© copyright 2012 tag and label manufacturers institute, inc. all rights reserved. title of...

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

Title of Presentation | Presenters Name

Set Up and Waste Reduction

Young Leaders Development Organization – TLMI Converter Meeting 2012

Presented by Brian Hurst, VP Production, Yerecic Label


YLDO | TLMI CONVERTER MEETING 2012

The One Best Way

-Created to meet the need for faster set ups on jobs while reducing make ready waste.

-Standard work developed by the Press teams, guided by management.

-Team roles are written and team members are trained and certified in their roles.

-Each team consists of a team leader (press operator), helper and finisher.



-All 3 team members have specific responsibilities during the set up.

-Through several video taped set ups the team split the duties, so no two team members would cross paths during the set up.

Determining responsibilities

-The team graphs each video taped set up to ensure optimum activity sequence.



The team was taught that there was two parts to a set up, internal and external:

-InternalWhat “must be done” while the press is stopped!

-ExternalWhat “could be done” while the press is running!

Separating Internal and External



External consists of two phases

1. Pre–Set up: Tasks completed while the press is running the current job.

2. Post-Set up: Tasks completed once the next job is up and running.



Internal consists of two phases

1. Set up: The press is stopped.

2. Set up: The press is running.



Pre Set Up(External)

Operator:

1. Monitors the quality of the run.

2. Completes all necessary documentation for the run.

3. Issues a “two minute warning” prior to the run ending.



Helper:

1. Get the cylinders for the next job.

2. Inspect and mount plates on cylinders and move cylinders to point of use.

3. Pull all raw stock for job.

4. Ink maintenance.




Finisher:

1. Pull die from die aisle to point of use.

2. Get cores for next job.

3. Slit finished master on rewinder or man turret.




Operator:

1. Start the clock.

2. Pull finished plates from the print stations.

3. Load new plates into correct stations.

4. Mesh gears and check the fine tunes.

5. Set and register print stations. (Starting at the die station)

Set Up – Press Stopped(Internal)



Helper:

1. Change raw stock on unwind (when needed).

2. Change ink and aniloxes.

3. Assist operator loading new plates.

4. Set and register print stations. (Starting at the Unwind)




Finisher:

1. Removed finished master from the rewind shaft. (Disconnect web from turret if in use)

2. Remove waste matrix.

3. Change die.

4. Set camera to correct gear size.




Operator:

1. Set and register print stations.

2. Push idle and begin to make final adjustments.(Done parallel with the Helper)

3. Push run and gradually increase the speed, making final adjustments.

4. Flag the master and stop the clock.

Set Up – Press Running(Internal)



Helper:

1. Reset the web guide if needed.

2. Set and register print stations.

3. Push run and gradually increase the speed, making final adjustments. (Done parallel with the operator)

4. Move on to post set-up activities.




Finisher:

1. Register the die into the print as soon as the first color reaches the die station.

2. Start waste matrix.

3. Set RD score knives.

4. Move on to post set-up activities.




Operator:

1. Perform quality assurance checks.

2. Monitors the quality of the run.

3. Complete quality checks.

Post Set Up(External)



Helper:

1. Clean out unneeded colors.

2. Clean and put away all aniloxes.

3. Demount plates from previous job.

4. Put cylinders away.

5. Return unused raw stock to inventory.

6. Return to Pre-Set up activities.




Finisher:

1. Slit finished master on rewinder or man the turret.

2. Case finished rolls to customer specifications.

3. Return to Pre-Set up activities.




Accountability

1. The Team Leader determines when their team is ready for certification testing.

2. Shift Managers will video tape and critique the performance with the team.

3. Once the shift manager is satisfied with the team’s performance, VP Manufacturing will observe a set up and score the team.

4. Managers use andon lights to monitor set ups.

(ONLY A PERFECT SCORE WILL QUALIFY FOR CERTIFICATION!)



One Best Way Team Testing

Press: Operator:

Shift: Helper:

Date: Finisher:

Who What Yes No N/A

Operator Issues the 2 minute warning

Operator Starts the clock

Operator Start at Rewind, load new plate into correct stations.

Operator Set and register print starting at the rewind end (parallel processing)

Operator Match plates with 1st color to with 1/8"

Operator Push idle and begin to make final adjustments.

Operator Gradually increase speed and make necessary adjustments

Operator Place flag in master or splice on the turret (finisher responsibility for turret)

Operator Stop the clock and record set up time

Operator Log previous job information onto Press Sheet

Operator Fill out QUALITY check approval for new job

Operator Monitor QUALITY

Helper PRE SET UP activities

Helper Change Paper (if needed)

Helper Change ink and aniloxes (if needed)

Helper Start at unwind, load new plate into correct stations

Helper Set and register print starting at the unwind end (parallel processing)

Helper Match plates with 1st color to with 1/8"

Helper Push idle and begin to make final adjustments.

Helper Gradually increase speed and make necessary adjustments

Helper Move on to POST SET UP activities

Finisher PRE SET UP activities

Finisher Remove finished master and put new core on rewind

Finisher Remove wsate matrix

Finisher Release RD score knives

Finisher Change die

Finisher Change camera settings

Finisher Register DIE to PRINT

Finisher Start waste martix

Finisher Set RD score Knives

Finisher Move on to POST SET UP activities

SET UP TIME CERTIFICATIONWASTE COUNT

Brian S. Hurst VP ManufacturingPASS/FAIL



-By developing and implementing this practice we have been able to increase up time and reduce waste.

-Up time has increased:

A 55% improvement has been achieved on set up times.

-Make ready waste has decreased:

A 63% improvement has been achieved in waste reduction.

One Best Way Results


Title of Presentation | Presenters Name

TLMI: Partnering to Grow Through Knowledge and Education

Thank you!

© copyright 2012 tag and label manufacturers institute, inc. all rights reserved. title of...

Documents

label manufacturers

yldo tlmi converter

yerecic label copyright

pre set upexternal copyright

label day

pre set upexternal operator

team members

faster set ups