The manufacturing operation was experiencing wound roll quality issues on film/film laminated products slit and rewound on a REM slitter/rewinder. The problem was described as rolls blowing out and is mostly an issue after winding although there have been problems on 3000 foot 5 to 6 inch wide slits during winding. The client was not sure whether the problem was due to circumferential slip (cinching) during winding or excessive conveyance and handling forces.


An Optimation web handling consultant visited the client site to perform the following work: (a) reviewed machine operation and observed process performance, (b) characterized the failure mechanism as blowing out, (c) characterized the REM machine process capability, (d) provided recommendations on process changes that would help to alleviate the problem, (e) proposed and observed trials aimed at monitoring the performance of the slitter/rewinder after implementation of recommendations, (f) provided written documentation on our observations and recommendations for client follow up, and (g) provided a machine specific winding model to enable product specific process optimization and standardization.


The summary report included a detailed analysis of all characterization work and measurements collected to provide fundamental process understanding of the current process. The report also detailed current process limitations, as well as a prioritized punch list of process, procedural, equipment maintenance, and equipment upgrade recommendations to improve process capability and reliability. In addition, an interactive winding model was developed, based on fundamental winding principles, using characterization data specific to the clients winding process. The model was developed to predict total wound in tension as a function of the specific product properties and machine process set-points. The model will enable the client to drive towards optimized standardized process conditions for its many product variations, and also help to develop process set-points for future products. The move to product specific, standard process conditions will reduce winding quality variability and improve overall process robustness.