Insert M/C SetupI-001 Revision 001

Version: 1Date Printed: 9/5/2013

1 Notes

Version Note Approved ByDateApproved Status

1Insert M/C Setup was approved byGreg Williams Greg Williams 5/09/2013 Completed

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2 ObjectiveWork Center: Inert M/C

2.1 Objective of Setup

The objective of this instruction is toensure correct setup of the insertingmachines first time every time and toreduce setup time by all operatorsfollowing the standard procedure.

Insert machine.JPG

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3 SafetyWork Center: Inert M/C

3.1 Pre start safety

Adhere to all safety controls,procedures and PPE if required.LIFT CORRECTLY.ENSURE POP UP STOP BUTTON ISDEPRESSED PREVENTINGACCIDENTAL START.ENSURE NO TRIP HAZARDS EXIST,CARTONS AND PALLETS OF RAWINSERT MATERIALS ARECORRECTLY PLACED.

lifting.jpg

 

Pop up stop button.jpg

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4 TrackWork Center: Inert M/C

4.1 Track

Using the make ready 'Track settingblock' - (Photo A) centre and positiontrack with no more room outside ofthe 'Setting block' left and right andmaintain the same principle the entireway to the end of the track (Photo B)The 'Setting block' has been made toalready allow the insert to land withadequate room.

Photo A - Setting block locations.JPG

 

Photo B - Make ready track setting block.JPG

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5 FeedersWork Center: Inert M/C

5.1 Feeders

Using make ready setting block -(Photo A) Set the left and rightmachine guides flush to the settingblock as it has been made to A5 sizewith room for the insert to sit flush atthe front. (Photo C)It is important to use the settingblock as it has been made to be inthe centre and suit the track.

Photo A - Setting block locations.JPG

 

Photo C - Feeder set block in place.JPG

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5.2 Feeder settings

FEEDER SETTINGS • AIR BLOWERS - (Photo D) Onlybottom 10-15 sheets

eg: Foxtel and Optus- Light/Thin inserts - 1/2 air blast  • PINS - (Photo E)- Light/Thin - All the way out- Medium - Out half way- Heavy/Thick (eg: catalogue) - Norear pins & minimal left and right pins  • STABILIZER PLATES - (Photo F)using the ruler on the feeders, setplate at the followingmeasurements

- Thin inserts (eg: Foxtel and Optus)Set at - 111mm on ruler- Medium - (eg: NRMA, WIV, Docletters & envelopes)Set at - 113mm on ruler- Thick - (eg: Brochures orCatalogues)Set at - 115mm on ruler  

Photo D - Feeder air blowers.JPG

 

Photo E - Feeder support pins .JPG

 

Photo F - Product support plate.JPG

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6 End of Track/InsertingWork Center: Inert M/C

6.1 End of Track/Inserting

Make sure that the end of the track iset with 2mm of play on either side andisn't tight. The side envelope guidesshould be set so that the envelope ispositioned with equal amount on bothsides of the inserts and there is nomore than 2mm either side to limitvariation. (Photo G). The tension onthe envelope stop should be enoughto stop the envelope, but allow thepack to pass through when inserted.ENVELOPE STOPMEASUREMENTS (Photo H and I)• DLX - V-flap - 152mm- Straight flap - 146mm• YELLOW ENVELOPES - 128mm• UA MAGNA- MAIL - .............mm 

Photo G - Inserting area end view.JPG

 

Photo H - End of track - inserting - stops.JPG

 

Photo I - Envelope stop position gauge.JPG

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7 SealingWork Center: Inert M/C

7.1 Sealing

Position the guides after exiting theenvelope area (white cones) so thatthe envelope passes over the sealingarea which allows 5mm over hang toassist in the folding under of the flap.Make sure that the envelope issealing correctly - but withoutexcess water as this can cause theenvelope to stick together whenpacked.RIGHT ANGLE GUIDEMEASUREMENTS• DLX - 226mm• YELLOW - 136mm• UA MAGNA-MAIL - ............mm• AIH - ...........mm 

Photo J - Sealing area top view.JPG

 

Photo K - Right angle guide rollers .JPG

 

Photo L - Setting gauge on right angle guide roller.JPG

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Photo M - Sealing area - turnover flap.JPG

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8 DeliveryWork Center: Inert M/C

8.1 Delivery

TO ENSURE THAT THERE ISLITTLE TIME LOST IN DELIVERYAREAMake sure that the delivery is neat &tidy and the speed is set to deliverconsistently.

Photo N - Delivery area.JPG

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9 Safety checkWork Center: Inert M/C

9.1 Safety check

PLEASE ENSURE ALL GUARDSARE CORRECTLY FITTED ANDCLOSED BEFORECOMMENCEMENT OFPRODUCTION RUN. (Photo O)

Photo O - Guards in place.JPG

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10 Quality CheckWork Center: Inert M/C

10.1 Quality Check

Ensure quality of finished product and'Inserting Quality Check Sheet' iscompleted (Photo P)

Photo P - Inserting Quality Check Sheet.jpg

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