WEB INSPECTION AND DUAL TURRET SLITTERS

Size: px

Start display at page:

Download "WEB INSPECTION AND DUAL TURRET SLITTERS"

Darren Davidson
6 years ago
Views:

1 WEB INSPECTION AND DUAL TURRET SLITTERS BLENDING QUALITY AND PRODUCTIVITY Presented by Amit Kawa

2 SP ULTRAFLEX S PRODUCT RANGE

3 FLEXIBLE LAMINATES Process Wastage - Scenario PROCESS Printing Lamination Slitting CAUSES OF WASTAGE Doctor blade lines Shade variation Mis-registration De-lamination (during reel change or while removing print defects) Doctor blade lines Job set-up & change over Wrong cut AVERAGE WASTE 3% to 5% 0.5% to 2% 0.5% to 1%

4 ISOLATION OF PRINT WASTE Conventional Approach-Without Web Inspection PRINTING LAMINATION SLITTING Print wastages are flagged on output reel and carried forward to the Laminator. The Laminator is stopped at the flags to remove print wastages, lowering it s productivity and creating delaminated sections, adding to the waste. Lamination wastages are flagged on output reel and carried forward to the slitter. The Slitter is stopped at the flags to remove Lamination wastages, lowering productivity and affecting the finish of slit reels.

6 ISOLATION OF PRINT WASTE Contemporary Approach-With Web Inspection PRINTING INSPECTION LAMINATION SLITTING Print wastages are flagged on output reel and carried forward to the Web Inspection Rewinder. Reels are scanned for flags and inspected for print defects using inspection devices. Wastages are accurately removed, after which registered joints are made to produce defect free reels for the Laminator. Defect free reels from Inspection machine allow uninterrupted runs of the Laminator. Defect free laminated reels allow uninterrupted runs, optimizing productivity and producing slit reels with good finish.

7 THE ROLE OF WEB INSPECTION IN WASTAGE CONTROL & MAXIMISING PRODUCTIVITY

8 PRODUCTION FLOW 12µ PET film 1m web width 800 mm Rewind Diameter 270 MPM Ink CASE STUDY 12µ PET printed film 1m web width 800 mm Rewind Diameter 300 MPM 32µ 2 ply laminate 1m web width 800 mm Rewind Diameter Adhesive, 22µ PE 600 MPM 32µ 2 ply laminate 200mm slit width 350 mm Rewind Diameter

9 EFFECT OF WEB INSPECTION ON LAMINATOR CASE STUDY PROCESS Tonnage per month in MT Capacity utilization PRINTING Capacity Tonnage per month in MT- 150 LAMINATION Capacity Tonnage per month in MT- 452 Without prior inspection With prior inspection PRODUCTIVITY INCREASE OF LAMINATION % 100% 75% 100% Assumptions: 3 Defects per laminated reel; Time taken for editing : 4 minutes for each defect

10 EFFECT OF WEB INSPECTION ON DUPLEX SLITTER CASE STUDY Tonnage per month in MT Capacity utilization DUPLEX SLITTER Capacity Tonnage per month in MT Duplex Slitter Without prior inspection With prior inspection PRODUCTIVITY INCREASE OF DUPLEX SLITTER DUE TO INSPECTION % 85% 100% Assumptions: 3 Defects per laminated reel; Time taken for editing : 4 minutes for each defect

11 DUAL TURRET SLITTER REWINDER Rewind reel change-over CASE STUDY REWIND REEL CHANGEOVERS are much more frequent on Slitter Rewinders as compared with Printing and Lamination processes. Factors responsible for frequent rewind changeovers: 1. Thicker substrates 2. Smaller rewind lengths 3. Higher speeds 4. Multiple ups On dual turret slitters, changeover related activities are carried out on the free shaft while the machine is running. The machine stops for just 25 seconds to allow the turret to index, before restarting.

