SETUP PROCEDURES

Machine: 122 United Rotary Die Cutter

Targeted Setup Time: 20 min

Machine Operator Takeoff Operator Floater

All these Duties should be DONE BEFORE the current order is complete
Ensure that floater has completed Complete pre-setup
their pre-set up checklist. checklist.

Check that the print card, load Ensure the correct board
tags, print plates, cutting die, and for the next setup is on
ink on the setup cart match the the conveyor and is
factory card. complete from
corrugator.
Duties to Be
As soon as the last box enters the
Done
hopper, raise the pre-feeder Ensure that correct
BEFORE
extender. dunnage is available for
Machine
next order.
Stops
Once the last box has passed
Running
through the machine, cut the air When set up cart and
off the feed table then raise the board are prepared, let
impression on the die-cut crew leader know.
cylinder.

Hit the Zero button to stop the

machine.

Individual Individual Duties

Duties to be (Perform these first once the machine stops running)
Done Roll stacker away from the
WHILE machine and remove key.
Machine is
open Unbolt cutting die from previous
order and place it in the “Last
Order” space on the setup cart.
Take the cutting die from the
“Next Order” space on the setup
cart, bolt it to cutting die cylinder.
Line up the cylinder and die
centerlines. Screw the first line
of bolts in the die into the first
row of bolt holes above the
cylinder scribe line.
Position layboy belts
Once the timing dial has
reached zero, open all
sections requiring work
during the setup.
Drain ink from the print
downs as required for
the next setup.
Remove printing plates
from previous order and
put them on return cart
for wash up.
Start wash cycle on
necessary ink systems.

Roll stacker into place.
Set the feed roll nip to incoming
board caliper.
Set impression setting on print
stations.
Attention: When you are done your individual tasks and Before moving to the next
step, you MUST check with the Crew Leader for additional duties to get the
machine closed as quickly as possible.
Duties to be
done Once the Takeoff Operator has set
AFTER the up the feed table, feed one sheet.
machine is
closed Measure the distance that the
register is out on the cutting die
and each print down. Make all
adjustments before running a
second box so the second sheet
will be in register.
Set die cut impression and run
second box. If further adjustments
are necessary, make adjustments.
Send box into stacker accumulator
and use it to set gates.
Once stacker is set, remove box
from stacker and perform 31
quality checks.
Attach the printing
plates for the next order.
Ensure that the plate
centerline is in line with
the cylinder centerline.
Remove the ink from
the previous order.
If a print down is used
on the next order, check
that the ink system is
clear, put new bucket of
ink in place and start
system.
Take a handful of board
from the pre-feeder
conveyor line and set
feed table backstop, side
gates and front stops.
Close machine and then
press zero button.
Setup pre-feeder: Post Set Up
a. Adjust the position a. Last order print card
of the stop. is filed away.
b. Lower pre-feeder b. Last order printing
extender. plates are washed
c. Set position of side and returned to
tampers. returns area.
d. Run board up c. Last order cutting die
extender. returned to returns
area.
Set Chicago Electric d. Tooling repair
requests completed
Set bundle breaker as required.
e. Last order ink
Once order is running: returned to returns
a. Enter last order’s area.
production f. All remaining load
information into tags from last order
computer. destroyed.
b. Send out last unit g. Unused dunnage
 of last order with returned to dunnage
Start running order. the factory card area.
attached.
Once order is running, check ink c. Perform 31 quality
PH and viscosity and maintain checks
during production run.

* Remember these are guidelines to reduce setup times on the machine. If your crew has a
method that is quicker and more efficient, let us know and we will change this form to fit the
enhanced method!! (Example: Machine Operator and Takeoff Operator set up roles can be
exchanged)