
Technically caused lost time of a packaging installation 3.1.9.2.1
t
vtf
Machine external, technically caused lost time 3.1.9.1.1.2
t
vtfA
Installation external, technically caused lost time 3.1.9.2.1.2
t
vtm
Machine related, technically caused lost time 3.1.9.1.1.1
t
vtmA
Installation related, technically caused lost time 3.1.9.2.1.1
v Availability of a packaging machine 3.2.2.2
v
A
Availability of a packaging installation 3.2.3.2
v
g
Total availability of a packaging machine 3.2.2.2.1
v
gA
Total availability of a packaging installation 3.2.3.2.1
v
m
Machine technical availability 3.2.2.2.3
v
t
Technical availability of a packaging machine 3.2.2.2.2
v
tA
Technical availability of a packaging installation 3.2.3.2.2
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 23 -
Appendix B (normative)
Types of linkages of packaging installations
B.1Sequential linkage
Illustration B.1 Uncontrolled rigid sequential linkage
Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Packungen Packages
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 24 -
Illustration B.1.1 Controlled rigid sequential linkage
Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Packungen Packages
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 25 -
Illustration B.1.2 Uncontrolled loose sequential linkage
Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Puffer Buffer
Packungen Packages
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 26 -
Illustration B.1.3 Controlled loose sequential linkage
Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Puffer Buffer
Packungen Packages
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 27 -
B.2Parallel linkage of identical elements
Illustration B.2.1 Uncontrolled parallel linkage of identical elements without buffer
Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Packungen Packages
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 28 -
Illustration B.2.2 Controlled parallel linkage of identical elements without buffer
Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Packungen Packages
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 29 -
Illustration B.2.3 Uncontrolled parallel linkage of identical elements with buffer
Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Puffer Buffer
Packungen Packages
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 30 -
Illustration B.2.4 Controlled parallel linkage of identical elements with buffer
Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Puffer Buffer
Packungen Packages
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 31 -
B.3Parallel linkage of different elements
Illustration B.3.1 Uncontrolled parallel linkage of different elelemnt without buffer
Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Packungen Packages
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 32 -
Illustration B.3.2 Controlled parallel linkage of different elements without buffer
Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Packungen Packages
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 33 -
Illustration B.3.3 Uncontrolled parallel linkage of different elements with buffer
Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Puffer Buffer
Packungen Packages
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 34 -
Illustration B.3.4 Controlled parallel linkage of different elements with buffer
Packgut Product
Packmittel Packaging materials
Packhilfsmittel Packaging ancilliaries
Anlagenelement Installation element
Puffer Buffer
Packungen Packages
VDMA Packaging Machinery Association (Translation by VDMA 05/2005) - 35 -
Bibliographical references
[1] DIN EN 415-2, Safety of packaging machines - Part 2: Packaging machines for pre-made formstable
packaging materials.
[2] DIN EN 415-3, Safety of packaging machines - Part 3: Form, Fill and Seal machines.
[3] DIN EN 415-4, Safety of packaging machines - Part 4: Palletising and Depalletising equipment.
[4] DIN 8783, Drinks filling equipment - investigate analysis of filling equipment technology.