Improving Efficiency and Product Quality with Precision Alignment of Equipment

Transcription

1 Improving Efficiency and Product Quality with Precision Alignment of Equipment 2015 ICE Technical Program February 10-12, 2015 Orlando, Florida Presented by: Roger Cross Project Manager OASIS Alignment Services, Inc.

2 Discussion Points What is Precision Alignment? Causes of Misalignment Effects of Misalignment on Product Quality & Run-ability Effects of Misalignment on Equipment Reliability & Efficiency Benefits from Precision Alignment Recommended Alignment Practices Precision Alignment Technologies

3 Defining Precision Alignment According to Webster s: With Words alignment-n. proper positioning or state of adjustment of parts in relation to each other precision-n. the quality or state of being precise (very accurate and exact)

4 Defining Precision Alignment Always utilize the OEM recommended tolerances or the following general alignment tolerances - whichever are tighter: +/ per lineal foot of effective roll face Can be modified as needed based on Product material Product weight/caliper Function in machine With Tolerances Nipped rolls to be parallel within.003 total

5 What Causes Misalignment? Improper alignment at initial installation Equipment modifications and rebuilds Breakdowns and emergency repairs Regular maintenance (bearing and roll changes misplaced keys, shims and pins) Vibration and settling Wear Corrosion

6 Effects of Misalignment On Product Quality and Run-ability Tension differentials within web Potentially resulting in: Diagonally running wrinkles Baggy edges and web flutter

7 Effects of Misalignment On Product Quality and Run-ability Uneven nip pressures Potentially resulting in: Uneven web caliper Uneven coating application

8 Additional Effects of Misalignment On Product Quality and Run-ability Uneven heat or chill transfers to the web Reduced trim width Static build-up Web guiding problems Increase of missed splices Increase of web breaks Inability to run at optimum speeds

9 Effects of Misalignment On Equipment Reliability and Efficiency Unplanned or excessive downtime caused by: Premature or uneven wear of roll covers Excessive wear or premature failure of bearings and couplings Increase in vibration and noise levels Higher than normal energy consumption

10 Benefits of a Precision Alignment Program Improved web control Improved uniformity within your processes Higher yields from your equipment Increased life expectancy for your equipment Decreased energy consumption Lower maintenance costs Above all, keep the following in mind:

11 An Aligned Machine is Efficient and Productive!

12 Recommended Alignment Practices Know Your Current Alignment Conditions Develop a Corrective Alignment Plan Develop a Preventative Alignment Plan Maintain Detailed Records

13 Recommended Alignment Practices Know Your Current Alignment Conditions 1) Perform a Centerline Survey

14 Reference Line of Sight

15 Recommended Alignment Practices Know Your Current Alignment Conditions 1) Perform a Centerline Survey 2) Install a new, or re-verify an existing, offset machine centerline reference (baseline)

16 X.XX X.XX BASELINE MONUMENT

17 Recommended Alignment Practices Know Your Current Alignment Conditions 1) Perform a Centerline Survey 2) Install a new, or re-verify an existing, offset machine centerline reference (baseline) 3) Obtain an overall machine alignment picture Obtain level and square inspection data on select rolls/components within all major sections of the machine Obtain additional detailed inspection data in known or suspected problem areas Evaluate all survey data

18 Recommended Alignment Practices Develop a Corrective Alignment Plan 1) Will the entire line be aligned? Normally performed during major outages Three or more days in duration Typically is the most cost effective approach 2) Will individual sections within the line be aligned? Can often be done during regular one or two day maintenance outages Will normally require transitioning from aligned to misaligned sections

19 Recommended Alignment Practices Develop a Preventative Alignment Plan Utilize precision alignment tooling and methodology to insure favorable alignment conditions are maintained whenever one of the following events occur: Sudden appearance of unexplained misalignment symptoms Critical roll and/or component replacement such as nipping rolls, coaters, extruder barrels, gearboxes, etc. Component or equipment additions, removals, modifications or upgrades Emergency Repairs

20 Recommended Alignment Practices Develop a Preventative Alignment Plan Unless any of the previous situations have dictated otherwise, perform regular preventative re-inspections and re-alignments. At a minimum; annually in critical areas Nipping rolls Coaters Laminators At a minimum; bi-annually in less critical areas Ovens/dryers Carrying rolls

21 Recommended Alignment Practices Maintain Detailed Records Very important for: Comparison of component alignment history over time Planning for future alignment efforts Planning for preventative alignment

22 Precision Alignment Technologies

23 Older, Less Precise Technologies Tight Wires Placed on machine centerline Plumb bobs and squares used to square components Machinist Levels Can be used on rolls or flat surfaces Graduations are.0005 to.005 per foot

24 Older, Less Precise Technologies Pi-Tapes Requires knowing, or having confidence in, the current alignment condition of the reference roll Trammels or Tram Rods Requires knowing, or having confidence in, the current alignment condition of the reference roll

