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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/

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&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