12 DUAL TURRET SLITTER REWINDER Example for cycle time calculation CASE STUDY DUPLEX SLITTER REWINDER DUAL TURRET SLITTER REWINDER Number of ups 6 6 Time to produce one set of rewind reels 4 mins 4 mins Rewind reel change-over time 3 mins 25 seconds Total cycle time 7 mins 4 mins 25 seconds

13 DUPLEX V/S DUAL TURRET SLITTER REWINDER Rewind Changeover time & Capacity utilization CASE STUDY Cycle Time - Duplex slitter Cycle Time-Dual Turret slitter Rewind change-over Productive time Rewind change-over Productive time As a result, a Duplex slitter is utilised to only 57% of its capacity. On the other hand a Turret slitter is utilised to 90% of its capacity.

14 EFFECT OF WEB INSPECTION ON DUAL TURRET SLITTER CASE STUDY Tonnage per month in MT DUAL TURRET SLITTER Capacity Tonnage per month in MT Dual Turret Slitter Without prior inspection With prior inspection PRODUCTIVITY INCREASE OF DUAL TURRET SLITTER DUE TO INSPECTION % Capacity utilization 81% 100% Assumptions: 3 Defects per laminated reel; Time taken for editing : 4 minutes for each defect

15 WEB INSPECTION AND DUAL TURRET SLITTERS A close connection CASE STUDY Dual Turret Slitter Rewinders fed with DEFECT-FREE reels run virtually non-stop, resulting in more output per Machine, Man and Unit space. SLITTER CAPACITY PLANNING TO SUPPORT ONE PRINTING MACHINE DUPLEX SLITTER DUAL TURRET SLITTER Machine 2 1 Manpower 4 2 Unit Space 104 sq. m 58 sq.m

16 TO SUMMARIZE CASE STUDY By adding the process of Inspection prior to Lamination - Productivity of Laminator increases by 33% - Productivity of Duplex Slitter increases by 17% - Productivity of Dual Turret Slitter increases by 23% Downstream machines run UNINTERRUPTED and are utilized to their FULL CAPACITY.

17 ADVANTAGES

18 QUALITY A lot of defective material is likely to be missed while removal on lamination machine which is far from an ideal machine for inspection. Fine defect removal is possible on inspection machine which is purpose built for accurate defect detection, defect removal and making registered joints. The machine features necessary tools to facilitate editing such as stroboscope, compatibility with 100% defect detection system, forward- reverse operation, splice table and waste rewind section. Inspection process ensures that only good material reaches the customer.

19 QUALITY As the slitting machine is not stopped for editing, flush rewind reels finish can be achieved. Inspection process ensures flush rewind reel finish for onward supply to the customer.

20 PRODUCTIVITY Defect free reel from the inspection machine ensures that the Laminator can run without interruptions for print defect removals. Defect free reel from the laminator ensures that the slitter can run without interruptions for lamination defect removals. In case of Turret Slitters, the drastically shortened rewind changeovers would be the only cause for machine stoppage resulting in an additional productivity over duplex slitters. Inspection process leads to full utilization and increased productivity of downstream Lamination and Slitting machines.

21 WASTAGE REDUCTION Wastages due to de-laminated material: Considering 3 defects per laminated reel in our Case Study the total loss due to delaminated material is 1.11 MT or Rs. 2 to 3 lakhs/month per printing machine. Wastages due to scrapping of good material: During defect removal on the laminator, depending on the expertise of the operator, a significant amount of good material is also scrapped. The Web Inspection rewinder, by making use of it s forward- reverse operation ensures that the defect point is precisely located and only defect material is removed from the reel.

22 MANAGEMENT INFORMATION SYSTEM On our Inspection machine wastage can be systematically tracked, and necessary steps taken towards wastage elimination. Wastage tracking is the first step towards wastage elimination.

23 CONCLUSION The potent combination of Web Inspection Rewinding and Dual Turret Slitting Rewinding in a production line are the mantra for ZERO DEFECT OUTPUT and MAXIMUM PRODUCTIVITY.

24 THANK YOU

:DOTRIX MODULAR Digital printing has come of age

:DOTRIX MODULAR Digital printing has come of age Introduce a :Dotrix Modular digital printing process to your Packaging or POP and Display Business and you will save money while significantly reducing