25 Newer, More Precise Technologies The accuracy of nearly all technologies used for precision alignment work today are rated, or referred to, as One Arc-Second Instruments One Arc Second = over a distance of feet

26 Newer, More Precise Technologies Optical Instruments Pros: Accuracy is comparable to newer laser tracker systems Rugged, reliable, versatile Adaptable to most alignment conditions A very cost efficient system Cons: Somewhat expensive Need regular calibration

27 Newer, More Precise Technologies Laser Trackers Pros: Best accuracy among today s laser systems Compact receiver with electronic interface Single operator capability Cons: Currently very expensive Steep learning curve Complicated software interface Delicate and environment sensitive

28 Newer, More Precise Technologies Laser Shaft Alignment Systems Pros: Cons: User friendly Generally Rugged and Reliable Compact/Portable Good Accuracy Relatively inexpensive Generally limited to drive alignment Requires the ability to rotate shafts Cannot measure level

29 Other Technologies Gyroscopic Systems Coordinate Measuring Total Station Laser LOS Unit

30 Can Individual Plants Fully Take On Precision Alignment Internally? The simple answer Yes; However, in most cases it will not be cost effective for them to attempt it. The initial equipment costs can be extremely high Lack of specialized, often custom designed, ancillary tooling The initial and ongoing training costs for personnel will be high Lack of frequent practice/utilization = lack of efficiency Limited simultaneous personnel capacity

31 So, Who Are You Going to Call? First, you will need to determine exactly what kind of alignment support you need. Inspection and documentation only Inspection, onsite support/guidance, and final alignment verification and documentation for realignment of various components/sections utilizing mechanics of your choosing Turnkey alignment support for anything from one component up to the entire production line

32 So, Who Are You Going to Call? Generally, you will find three basic types of companies performing alignment: General Contractors who perform varying levels of alignment as a supplement to their core businesses Alignment companies who are very capable at gathering data and possibly supporting a contractor or your mechanics to perform some realignment Alignment companies that provide a wide range of precision alignment services; optical, laser, mechanical, turnkey alignment projects Above all else, keep this in mind: You are hiring the expertise and the experience of the people in the company, not the tooling!

33 Case Study A flexible packaging producer operating a 10-color Rotogravure printing press with in-line coating and lamination capability had become increasingly frustrated with product quality and run-ability issues including: Severe wrinkling through the foil section of the Coater/Laminator Skipped coating Baggy edges Web tracking issues Wrinkles throughout the machine Registration problems Excessive waste Loss of approximately 5% of scheduled run time

34 Case Study In an attempt to address these issues, the plant requested precision alignment support from OASIS to assist their maintenance team in the replacement of the chilled water rolls. While onsite, the alignment team was also requested to perform a survey of the rest of the line. The survey results revealed varying degrees of misalignment throughout the entire line The plant then decided to expand their alignment effort to include all rolls within their coater/laminator and all 10 press stations. A total of more than 500 rolls The plant s maintenance team was not capable of handling that level of alignment so OASIS was contracted to bring in the necessary additional resources (personnel and equipment) to complete the alignment.

35 Case Study The Benefits Realized from the Alignment Effort Lower web operating tension Substantial reduction in wrinkles Significant registration improvement Improved winding at the Coater/Laminator A 10% increase in Coater/Laminator operating speed Coater/Laminator scrap reduced by 5.2% Printing Press scrap reduced by 5.6% Payback on the alignment investment was less than 3 months

36 Are There Any Questions? Thank you for Attending For more information or to download a FREE copy of our Machine Alignment Handbook, please visit

37 How to Reach OASIS Corporate Headquarters/Northeast Service Center 255 Pickering Road Rochester, NH T: F: Regional Manager: Steve Pepin Account Manager: Ted Grimbilas Southeast Service Center 9009-E Perimeter Woods Drive Charlotte, NC T: F: Regional Manager: Jon Ray Account Manager: George LeGrand South Service Center 7501 Sears Blvd Pensacola, FL T: F: Regional Manager: Myron Smith Midwest Service Center N922 Tower View Drive, Suite L Greenville, WI T: F: Regional Manager: Larry Kubale Midwest Satellite Service Center/Ohio 330 Carr Drive, Suite A Brookville, OH T: F: Regional Manager: Larry Kubale West Service Center Collier Ave, Suite A Lake Elsinore, CA T: F: Regional Manager: Joel Farnum Account Manager: Bill McTague West Satellite Service Center/Washington 3800 NE 68 th Street, Unit 3A Vancouver, WA T: F: Satellite Manager: Larry Morton Canada Service Center 2845 Halpern Street Saint-Laurent, QC H4S 1P8 T: F: Regional Manager: Nicolas Béland Account Manager: Bassirou Samb