Set Up and Waste Reduction Presented by Brian

Set Up and Waste Reduction Presented by Brian Hurst, VP Production, Yerecic Label Title of Presentation | Presenters Name Young Leaders Development Organization – TLMI Converter Meeting 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

The One Best Way -Created to meet the need for faster set ups on jobs while reducing make ready waste. -Standard work developed by the Press teams, guided by management. -Team roles are written and team members are trained and certified in their roles. -Each team consists of a team leader (press operator), helper and finisher. YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

Determining responsibilities -All 3 team members have specific responsibilities during the set up. -Through several video taped set ups the team split the duties, so no two team members would cross paths during the set up. -The team graphs each video taped set up to ensure optimum activity sequence. YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

Separating Internal and External The team was taught that there was two parts to a set up, internal and external: -Internal What “must be done” while the press is stopped! -External What “could be done” while the press is running! YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

External consists of two phases 1. Pre–Set up: Tasks completed while the press is running the current job. 2. Post-Set up: Tasks completed once the next job is up and running. YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

Internal consists of two phases 1. Set up: The press is stopped. 2. Set up: The press is running. YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

Pre Set Up (External) Operator: 1. Monitors the quality of the run. 2. Completes all necessary documentation for the run. 3. Issues a “two minute warning” prior to the run ending. YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

Pre Set Up (External) Helper: 1. Get the cylinders for the next job. 2. Inspect and mount plates on cylinders and move cylinders to point of use. 3. Pull all raw stock for job. 4. Ink maintenance. YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

Pre Set Up (External) Finisher: 1. Pull die from die aisle to point of use. 2. Get cores for next job. 3. Slit finished master on rewinder or man turret. YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

Set Up – Press Stopped (Internal) Operator: 1. Start the clock. 2. Pull finished plates from the print stations. 3. Load new plates into correct stations. 4. Mesh gears and check the fine tunes. 5. Set and register print stations. (Starting at the die station) YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

Set Up – Press Stopped (Internal) Helper: 1. Change raw stock on unwind (when needed). 2. Change ink and aniloxes. 3. Assist operator loading new plates. 4. Set and register print stations. (Starting at the Unwind) YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

Set Up – Press Stopped (Internal) Finisher: 1. Removed finished master from the rewind shaft. (Disconnect web from turret if in use) 2. Remove waste matrix. 3. Change die. 4. Set camera to correct gear size. YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

Set Up – Press Running (Internal) Operator: 1. Set and register print stations. 2. Push idle and begin to make final adjustments. (Done parallel with the Helper) 3. Push run and gradually increase the speed, making final adjustments. 4. Flag the master and stop the clock. YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

Set Up – Press Running (Internal) Helper: 1. Reset the web guide if needed. 2. Set and register print stations. 3. Push run and gradually increase the speed, making final adjustments. (Done parallel with the operator) 4. Move on to post set-up activities. YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

Set Up – Press Running (Internal) Finisher: 1. Register the die into the print as soon as the first color reaches the die station. 2. Start waste matrix. 3. Set RD score knives. 4. Move on to post set-up activities. YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

Post Set Up (External) Operator: 1. Perform quality assurance checks. 2. Monitors the quality of the run. 3. Complete quality checks. YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

Post Set Up (External) Helper: 1. Clean out unneeded colors. 2. Clean and put away all aniloxes. 3. Demount plates from previous job. 4. Put cylinders away. 5. Return unused raw stock to inventory. 6. Return to Pre-Set up activities. YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

Post Set Up (External) Finisher: 1. Slit finished master on rewinder or man the turret. 2. Case finished rolls to customer specifications. 3. Return to Pre-Set up activities. YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

Accountability 1. The Team Leader determines when their team is ready for certification testing. 2. Shift Managers will video tape and critique the performance with the team. 3. Once the shift manager is satisfied with the team’s performance, VP Manufacturing will observe a set up and score the team. 4. Managers use andon lights to monitor set ups. (ONLY A PERFECT SCORE WILL QUALIFY FOR CERTIFICATION!) YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

One Best Way Team Testing Press: Operator: Shift: Helper: Date: Finisher: Who What Operator Operator Operator Issues the 2 minute warning Starts the clock Start at Rewind, load new plate into correct stations. Set and register print starting at the rewind end (parallel processing) Match plates with 1 st color to with 1/8" Push idle and begin to make final adjustments. Gradually increase speed and make necessary adjustments Place flag in master or splice on the turret (finisher responsibility for turret) Stop the clock and record set up time Log previous job information onto Press Sheet Fill out QUALITY check approval for new job Monitor QUALITY Helper Helper Helper PRE SET UP activities Change Paper (if needed) Change ink and aniloxes (if needed) Start at unwind, load new plate into correct stations Set and register print starting at the unwind end (parallel processing) Match plates with 1 st color to with 1/8" Push idle and begin to make final adjustments. Gradually increase speed and make necessary adjustments Move on to POST SET UP activities Finisher PRE SET UP activities Finisher Remove finished master and put new core on rewind Finisher Remove wsate matrix Finisher Release RD score knives Finisher Change die Finisher Change camera settings Finisher Register DIE to PRINT Finisher Start waste martix Finisher Set RD score Knives Finisher Move on to POST SET UP activities SET UP TIME WASTE COUNT PASS/FAIL YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. Yes No CERTIFICATION Brian S. Hurst VP Manufacturing N/A

One Best Way Results -By developing and implementing this practice we have been able to increase up time and reduce waste. -Up time has increased: A 55% improvement has been achieved on set up times. -Make ready waste has decreased: A 63% improvement has been achieved in waste reduction. YLDO | TLMI CONVERTER MEETING 2012 © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.

TLMI: Partnering to Grow Through Knowledge and Education Thank you! Title of Presentation | Presenters Name © Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved.