2. 1 Notes
Version Note Approved By
Date
Approved Status
1
Insert M/C Setup was approved by
Greg Williams Greg Williams 5/09/2013 Completed
I-001 Rev:001 Version:1
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10:00:41 AM Supercedes:
Page 2 Date Printed:9/5/2013
3. 2 Objective
Work Center: Inert M/C
2.1 Objective of Setup
The objective of this instruction is to
ensure correct setup of the inserting
machines first time every time and to
reduce setup time by all operators
following the standard procedure.
Insert machine.JPG
I-001 Rev:001 Version:1
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10:00:41 AM Supercedes:
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4. 3 Safety
Work Center: Inert M/C
3.1 Pre start safety
Adhere to all safety controls,
procedures and PPE if required.
LIFT CORRECTLY.
ENSURE POP UP STOP BUTTON IS
DEPRESSED PREVENTING
ACCIDENTAL START.
ENSURE NO TRIP HAZARDS EXIST,
CARTONS AND PALLETS OF RAW
INSERT MATERIALS ARE
CORRECTLY PLACED.
lifting.jpg
Pop up stop button.jpg
I-001 Rev:001 Version:1
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10:00:41 AM Supercedes:
Page 4 Date Printed:9/5/2013
5. 4 Track
Work Center: Inert M/C
4.1 Track
Using the make ready 'Track setting
block' - (Photo A) centre and position
track with no more room outside of
the 'Setting block' left and right and
maintain the same principle the entire
way to the end of the track (Photo B)
The 'Setting block' has been made to
already allow the insert to land with
adequate room.
Photo A - Setting block locations.JPG
Photo B - Make ready track setting block.JPG
I-001 Rev:001 Version:1
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10:00:41 AM Supercedes:
Page 5 Date Printed:9/5/2013
6. 5 Feeders
Work Center: Inert M/C
5.1 Feeders
Using make ready setting block -
(Photo A) Set the left and right
machine guides flush to the setting
block as it has been made to A5 size
with room for the insert to sit flush at
the front. (Photo C)
It is important to use the setting
block as it has been made to be in
the centre and suit the track.
Photo A - Setting block locations.JPG
Photo C - Feeder set block in place.JPG
I-001 Rev:001 Version:1
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7. 5.2 Feeder settings
FEEDER SETTINGS
• AIR BLOWERS - (Photo D) Only
bottom 10-15 sheets
eg: Foxtel and Optus
- Light/Thin inserts - 1/2 air blast
• PINS - (Photo E)
- Light/Thin - All the way out
- Medium - Out half way
- Heavy/Thick (eg: catalogue) - No
rear pins & minimal left and right pins
• STABILIZER PLATES - (Photo F)
using the ruler on the feeders, set
plate at the following
measurements
- Thin inserts (eg: Foxtel and Optus)
Set at - 111mm on ruler
- Medium - (eg: NRMA, WIV, Doc
letters & envelopes)
Set at - 113mm on ruler
- Thick - (eg: Brochures or
Catalogues)
Set at - 115mm on ruler
Photo D - Feeder air blowers.JPG
Photo E - Feeder support pins .JPG
Photo F - Product support plate.JPG
I-001 Rev:001 Version:1
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10:00:41 AM Supercedes:
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8. 6 End of Track/Inserting
Work Center: Inert M/C
6.1 End of Track/Inserting
Make sure that the end of the track is
et with 2mm of play on either side and
isn't tight. The side envelope guides
should be set so that the envelope is
positioned with equal amount on both
sides of the inserts and there is no
more than 2mm either side to limit
variation. (Photo G). The tension on
the envelope stop should be enough
to stop the envelope, but allow the
pack to pass through when inserted.
ENVELOPE STOP
MEASUREMENTS (Photo H and I)
• DLX - V-flap - 152mm
- Straight flap - 146mm
• YELLOW ENVELOPES - 128mm
• UA MAGNA- MAIL - .............mm
Photo G - Inserting area end view.JPG
Photo H - End of track - inserting - stops.JPG
Photo I - Envelope stop position gauge.JPG
I-001 Rev:001 Version:1
Approved:5/09/2013
10:00:41 AM Supercedes:
Page 8 Date Printed:9/5/2013
9. 7 Sealing
Work Center: Inert M/C
7.1 Sealing
Position the guides after exiting the
envelope area (white cones) so that
the envelope passes over the sealing
area which allows 5mm over hang to
assist in the folding under of the flap.
Make sure that the envelope is
sealing correctly - but without
excess water as this can cause the
envelope to stick together when
packed.
RIGHT ANGLE GUIDE
MEASUREMENTS
• DLX - 226mm
• YELLOW - 136mm
• UA MAGNA-MAIL - ............mm
• AIH - ...........mm
Photo J - Sealing area top view.JPG
Photo K - Right angle guide rollers .JPG
Photo L - Setting gauge on right angle guide roller.JPG
I-001 Rev:001 Version:1
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10.
Photo M - Sealing area - turnover flap.JPG
I-001 Rev:001 Version:1
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11. 8 Delivery
Work Center: Inert M/C
8.1 Delivery
TO ENSURE THAT THERE IS
LITTLE TIME LOST IN DELIVERY
AREA
Make sure that the delivery is neat &
tidy and the speed is set to deliver
consistently.
Photo N - Delivery area.JPG
I-001 Rev:001 Version:1
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10:00:41 AM Supercedes:
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12. 9 Safety check
Work Center: Inert M/C
9.1 Safety check
PLEASE ENSURE ALL GUARDS
ARE CORRECTLY FITTED AND
CLOSED BEFORE
COMMENCEMENT OF
PRODUCTION RUN. (Photo O)
Photo O - Guards in place.JPG
I-001 Rev:001 Version:1
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10:00:41 AM Supercedes:
Page 12 Date Printed:9/5/2013
13. 10 Quality Check
Work Center: Inert M/C
10.1 Quality Check
Ensure quality of finished product and
'Inserting Quality Check Sheet' is
completed (Photo P)
Photo P - Inserting Quality Check Sheet.jpg
I-001 Rev:001 Version:1
Approved:5/09/2013
10:00:41 AM Supercedes:
Page 13 Date Printed:9/5/2013
