With both labor and machinery costs rising at a rapid pace, converters are finding it increasingly important to maximize the output of high-speed equipment. The operating speed is often governed not by the machine, but by the people running it. Fatigue is a real problem.
Studies have shown that a typical flexo folder gluer/rotary diecutter runs cartons approximately 60% of the shift time, often at reduced speeds. The remaining 40% is lost to setups and downtime. A machine running an 8.7-ft 2, 200-lb test, C flute sheet at a rate of 120 sheets per minute processes 19 tons of board in an 8-hour shift. The operator at the offbearing end of the machine must handle this volume; position pallets, slip sheets, tie sheets, load tags, etc.; and sometimes check for quality. To compound the problem, this employee is usually the crew member with the least experience.
