Foil Separator Machine

PURPOSE

• 1.1 To establish a standard procedure for the safe and effective operation of the Foil Separator Machine, to ensure correct separation of aluminium foil rolls while maintaining product quality and minimizing damage.

SCOPE

• 2.1 This SOP applies to all production Department.

REFERENCE(S) & ATTACHMENTS

• 3.1 References

  • 3.1.1 In-house

• 3.2 Attachments

  • 3.2.1 Attachments: Production Logbook: SIPL/PDI/003/F01/00

RESPONSIBILITY

• 4.1 Production Department Person:

  • 4.1.1 To prepare the SOP.

• 4.2 Production Head:

  • 4.2.1 To ensure the training of the SOP to all concerned personnel involved in implementation of the SOP.

  • 4.2.2 To ensure the implementation of the SOP after training.

• 4.3 Quality Assurance Person:

  • 4.3.1 To check the SOP and to maintain the original copy of the SOP.

  • 4.3.2 To issue the controlled copy of the SOP and maintain its issuance record. To retrieve the controlled copy of the SOP when it is superseded/obsolete and maintain its record.

• 4.4 QA Head / Plant Head:

  • 4.4.1 To approve new or revised SOP.

  • 4.4.2 To ensure the implementation of the defined system.

DISTRIBUTION

• 5.1 Quality Control

• 5.2 Production

DEFINITION(S) & ABBREVIATION(S)

• 6.1 Definitions

  • 6.1.1 Nil

• 6.2 Abbreviations

  • 6.2.1 Nil

PROCEDURE

• 7.1 JOB cards are given to the operators, which give the permission and identification of the planned job to start.

• 7.2 Check the width of the input coil against the instruction of the programme book.

• 7.3 Check the thickness on the top portion of the part coil and discard the off-gauge portion, if any.

• 7.4 Set the blade / cutter as per the instruction of the programme / planning book.

• 7.5 Clean all path rolls with a microfiber cloth to remove dust and foreign particles.

• 7.6 Load the coil on the input and thread it to ensure proper centering on the output rewinder.

• 7.7 Set the tension value and start the machine in run mode.

• 7.8 Monitor the output foil surface and report to the Shift In-charge for any abnormality.

• 7.9 Join each break by ultrasonic welding and insert a marker.

• 7.10 Check the thickness of the foil near the joint portion and discard the off-gauge portion before joining.

• 7.11 Check the reel density as per planning.

• 7.12 Remove finished reels from the machine, weigh them and stack them on the appropriate rack / tray.

• 7.13 Record the reel number, specification and net weight of each reel.

• 7.14 Enter the relevant details in the production log book.

• 7.15 Tension Setting Chart:

+-----------------+-----------+-------------------+-------------------+ | Foil Thickness | Pack | Width (mm) | Abs. Tension | | (mm) | Density | | (N/mm²) | +:===============:+:=========:+:=================:+:=================:+ | 0.040 | 92-94 % | 1001-1500 | 40-43 | | | +-------------------+-------------------+ | | | 901-1000 | 35-37 | | | +-------------------+-------------------+ | | | 801-900 | 33-35 | | | +-------------------+-------------------+ | | | 701-800 | 31-35 | | | +-------------------+-------------------+ | | | 500-700 | 29-33 | +-----------------+-----------+-------------------+-------------------+ | 0.030 | 90-92 % | 1001-1500 | 39 - 41 | | | +-------------------+-------------------+ | | | 901-1000 | 29 - 33 | | | +-------------------+-------------------+ | | | 801-900 | | | | +-------------------+-------------------+ | | | 701-800 | 25 - 28 | +-----------------+-----------+-------------------+-------------------+ | 0.020-0.025 | 87-90 % | 1001-1500 | 26 - 30 | | | +-------------------+-------------------+ | | | 901-1000 | | | | +-------------------+-------------------+ | | | 801-900 | | | | +-------------------+-------------------+ | | | 701-800 | | +-----------------+-----------+-------------------+-------------------+ | 0.012-0.018 | 86-89 % | 701-1000 | 36 - 40 | | | +-------------------+-------------------+ | | | 501-700 | | | | +-------------------+-------------------+ | | | 401-500 | | | | +-------------------+-------------------+ | | | 301-400 | | | | +-------------------+-------------------+ | | | 200-300 | | +-----------------+-----------+-------------------+-------------------+ | 0.008-0.010 | 86-89 % | 1001-1500 | 28 - 30 | | | +-------------------+-------------------+ | | | 701-1000 | | | | +-------------------+-------------------+ | | | 500-700 | | +-----------------+-----------+-------------------+-------------------+ | 0.006-0.0075 | 85-87 % | 1001-1500 | 28 - 32 | +-----------------+-----------+-------------------+-------------------+

REVISION HISTORY

+----------------+----------------+----------------+----------------+----------------+----------------+ | Revision No. | 00 | Effective | | CC No. | | | | | Date | | | | +----------------+----------------+----------------+----------------+----------------+----------------+ | Details of revision: New SOP | +-----------------------------------------------------------------------------------------------------+