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Manufacturing speeds, flexibility and capabilities, and costs of outsource slitters are far often key determinants in traditional supplier selection for manufacturing. While these factors are important, they often overlook the operating competences and areas of innovation that can benefit the supplier-vendor relationship. This project emphasises other aspects crucial in the evaluation of outsource slitters- human factors and materials management processes. These factors have a substantial impact in the operating competencies of the supplier. Without looking into these factors, the client often has to deal with quality and delivery issues due to manufacturing defects and downtime that would have offset upfront cost savings.
Citation preview
1
Case Study: Understanding Human Factors and Materials
Matching in selection of Slitters
Stefan Choo
Image obtained from http://www.google.com/imgres?
biw=1366&bih=587&tbm=isch&tbnid=KHFSNVzpOAAfrM:&imgrefurl=http://
www.rasmart.co.uk/ra-smart-to-supply-new-transmatic-machines-for-2012/
&docid=HCDS5dxh8j7hmM&imgurl=http://www.rasmart.co.uk/wp-content/uploads/
2011/12/TRANSMATIC-SONIC-SLITTING-MACHINE.jpg&w=450&h=469&ei=YiGTUf71JPb84APn9YG4BQ&zoom=1&iact=rc&dur=312&page=1&tbnh=146&tbnw=149&start=0&ndsp=21&ved=1t:429,r:10,s:0,i:110&tx=89
&ty=98
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Presentation Outline
Definition of Slitting
Slitting Technologies: A comparison between Razor, Crush/Score and Shear Slitting
Selecting the right methods of cut for the right material and the right cut.
Technology Value Chain & Identification of Core Technology Differentiators
Innovation approach
Conclusion
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Slitting technologiesTerms and Definitions
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Definition of Slitting(From Oxford Dictionary Online)
noun
a long, narrow cut or opening: make a slit in the stem under a bud arrow slits
verb (slits, slitting, slit)
[with object] make a long, narrow cut in: give me the truth or I will slit your throat [with object and complement]:he slit open the envelope
cut (something) into strips: a wide recording head magnetizes the tape before it is slit to domestic size
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(From Colins Dictionary Online)noun• a long narrow cut• a long narrow openingverb• Word forms: slits, slitting,
slit• tr to make a straight long
incision in; split open• to cut into strips lengthwise• to sever
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Slitting: A concise comparison between Razor, Shear & Crush
Methods
Video Omitted
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Razor Slitting: An Overview
4 Key factors to consider1. Safety
2. Principles of separation
3. Installation Parameters
4. Blade Parameters
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Score Slitting: An Overview
5 Key factors to consider
1. The web
2. Nip force
3. Blade profile
4. Metallurgy
5. Mounting Geometry
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Score Slitting: Matching blade to materials
Do suppliers have range of blades for different applications?
Smaller RadiusLess energy requiredRapid tip fracture & Anvil Roll Grooving
Larger tips radiiHigher force & energy consumption Tools dull/ break easily
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Profiles of materials cut using score slitting
A. Clay-coated paperboard (0.45mm). Ridge formation due to blade displacement.
B. Polyethylene (0.1mm). Flaky edges. Edge extrusion by blade.
C. Polypropylene (0.07mm). No material defects, but slitter dust leftover1.
D. Paper towel. Effectively and cleanly crushed.
E. Nonwoven towel. Flakes of resin deposited during scoring.
Images obtained from Tidland (2003)
eImage Obtained from Schaber, R (1993)
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Shear Slitting: An Overview
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Match Material Properties to Blade Profiles &
Parameters: Shear Slitting
Stefan Choo Source: Slitting Techniques (2002)
ρ
δ
σUTS
μ
σyck
t
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Key Criterion- Slitting Selection
1. Identify most important characteristics of each slitting method.
2. Identify characteristics of materials to be slit.
3. Match materials to best method.
4. Value Added Services to Buyer. (Stuarda)
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Blade Life
Cross Comparison of Slitting Technologies
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Razor Slitting• Thin film products
• - Simplest- Least Expensive
• - Uneven thickness (Flow distortion)
• - Permanent distortion (Entrapped air)- Low tolerance
• ≤25 microns• <1000ft/min
Crush/ Score Slitting• Adhesives
• - Works well for thin edge trim- Ease of blade cleaning
• - Dusty, largest amount of dust- Poorest Edge Quality- Not for stiff products or tensile plastic films
• >25 microns• Unstated. Slow.
