by clicking the arrows at the side of the page, or by using the toolbar.
by clicking anywhere on the page.
by dragging the page around when zoomed in.
by clicking anywhere on the page when zoomed in.
web sites or send emails by clicking on hyperlinks.
Email this page to a friend
Search this issue
Index - jump to page or section
Archive - view past issues
FLEXO Magazine : January 2010
www.flexography.org JANUARY 2010 FLEXO 49 producing saleable product, the converter is incurring a loss on turnover. When the reason for not producing saleable product is downtime to change rolls manually, here is the magnitude of turnover loss incurred on our model press: • Manual roll change takes 7min. (average) • Assume a sales value of $5/1,000 labels 12 labels/Lft. (4 across x 3/ft.) At 150fpm average speed = 1,800 labels/min. At $5 per 1000 labels = $9/min. • Total loss on turnover = $63/roll change (7min./stop x $9 possible turnover) • Total annual loss on turnover = $252,000 (4,000 rolls/yr. x $63/roll change) If the converter in our model can earn a 15 percent margin on turnover, his or her annual loss on profit is equal to $37,800 (.15 x $252,000). Summarizing the findings below, the production model is losing over $150,000 per year. The three largest components are those that can in large measure be eliminated by the ad- dition of automatic roll changing. AUTO-ROLL CHANGE ADVANTAGES In addition to the advantages described above (eliminating material waste, reducing core waste, making efficient use of butt rolls, and eliminating lost time and unrealized turnover), automatic splicing will likely contribute other advantages to an operation. It is not uncommon, for example, to realize an increase in net production speed of 5 percent to 15 percent. This is a function of several factors, including the confidence of an operator to run faster with automation; and a more straight-line production speed unaffected by slowing, stop- ping, and restarting at every roll change. In addition to pushing more work through the press faster, automatic splicing can improve process quality. Running at a consistent speed has a positive effect, for example, on curing quality, as speed reductions on UV presses can often result in changes in UV power output and curing intensity. Automation may also have a positive effect on other opera- tions. The loss of 150ft. of stock in a press, due to a manual roll change, also requires that same 150ft. to be edited out of the printrun. Eliminating that loss also affords substantial savings in post-press editing. The combination of these advantages means improved service and delivery to your customers; and for you, a faster turnaround on jobs, a shorter billing cycle, and a greater abil- ity to compete for orders that you might otherwise have had to decline. All of which will contribute to your reason for being in busi- ness---profitability. ABOUT THE AUTHOR: Craig Thomson has more than 20 years' experience in web handling and roll changing. He is southeast (U.S.) regional manager and marketing manager for Martin Automatic Inc. Martin Automatic, headquartered in Rockford, IL, is a global provider of automatic splicing, rewinding and tension control systems. Summary on waste figures Total value per year Stripped waste $8,880 Waste left on core $27,800 Waste due to manual roll change (stop/start) $83,400 Margin loss due to loss of turnover (stop/start) $37,800 Total waste/lost profit $157,880 Revenue lost due to manual roll change (press stop) $112,000 Not realized turnover due to press stops $252,000 PLANTS & PROCESSES
Sustainable EOY 2009