Increasing efficiency with innovative machine alignment solutions.
Many costly equipment and product quality issues faced by manufacturers on a day to day basis can be attributed to the misalignment of components within their production lines. Our years of experience can help you design an alignment plan specific to your equipment, process, and business objectives. By applying the right solution for your needs, we can help you increase operating efficiency and allow you to spend more of your time where it is needed most.
Learn how machine alignment helps you gain much needed time.
Increased Speed, Reduced Waste
A corrugating client contacted OASIS about their desire to increase their machine’s operating speeds, while at the same time improving the quality of their board and reducing the amount of waste due to delamination and twist warp problems. OASIS first performed an initial machine alignment survey of the corrugating line – from the first flute section through to the end of the double backer. Numerous components and rollers were inspected for their machine centerline relationship to one another, as well as their level and horizontal alignment conditions. An offset machine centerline baseline was installed along the operator side aisle floor to serve as a reference for future inspection and alignment work on this machine.
OASIS then prioritized the problem areas and provided multiple alignment options for consideration. A decision was made to align all corrugating components through the double backer, including all of the hot plates. OASIS performed the alignment on a weekend accomplishing it within four 12-hour shifts. With the rollers within certain units now parallel to one another, and all of the units now parallel to each other, the product is tracking more uniformly, with less baggy edges, and more consistent heat measurements across the board. Results showed a 10% increase in operating speed, with vast improvements to the quality of the board, resulting in significantly reduced waste.
Converter Sees Large ROI
A leading producer of printed flexible packaging began having issues in one of their printing presses and one of their coater/laminator lines. The facility first began noticing web weave issues and wrinkles that resulted in registration problems and excessive waste in their rotogravure printing press. In order to correct this, they began replacing the chill rolls. OASIS was contracted to survey the line and provide alignment support to the mill’s in-house team as they replaced the chill rolls. While doing the survey, measurements showed that the entire line was grossly misaligned. As a result, the facility expanded the scope of OASIS duties to include complete assessment and press realignment.
Ten separate stations involving more than 500 rolls were involved in the printing press alignment project. The coater/laminator had developed severe wrinkles, coating skipping, baggy edges and tracking issues. These problems were costing the company approximately 5% of scheduled run time. OASIS completed a survey and the alignment of the entire line – a total of 237 rolls. The facility saw a significant improvement in both lines. Scrap was reduced by 5.6% in the printing press for a savings of $250,000 over 3 months and reduced by 5.2% in the coater/laminator for a savings of $350,000 over 2 months for a total savings of $600,000!
Improved Plastic Film Quality
A large manufacturer of plastic film products began receiving feedback from several of their customers stating that the final product did not meet their quality standards. The engineering group at this facility, hired OASIS to perform a thorough inspection of the components within the line in order to determine if misalignment was the cause of the quality issues. Using optical alignment tooling, the OASIS team performed an initial alignment survey of the rolls in the line. This inspection found that the overall alignment of the rolls was acceptable, however there was significant misalignment at the unwind and rewind turrets, as well as in the accumulator. OASIS worked with the team from this location to develop a plan to address the major alignment concerns.
The plan involved having OASIS perform a complete alignment of the line using optical alignment tooling and the mechanical capabilities of an OASIS large tool crib/truck. A seven-person OASIS team was able to complete this project in one 10-hour shift. This project resulted in improved film tracking and a substantial quality improvement that now met their customers’ stringent requirements.
Excessive tension, twist warp