The Importance of Precision Cutting on Product Quality

What happens when slits are not precise

Imprecise slits when converting rolled goods can lead to a number of problems, both within the production process and with the finished goods themselves. Most of these issues fall into one of these three categories:

Loss in quality

Imprecise slits can result in products with defects or inconsistencies that do not meet desired standards. Should these products make it into the hands of consumers, this loss in quality can lead to dissatisfied customers and affect a brand’s reputation.

Production waste

When slits are not precise, there is a higher chance of generating excess scrap and waste. This has financial implications in terms of material costs, and materials that cannot be recycled or repurposed have a negative impact on the environment.

Safety issues

When rolled goods are being converted for critical industries like medical equipment manufacturing, precision slits are crucial for ensuring safety. Any deviations from the intended measurements can compromise the structural integrity and functionality of products, posing a safety risk to users.

How to ensure precision slits in the converting process

Ensuring precision in the converting process requires the right equipment and meticulous planning and monitoring. More specifically, these strategies can reduce the margin for error and enhance efficiency:

Use the right slitting or cutting method

Selecting the best cutting method for the material and application can help improve precision. Outfitting your equipment with the correct blades and slitting method is also paramount. It is critical to know whether you need a hot knife, score, crush, or razor for your material and application needs. Slit width tolerances may vary based upon the slitting methodology, anywhere fro 0.005” to 0.020”.

Calibrate your machine

Make sure your machines are calibrated and operating efficiently. This should be performed on a regular basis to prevent small issues from snowballing into significant problems. You may want to consider an ISO 9001:2015 program to further define the machine calibration process for the encoders or servo controllers used to measure length.

Provide regular maintenance

Much like proper calibration, regular machine maintenance will keep machines precise and accurate. Follow the manufacturer’s guidelines for routine maintenance and make sure that nips or s-wraps are not allowing the material to slip.

Replace slitter blades

Blunt, dull or damaged slitting blades can affect the precision of slits, so it’s essential to replace them regularly. The frequency required will depend on the material being cut and the amount of use a machine is getting. Often times these blades may be resharpened before they need to be removed from service.

Buy machines from a reputable source

When purchasing slitters, it’s crucial to buy from a reputable source that offers high-quality machines and excellent customer support for service needs after the machine has been commissioned. Manufacturers that offer custom-built equipment can help ensure more accuracy as well by tailoring a machine to your business’s unique needs.

The Bottom Line

It is critical for production to be precise and accurate. The smallest deviation in measurements can result in significant consequences for a manufacturer, ranging from product waste to decreased quality and safety concerns. By investing in high-quality machinery, performing proper maintenance, and selecting the right slitting methods, manufacturers can ensure precision slits in their rolled goods.