While an annual doctors visit is widely accepted and recommended as a path to good health, no one really enjoys going to a doctor and undergoing tests that are performed. The same is true on preventive maintenance on equipment.  While it takes planning and time to coordinate it, it is a necessary and important path for the continued successful performance of equipment, operators, and UPTIME=$.  While there are many variables in the die cutting process, controlling such variables and standardizing processes, where possible, can be key to increased uptime.

One variable that is often overlooked is the “airgap/undercut” being out of tolerance on magnetic cylinders.  While magnetic cylinders are very durable, they are not indestructible. Magnetic cylinders can become out of tolerance either through physical damage or due to the natural wear of the bearers over time.  Often a magnetic cylinder that is out of tolerance can mislead an operator into believing he has a flexible die that is out of specification, thus creating downtime in installing and removing the flexible die as well as time and aggravation spent in re-ordering another die only to achieve the same die cutting result.  When investigated, and audited, the magnetic cylinder that is out of tolerance, is found to have affected the dies capability to perform its function precisely and efficiently, creating the die to cut unevenly or too deep into the liner.

In today’s industry the tolerances on magnetic cylinders, flexible dies, and liners are held to within microns, but not knowing if the air gap/undercut of a magnetic cylinder in production is within specification, can too often lead to costly and what should be avoidable downtime.

To avoid this pitfall and control such a variable on the press, an annual audit of all magnetic cylinders will allow standardization of the library of cylinders while providing a detailed report of the tooling that are within tolerance and specifications.  In addition, ones that are on the cusp of needing repair can be identified and monitored. And finally, cylinders that are out of tolerance can be pulled from inventory and be repaired or replaced providing there is enough material height to permit repairs, limiting the cost of a total replacement.

In summary, identifying your magnetic cylinder inventory through an annual audit can be an effective way of controlling a variable within the die cutting process.  While certainly not as intimidating as seeing a doctor, the audit can be a healthy prescription to your bottom line!



Jim Kissner is National Sales Manager at Kocher + Beck USA, L.P.