Shear Slitting• Any flexi-web material
• - Customizable- Fast
• - Min amount of slitting dust
• Complex-Tacit knowledge of operators
• >25 microns• >1000ft/min
Advantages
Weaknesses
**Generally Best for
Source: Wolf, M (2005), Rowe, R(2001), Bentley DJ (2005)
Prescribed thicknessSpeed
Cost
Longest Blade Life (~10-15X Shear)
Shortest Blade LifeIntermediate Blade Life (15X > Crush)
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Materials Based Selection of Slitting
Process
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Is material thin ≤25μm
YesIs material sufficiently flexible?
Good interlayer bond strength
Knowledge & competency of manpower in
Machine Setup and Customization
Ease of Blade Penetration into
material?
Material pulls apart easily without brittle
breaking.
Speed Critical?
Does material soften (Tg) at machining
temperature?
Razor Slitting
Yes
Safety procedures & handling
Does material deposit on/ stick to
blade easily?
No
Ok
Material needs to stretch significantly
in direction of applied force before
breaking?No
No
No
No
No
Yes
Material recoverable from compression?
No
Yes
No
No
Yes
Yes
No/ Variable Thickness
Crush/ Score SlittingYes
No
No
Yes
Yes
Appropriate Roll Handling &
Tension Control
Shear Slitting
Speed/ Quality Critical?Yes
Yes
Includes exception: woven materials
Assumption:- Uniform material across single layer.
Exclusions:- Fibers- Aligned composite materials
Yes
Start
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Post ProcessingTechnology
Technology Value Chain- Slitting Suppliers
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Raw Materials
Equipment and Supply
Vendors
3M- Us
Manpower- Skilled Labor
Freight
Packaging
Technical Know-How
Material-Blade Selection
Machine Parameters
Engineering Value Added
Services
Machine
Knife holder
Tension Control
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Impacts on Knife holder on Slitting V.C.
Rigidity, Compliance and Vibration
Setup and Repositionabilit
y
Can’t Angle Adj/
Load Regulation
Engage/Dis- Sequencing
Safety- Blade Changing and
Adjustment
Safety
Productivity (Manpower) &
Quality (Output)
Source: Tidland (2002)
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What to look out for during supplier visit:
Safety-control mechanisms
Are they-1. Present?2. Clearly visible3. Adhered to?
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Survey Results- What influences Suppliers to
purchaseUpgradability of Machines
Differential winding- Aligns rolls of different thicknesses with precision (
Differential Winding)
# Able to slit in register with applied coatings
Controls for specific features
Diagnostic and Troubleshooting
**Automation
56%
48%
38%
36%
31%
19%Image copied from “Slitting Survey: Results Let Us Hear Reader’s Voices
-Budget shrinking for Suppliers Frugal Innovations that improve converter output will be useful.
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Wherein lies the margin for supplier innovation?
Source: BTS industries website
To retrofit machine & upgrade Knifeholder?
To buy a new machine to upgrade from score to razor slitting/ shear slitting?
New: USD$1,400Used: USD $795
Source: http://stores.margot.com/Manufacturing_Process_Equipment/Web_Handling_and_Process_Equipment/Knives_and_Knife_Holders/Slitter_Knife_Holders/Used_Tidland_Class_II_Shear_Knife_Holder_5_RH_p157.html
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Conclusion:What matters most
Tidland Corp
Use the right method of cut for the right material and right cut!
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Q&A/ Objections?“It’s much cheaper, easier and saves time
to choose a slitter who has machines that run at fast speeds and promise to slit across most materials.”
“We outsourced to them since it’s not our core capability, they should serve us accordingly. I don’t see any point in investing more time and resources to study their processes”
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Outsourcing: Why outsource?A creative conundrum
Present/ PastCost
Economy of ScaleLower Wages
Redistribute resources from non-core to innovation
activitiesAccess to new, non-core
Competencies
CapacityLoss of Knowledge
ArchitectureLoss of Process
Architecture
Acquisition of Product and Process Architecture
Development of Knowledge Architecture
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↓ CostsImproving Innovation Capability
Faster Time To Market
Better Products
Slower time to market,
Lower costs (but really so in the long term?)
InnovateOperate
Source: Bengstsson, L (2009)
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Glossary of terms Converting companies are companies that specialize in combining raw
materials such as polyesters, adhesives, silicones, tapes, foams, plastics, felts, rubbers, liners and metals, as well as other materials, to create new products. (Source: Wikipedia)
Web speed: (inferred) Feed speed of the substrate material that is to be processed. The web is usually a long thin flexible material passed over rollers.
* Web handling is the art and science of getting a web through a machine with maximum productivity and minimum waste.
Differential core technologies: Technology that allows for uneven cuts to be processed by the slitter
Slit Edge: The edge of a coil or sheet after being fed through a highly tempered knives located on the slitter head. The edge of slit coils has tighter tolerances than normal mill run edges.
Nip: a pinching force between two surfaces. In manufacturing,
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Bibliography Bentley Jr, D. J. (2005). Razor, Crush, And Shear Slitting Principles: Advantages And Disadvantages For Film And Foil
Applications. Paper, Film and Foil Converter, 79(5), 67. Retrieved from http://libproxy1.nus.edu.sg/login?url=http://search.proquest.com/docview/211371591?accountid=13876
Egeröd, J., & Nordling, E. (2010). Strategic Supplier Evaluation-Considering environmental aspects. Linköping.
Hamilton. (2005). Principles of Shear Slitting. Hamilton, OH. Retrieved from http://www.hamiltonknife.com/educational_materials.htm
Hawkins, W. E. (1999a). Slitting technology - part I: A look at razor slitting. Paper, Film and Foil Converter, 73(5), 28. Retrieved from http://libproxy1.nus.edu.sg/login?url=http://search.proquest.com/docview/211390590?accountid=13876
Hawkins, W. E. (1999b). Slitting technology--part II: Razor slitting continued. Paper, Film and Foil Converter, 73(6), 26. Retrieved from http://libproxy1.nus.edu.sg/login?url=http://search.proquest.com/docview/211407551?accountid=13876
Lowe, R. (2001). Slitting survey. Paper, Film and Foil Converter, 75(8), 45. Retrieved from http://libproxy1.nus.edu.sg/login?url=http://search.proquest.com/docview/211397925?accountid=13876
Schable, R. (1993). Slitting Solutions. Paper, Film and Foil Converter. Retrieved May 29, 2013, from http://tidland.maxcessintl.com/slitting/slitting-materials-technical-articles
Schable, R. (2003). A guide to slitting. Converting Magazine. Retrieved from http://tidland.maxcessintl.com/slitting/selecting-slitting-method-technical-articles
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Biblography Shea, B., & Benson, G. (1999). Is your slitting system cutting into your profits? Paper, Film and Foil Converter, 73(6),
64. Retrieved from http://libproxy1.nus.edu.sg/login?url=http://search.proquest.com/docview/211376630?accountid=13876
Slitting Techniques, Choosing the best Method. (1998). Chicago, United States, Chicago.Slitting Technology. (2002).The Plastic Film and Foil Web Handling Guide. CRC Press. doi:doi:10.1201/9781420031782.sec2
Spaulding, M. (2008). Outsourcing speeds “time to market”. Converting Magazine, 26(8), 50–n/a. Retrieved from http://libproxy1.nus.edu.sg/login?url=http://search.proquest.com/docview/200120945?accountid=13876
Stundza, T. B. T.-P. (2005). Buyers want more than what is being offered: service centers offer metal processing, on-time deliveries; buyers want market research, customer analysis. Purchasing, 134(18), 32B1+. Retrieved from http://go.galegroup.com/ps/i.do?id=GALE|A138755671&v=2.1&u=nuslib&it=r&p=AONE&sw=w
Troubleshooting Webhandling Problems. (2002).The Plastic Film and Foil Web Handling Guide. CRC Press. doi:doi:10.1201/9781420031782.sec3
Web Stability. (2002).The Plastic Film and Foil Web Handling Guide. CRC Press. doi:doi:10.1201/9781420031782.sec1
Wolf, M. (2005). Choosing the Right Equipment: A Hair-Slitting Ordeal. PackagePrinting, 52(2), 22–27. Retrieved from http://libproxy1.nus.edu.sg/login?url=http://search.proquest.com/docview/224560827?accountid=13876
Zelt, A. (2006). How to avoid slit-in coil slitting problems. TheFabricator.com. Retrieved May 29, 2013, from http://www.thefabricator.com/article/coilprocessing/how-to-avoid-slit-in-coil-slitting-problems
