Development of a Slitter-Rewinder’s Productivity and Quality
Henttonen, Pasi Juhani (2016)
Henttonen, Pasi Juhani
2016
Konetekniikan koulutusohjelma
Teknisten tieteiden tiedekunta - Faculty of Engineering Sciences
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Hyväksymispäivämäärä
2016-06-08
Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:tty-201605183998
https://urn.fi/URN:NBN:fi:tty-201605183998
Tiivistelmä
This thesis is made for UPM Raflatac to support slitter-rewinders’ quality and productivity projects by finding out which elements on a self-adhesive label slitter-rewinder affect on coil quality and machine’s productivity. Simultaneously with this thesis, a few upgrade projects were ongoing for some old slitters to improve both productivity and coil quality with smart and economical solutions. The knowledge gathered before the projects for the thesis was used in the projects and testing. Also the knowledge gathered from the projects and testing was used in this thesis. The knowledge was gathered from literature, by analyzing test results and talking to people from different organizations and comparing all those together.
In this thesis all different parts and main parameters of a slitter-rewinder are introduced in order to find out why those are needed and if there is something that could be done in a different way. The concept of a slitter’s productivity can be understood by knowing how the machine works and why it is designed like that. By following the process it is easy to recognize the time consuming processes. However, it is harder to say what should be done to improve the situation.
By understanding how quality is built and why the defects occur, it is possible to understand the original design reasonings, which can be used to make changes to a machine. This thesis is based on gathering and sharing the information for machine developers and defect troubleshooters so that they could easily find the correlations between the machine and the end product.
The results are also presented as design reasoning patterns. The design reasoning maps are made only for UPM Raflatac’s use. The individual productivity elements and coil defects that are the base for the maps are explained in this thesis. The idea in the productivity and quality maps is to share the information in a visual way that could be used as a tool to find information and get new ideas. The maps will be updated when new theories or machine elements are introduced. So far the mapping seems to be a good way to share designing ideas even though the maps are quite big at first glance. The goal is to increase organizational knowledge, save time and avoid surprises resulted from new desingning ideas.
Several factors to achieve better quality and productivity were found. Some of these factors are, for example good tensions control, good tension profile, symmetrical web path, good roller alignment, short down times and good production planning.
In this thesis all different parts and main parameters of a slitter-rewinder are introduced in order to find out why those are needed and if there is something that could be done in a different way. The concept of a slitter’s productivity can be understood by knowing how the machine works and why it is designed like that. By following the process it is easy to recognize the time consuming processes. However, it is harder to say what should be done to improve the situation.
By understanding how quality is built and why the defects occur, it is possible to understand the original design reasonings, which can be used to make changes to a machine. This thesis is based on gathering and sharing the information for machine developers and defect troubleshooters so that they could easily find the correlations between the machine and the end product.
The results are also presented as design reasoning patterns. The design reasoning maps are made only for UPM Raflatac’s use. The individual productivity elements and coil defects that are the base for the maps are explained in this thesis. The idea in the productivity and quality maps is to share the information in a visual way that could be used as a tool to find information and get new ideas. The maps will be updated when new theories or machine elements are introduced. So far the mapping seems to be a good way to share designing ideas even though the maps are quite big at first glance. The goal is to increase organizational knowledge, save time and avoid surprises resulted from new desingning ideas.
Several factors to achieve better quality and productivity were found. Some of these factors are, for example good tensions control, good tension profile, symmetrical web path, good roller alignment, short down times and good production planning.