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Roll Converting in a Manufacturing Process

IP.com Disclosure Number: IPCOM000012049D
Publication Date: 2003-Apr-03
Document File: 6 page(s) / 135K

Publishing Venue

The IP.com Prior Art Database

Abstract

Since it is impossible to avoid the production of defects in many manufacturing film coating applications, there is significant value in cutting the film in a manner that reduces both trim waste as well as final defective product that is produced. This paper describes a software application that seeks to reduce the amount of defect waste produced, and minimize inspection of final product, through making use of: (1) information about the quality of a master roll; (2) a set of constraints and rules describing how best to achieve minimum waste and minimum need for additional inspection; and (3) a set of cut widths for production based on customer orders. As a result of using the application, henceforth called the Converting Optimizer, a cutting strategy is identified that can reduce final product waste and minimize the need for final product manual inspection.

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Roll Converting in a Manufacturing Process

Abstract

Since it is impossible to avoid the production of defects in many manufacturing film coating applications, there is significant value in cutting the film in a manner that reduces both trim waste as well as final defective product that is produced.� This paper describes a software application that seeks to reduce the amount of defect waste produced, and minimize inspection of final product, through making use of:� (1) information about the quality of a master roll; (2) a set of constraints and rules describing how best to achieve minimum waste and minimum need for additional inspection; and (3) a set of cut widths for production based on customer orders.� � As a result of using the application, henceforth called the Converting Optimizer, a cutting strategy is identified that can reduce final product waste and minimize the need for final product manual inspection.

In this paper we will describe the following:

 

  • Introduction – Brief description of the application.
  • Background Information – Brief description of related art.
  • Application Description – Description and utility of application.
  • Application Example – Example of the function of the Converting Optimizer application.
  • Cut Placement Optimization Algorithm – The algorithm used to identify cut placement is described.
  • Conclusion.

Introduction

It is often impossible to avoid the production of defects in many manufacturing film coating applications.� Since defects are often an inherent part of such operations, there is significant value in cutting the film in a manner that reduces both trim waste as well as final defective product that is produced.� Equally important is the ability to determine, based on defect information and cut placement, which rolls need additional inspection and what level of additional inspection is required.� In this paper we describe a software application that seeks to reduce the amount of defect waste produced and minimize the need for inspection of final product.� In order to accomplish this goal, we utilize several pieces of information including the following:� (1) information about the quality of a master roll; (2) a set of constraints and rules describing how best to achieve minimum waste and minimum need for additional inspection; and (3) a set of cut widths for production based on customer orders.� � As a result of using the application, henceforth called the Converting Optimizer, a cutting strategy is identified that can reduce final product waste and minimize the need for manual inspection.

Background Information

In the production of certain film products, a thin film is coated in a specific manner to achieve the proper qualities.� In this process, a large (master) roll of film is produced and then converted into smaller (cut) rolls.� In most cases the cut rolls pass through additional processing steps, such as conversion into piece parts, until a final product is produced.� As the master roll is conver...