PAPER INDUSTRY WEB
HINTS PAGE for Winder Study
Helpers
The Winder Study Helpers are powerful tools but their usefulness and accuracy depends on the users' good judgment. The following hints will be useful in the proper use of the Helper Tools. Review this information carefully.
EXAMPLES:
CASE1-EXISTING WINDER OPERATION. Assuming you are operating a manual winder. Enter the values for your existing winder operation and print the finished program. The program will print a single page hard copy. By reviewing the curves, you have a pretty good picture of the production capabilities of your winder operation. Its obvious, the more accurate the data used for your study, the more reliable the picture will be.
CASE2-ADD AUTOMATIC SLITTERS. Now suppose you want to consider the use of automatic slitter positioning. Replace the manual slitter time entry with the automatic slitter time value (you can get this time interval form your winder supplier). Leave all the other data as entered for the existing winder. Print the program and you have an idea of the potential of using automatic slitter positioning.
CASE3-ADD AUTO ROLL SET CHANGE. The same routine can be followed for auto set change. Substitute the value for manual set change in CASE1with automatic set change. Get this number from your winder supplier to). Print the program and you have an idea of the potential of using automatic set change equipment in your winder.
CASE4-ADD BOTH AUTO SLITTERS &
AUTO SET CHANGE.
The same routine can be followed for adding both auto slitters
and auto set change to your manual winder of CASE1. Substitute
the value for manual set change to automatic set change in CASE2. Print the program and you have an idea of the
potential of using both automatic slitter positioning and auto
roll set change equipment in your manual winder.
CASE5-CHANGES IN ACCEL/DECEL RATES. Suppose you are considering increasing the acel/decel rate of your winder and would like to know the value of various rates? Using CASE1, do an additional study but increase the accel or decel rate (or both) by 10 FPM/SEC. Do a second study and increase the values again. Now you have 3 chars to compare performance. Print the programs and you now have an idea of the potential increasing the accel/decel rate of your manual winder. It may be you can increase the accel/decel rate in the first step without changes to the winder drive and increase winder productive potential immediately. The second step may require an increase in unwind braking or larger winder drum motors. This can be combined with CASES 1, 2 & 3 to evaluate subsequent improvements
ROIs & PRIORITIES The above described changes are very useful in Making ROIs and establishing winder improvement priorities.
CASE5-SHIPPING ROLL OR GRADE CHANGE. Using any of the case studies above, you can run additional studies for other winding variable to evaluate paper grades or new customer order requests.
EXAMPLE-SETS PER REEL Suppose CASE1 was for a winder running 32# news, 40" diameter shipping rolls, 3 set reels and the winder is experiencing problems staying up with the paper machine. After doing studies like CASE 3, 4 and 5 above (that all involve winder modification), look at opportunities that may only involve operation changes. Run a couple studies with 4 and 5 set reels. It may be by increasing to a 4 sets reel will increase winder productivity without changes and 5 set reels may involve a minor change like raising the unwind stand for clearance.
ABOUT ACCEL/DECEL RATES: For the most accurate study, accel/decel rates should be "timed" intervals as opposed to actual drive data. To obtain "timed intervals"-use the following method: The more cycles that are timed, the more reliable the timed interval.
Accel Rate: Time this at the winder with a stop watch,. Start the stop watch when the winder drums start to rotate. Stop the watch when the winder drums reach maximum operating speed. To calculate the FPM/SEC acceleration rate, divide accel time interval in seconds by the average winder operating speed.
EX: Winder accelerates to 6000 FPM in 75 second. 6000/75=80 FPM/SEC.
Use the same method to obtain a timed decel interval. Start the watch when the winder starts to decelerate. Stop the watch when the winder drums stop rotating. Use the same formula as above to calculate the deceleration rate.
LET US HEAR FROM YOU! We invite you to share your experiences using the Paper industry Helpers. If you find shortcuts, new uses or bugs let us know so we can continue to update this program. With your permission, we will post your shortcuts or new uses on this page.