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Qualitek Results Report

Do you know how much is being wasted at the Rotary Shear?

A major integrated in the Southeast was looking for a way to automatically determine  the quantity of shear chops initiated for each shift.  Although shear waste was supposed to be manually weighed for each shift, it was not done regularly and in a timely manner.  Qualitek was asked to develop a solution which would take less time and less manpower to provide consistent measurement.
Qualitek’s solution counts shear chops when board is present and reports the total number of chops on a shift-by-shift basis.  The amount chopped out is then converted into area and weight, thereby eliminating the need for the crew to weigh the shear waste.

Premise:The rotary shear is used for many purposes other than for just  severing the web on order changes or for chop out on paper size changes. For example, It is also used to chop out dry spots and poor quality board to avoid dry end jam ups. In certain cases, it is sometimes overused creating  unnecessary waste.

Promise: Knowing how much board is being chopped out at the shear by each shift allows for better management of the operation (by asking the right questions) leading to better accountability and less waste.
Uncontrolled Shear Chop Waste  can get out of  control without consistent measurement
Proof: Thru active management, awareness and even friendly competition between shifts the customer reported a 50% reduction in shear waste since the system was installed.  The individual shift reports and overall summary reports  gave them an unbiased look at shear waste over any period of time as shown in the following examples. 
Shear Chops for a Single Shift (highlighted in Yellow)
Shear Chops Summary for All Shifts (highlighted in Yellow)
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