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Additional Information
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Schematic overview of Slitting Machines
Roll Setup for Basic Razor Slitting
Schematic Setup for Automated Shear Slitting
Sourced from Hawkins, WE (1999)
Blade
Blade oscillation system for razor slitting
Razor Slitting
Shear Slitting
Shear Knives
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Key Constraints of Machining Methods
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Razor Slitting
Safety
Slit Edge Quality:
Tension Control
Blade Life
Crush/ Score Slitting
Blade Life
Slit Edge Quality
Slitting Speed
Shear Slitting
Blade Wear
Difficult to customize various slit widths for
various products
Precision of slit configuration- • 1. Operator skill• 2. Knifeholder design
Safety
Source: Slitting Techniques, Solutions (2002)
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Improvements to slitting processes/ designs
“Having the right machine for the job is the biggest cost savings a converter can have”-------- Megan Wolf, Package Printing (2005)
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How issues can be addressed by slitters
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Razor Slitting
Use premium blades against wear
Better holder and tool design such that manual
changes are less needed
Crush/ Score
Slitting
Blade Life
Slit Edge
Quality
Slitting Speed
Shear Slitting
Blade Wear
Difficult to customize various
slit widths for various products
Precision of slit configuration- • 1. Operator skill• 2. Knifeholder
design
Safety
Lineal Die Slitting
Ultrasonic Slitting
Source: Slitting Techniques, Solutions (2002)
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Issues Possible solutions
Affects Impact to Company & 3M
Competitive Advantage
Downsides to Company/ 3M
Downtime due to manual blade changes (number + frequency)
Automatic set-up to the slitter bladed carriers
Frequency of tool change
↓ manual labor & production downtime
Outpaces, ↓ competition
-Expensive-Initial cost of equipment purchase is passed on to 3M
Long setup time for specific configurations
CAD integration
Design automation & integration with manufacturing outputs
Responsiveness to user needs.-Configuration & Design changes- Complementary operations
Localization of services to the user
↑ Range of outputs to the user
+ Differentiation point (Supplier has more bargaining power)
Supplier competes in niched marker, Limits choices to 3M
Improvements to slitting processes
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Issues Improvements
Affects Impact to Company & 3M
Competitive Advantage
Downsides to Company/ 3M
Score slitters fitted on old machines- Cheap to supplier, resistant to change
Retrofit old machines using score slitters with shear slitters
Frequency and tools of production
↓ labor cost ↑ capacity of service to customer
↑setup costs.
Quick change knife holder cartridge
Eliminates downtime
↓↓ or x manual labor
↑↑Quality↑↑Safety↓Lead time & TTM
Sequential air valving
Prevents blade impact and damage
↓ replacement of blades
↑Quality
Clear & Consistent Shear Angle
Cut quality &Productivity
↑ Yield↓ Defects/ Damage
↑Quality
Improvement to slitting processes
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Quality of Slits
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Common problems with Slitting & Proposed
Solutions
Excessive Dusting
↑ Grind Angle
Use tougher blade material
Tearing/ Dusting of Non-woven fabrics
↓ Blade Overlap
↑Slitter Overspeed
Carbonless paper
↓ Blade Overlap
Correct the Blade Mounting
Blade wear
Method of slitting
Shear Slitting
Scoring
Scoring
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Common problems with Slitting & Proposed
Solutions
Excessive Dusting
↑ Grind Angle
Use tougher blade
material
Tearing/ Dusting of Tissues
↓ Blade Overlap
↑Slitter Overspeed
Laminates
Tailor specific
grind angles
↑Slitter Overspeed
Method of slitting
Scoring
Shear
Shear/ Scoring
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Knife holder types and capabilities
Additional Information can be accessed at http://tidland.maxcessintl.com/slitting/tidland-e-knifeholder