Road Map to make Merit No 1 Packaging Company.

Reduce M/R time.

No Dog Fixtures which means safety Foiling
No compromise on quality
Currently we are using 120m rolls .
Machine runs at 4000 sheets to 6000
sheets/hour. The operator will have to
change the rolls every 10 to 20 mins.
Placing each roll on machine 1) requires
manpower, 2) binding the previous roll to
the next roll wastes 2 meters of foil.
If the operator keeps changing rolls at
every 15 mins how will he get time to look
at the quality of foiled sheets. Solution we
will look at the manual to find out the max
size of roll the machine can take, and
procure them.
 Setting the correct
Crease and Channel
Combination.
 Existing combination of crease rule and channel
Height of crease +
channel must be
equal to = 23.80
which is the height of
Height of creasing rule = 23.30 mm cutting rule.

Height of channel = 0.4 mm On Impression there

Height of channel must must be no gap between
equal to height of micron of channel and crease rule.
board. Current Gap = 0.01 mm
 Most of our boards
microns lie between
0.3 micron to 0.4
micron so channel of
0.4 is recommended.
With a 0.4 channel
23.4 mm crease rule
should be installed.
On Impression now there is
no gap between crease rule
and channel. Which gives best
crease. This reduces customer
complaint for runnability
Die cutting production speeds are less dependent on operator.
It is more dependent on 1) layout 2) tools.
Headlay Side Headlay Side
Ok vs not ok
orientation
Directly
dictates
1) Make
Ready time
2) Machine
Speed
3) Reduces
Crack
Backlay Side Backlay Side
Use of double knives reduce die cutting speeds significantly. Where
possible double knives must be avoided. Every knife used in die
cutting means that the sheet is being cut into more pieces and the
more the number of pieces the harder it becomes to run the job at
high speeds. It also means more time to do make ready. c
 Advantages.
1) Board Saving
2) Shorter Die cutting make ready time
3) Higher die cutting production speed
4) Less board elements to strip out in breaking.
Following re lay outing activity should start right
away before we order palletized board.
Fortunately this is the best time.
 The life of the cutting counter parts is directly dependent on the
combination of cutting rules and plate. We have to opt for the right
combination by 1) using counterparts with hardness as high as possible
and 2) by eliminating the gap between their individual hardness.
Current cutting rule hardness 66 HRC.
Current counter plate hardness 40 HRC.
Gap 16 HRC.
With our current cutting rule and plate
combination we are reaching 0.6 million
impressions.
 Recommended Combination.
Hardness of m-Power-S rules 69 HRC (Same Price)
Hardness of plate 60 HRC (1.5 Times Price)
Gap 9 HRC. Impressions 1.2 million to 1.5 million.
PMI is continuously narrowing down its quality tolerances. At
PMI the machine runs at 200 to 300 cards per min. They have
installed softwares to monitor their production downtimes
which are highlighted directly to the region. For this reason I
believe that there are chances that a printing fault might skip
the eye but a cutting fault that will cause a machine stop will
not go without getting a NC. For this I believe we should revise
the way we pack material for PMI, as the pallets are die cut,
they should be packed near the machine itself, so the cutting
operator can see his faults and correct them there and then
and not after a night’s shift where more than 12 to 14 pallets
are cut already.
 The width of a cutting rule is 0.7 mm. The
standard width of patching tape is 3 mm. currently
we are using two in house patching tapes of 4 mm
width. Which is not a good practice.

The standard micron of patching tapes are

0.03 mm 0.05 mm and 0.08 mm
We are using 1 mm patching tape and 0.07 mm
patching tapes
I would also recommend that to make die a better
department it is important that we start procuring
dies with laser jet rubber on the die. And have a die
library. Which will help keep a track how much each
die is used, and when the die is being sent for
reknifing.
Lastly I want to talk about a recent issue that was
faced in bake parlour job. Where the printed
material got cut before the process of offline uv.
The easiest way to rectify this issue is by printing
with UV on every printed sheet.