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Aicc 2012 meeting_centerlining_croker
Centerlining is a process to reduce variability and consistently produce quality product. It involves ensuring consistent raw materials, operating conditions, and parameters. Recipes are developed through trials to determine the optimal machine settings and speeds needed to produce good quality board. All relevant information is recorded on a recipe sheet kept at the machine for reference.
Aicc 2012 meeting_centerlining_croker
- 1. CENTERLINING What is it? Whydo I want it? How do I do it?
- 2. What Is Centerlining? Centerlining is a program or methodology that a Plant can use to reduce variability in a process.
- 3. Why do Iwant Centerlining? Would you rather build good quality into a Process or inspect bad quality out? Centerlining helps a Plant build quality into the process. If a Process is out of control, the quality of the finished product is a random event. A Process that is Centerlined reduces the randomness of the quality of the finished product. You consistently make good quality product. Reduce Waste = $ Improve Machine Operating Efficiency = $
- 4. How Do IDo It? To ensure a consistent outcome, you must ensure consistent raw materials, consistent operating conditions and consistent parameters. Raw Materials Starch Paper Conditions Corrugator Heat Parameters Recipes Gaps
- 5. Raw Materials Starch COA Certificate Of Analysis Viscosity Temperature Gel Point Paper Damaged Rolls Established Specifications
- 6. Conditions Corrugator AtOEM Specifications Mechanical Audit Level Alignment TIR Bearings Corrugator Rolls Scheduled verification inspections Heat checks Steam System
- 7. Parameters Recipe’s (BestRun Settings) Machine Settings Speed Gap and setting verification must be done on a regular basis Does .005” on display equal .005” on machine? If Hotplates are supposed to be 350 degrees…..are they?
- 8. How do IMake a Recipe? Get EVERYONE on board and involved in determining your recipes. Determine what machine settings are adjustable. Determine what speed each grade should run at.
- 9. Expected Speed Mustbe established by incremental speed trials Must be done in conjunction with the entire crew Must be recorded The expected speed from the data must be agreed to by the crews All crews must participate plus the starch man and roll stock man The expected speed should be listed on the recipe on the schedule or set automatically by the corrugator computer Any reason for not meeting the expected speed must be recorded
- 10. What Is GoodBoard? You only want to record recipes when you are running good board at the right speed. What is good board? Each Plant will have different resources available to measure good board. Visual – Is it flat? (+/- ¼” per 2’) Manual – Is it stuck together? Rip Bond Test Pin Test Dimensions Moisture ECT
- 11. Continuous Improvement – Whatand When To Record Basic approach - only record when the centerlined conditions cannot be met. When the Expected speed cannot be achieved the cause must be recorded When bad paper is the cause the roll is best removed and held aside for mill inspection Running slow to save the extra effort of a roll change is a bad practice Adopt this practice and increase productivity and decrease waste
- 12. RESPONSIBILITIES Before thiscan be started, the corrugator must be brought up to a sound mechanical condition A simple planned maintenance program needs to be started Crews must be trained and checked out under the new procedures Management is responsible for organizing the speed trials Expected speeds must be committed to by the crews - all shifts The production manager must review the results daily Solutions must be sought to overcome all causes of slow downs in future runs. Regularly reviewed
- 13. What Does aRecipe Look Like? Where Do I Keep It? Has all the settings needed for that machine center It must be tailored to your machine Needs to be at the machine Could be laminated and taped to side of machine Could be on a TV screen at each station Could be programmed into a Corrugator Control System
- 14. Sample Recipe ForSF Single-Facer #2 CORR PH LINER MED PR/ MR/AR LINER ROLL AR/CR WRAP SPLICER SPLICER CR Glue TEMP PRESS GAP BOARD RUN ARM TENSION TENSION GAP Gap URE % STEAM GRADE SPEED SHOWER E32B E32BWT E32C E32CWT 200C E44C 33UM E48BC E51BC
- 15. Sample Recipe ForDB GM Triple Stack / Glue Machine Top Web Mid Web Bottom Top GM Btm GM Temps At Temp At Liner Glue Gap Glue Gap Flute Tips Flute Tips Temp BOARD GRADE Speed E32B E32BWT E32C E32CWT 200C E44C 33UM E48BC E51BC
- 16. Sample Recipe Format Plant C - Flute LINER TEMP 185-195 GLUE STATION STEAM SHOWER AUTO METERING ROLL .005 METERING ROLL .015 DB EXIT TEMP 260 LINER SETTING LOW E&L Web Tension 60 PRESSURE ROLL .017 Target Temp - Top (Flutes) 135 GLUE GAP .0065 Middle (Flutes) N/A CORR. ROLL PRESS. 800 DB Liner 170 Med Tension 120 Liner Tension 170 Liner Tension 170 Zone Temps:330 - 350 - 370 SF Chamber Pressure 26 Infeed Nip Caliper .250 E32C Paper Comb Machine Speed 800 Med. Type