© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. Title of Presentation | Presenters Name Set Up and Waste Reduction Young Leaders Development Organization – TLMI Converter Meeting 2012 Presented by Brian Hurst, VP Production, Yerecic Label

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 The One Best Way -Created to meet the need for faster set ups on jobs while reducing make ready waste. -Standard work developed by the Press teams, guided by management. -Team roles are written and team members are trained and certified in their roles. -Each team consists of a team leader (press operator), helper and finisher.

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING All 3 team members have specific responsibilities during the set up. -Through several video taped set ups the team split the duties, so no two team members would cross paths during the set up. Determining responsibilities -The team graphs each video taped set up to ensure optimum activity sequence.

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 The team was taught that there was two parts to a set up, internal and external: -Internal What “must be done” while the press is stopped! -External What “could be done” while the press is running! Separating Internal and External

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 External consists of two phases 1. Pre–Set up: Tasks completed while the press is running the current job. 2. Post-Set up: Tasks completed once the next job is up and running.

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 Internal consists of two phases 1. Set up: The press is stopped. 2. Set up: The press is running.

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 Pre Set Up (External) Operator: 1. Monitors the quality of the run. 2. Completes all necessary documentation for the run. 3. Issues a “two minute warning” prior to the run ending.

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 Helper: 1. Get the cylinders for the next job. 2. Inspect and mount plates on cylinders and move cylinders to point of use. 3. Pull all raw stock for job. 4. Ink maintenance. Pre Set Up (External)

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 Finisher: 1. Pull die from die aisle to point of use. 2. Get cores for next job. 3. Slit finished master on rewinder or man turret. Pre Set Up (External)

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 Operator: 1. Start the clock. 2. Pull finished plates from the print stations. 3. Load new plates into correct stations. 4. Mesh gears and check the fine tunes. 5. Set and register print stations. (Starting at the die station) Set Up – Press Stopped (Internal)

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 Helper: 1. Change raw stock on unwind (when needed). 2. Change ink and aniloxes. 3. Assist operator loading new plates. 4. Set and register print stations. (Starting at the Unwind) Set Up – Press Stopped (Internal)

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 Finisher: 1. Removed finished master from the rewind shaft. (Disconnect web from turret if in use) 2. Remove waste matrix. 3. Change die. 4. Set camera to correct gear size. Set Up – Press Stopped (Internal)

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 Operator: 1. Set and register print stations. 2. Push idle and begin to make final adjustments. (Done parallel with the Helper) 3. Push run and gradually increase the speed, making final adjustments. 4. Flag the master and stop the clock. Set Up – Press Running (Internal)

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 Helper: 1. Reset the web guide if needed. 2. Set and register print stations. 3. Push run and gradually increase the speed, making final adjustments. (Done parallel with the operator) 4. Move on to post set-up activities. Set Up – Press Running (Internal)

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 Finisher: 1. Register the die into the print as soon as the first color reaches the die station. 2. Start waste matrix. 3. Set RD score knives. 4. Move on to post set- up activities. Set Up – Press Running (Internal)

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 Operator: 1. Perform quality assurance checks. 2. Monitors the quality of the run. 3. Complete quality checks. Post Set Up (External)

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 Helper: 1. Clean out unneeded colors. 2. Clean and put away all aniloxes. 3. Demount plates from previous job. 4. Put cylinders away. 5. Return unused raw stock to inventory. 6. Return to Pre-Set up activities. Post Set Up (External)

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 Finisher: 1. Slit finished master on rewinder or man the turret. 2. Case finished rolls to customer specifications. 3. Return to Pre-Set up activities. Post Set Up (External)

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 Accountability 1. The Team Leader determines when their team is ready for certification testing. 2. Shift Managers will video tape and critique the performance with the team. 3. Once the shift manager is satisfied with the team’s performance, VP Manufacturing will observe a set up and score the team. 4. Managers use andon lights to monitor set ups. (ONLY A PERFECT SCORE WILL QUALIFY FOR CERTIFICATION!)

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING 2012 One Best Way Team Testing Press: Operator: Shift: Helper: Date: Finisher: WhoWhatYesNoN/A OperatorIssues the 2 minute warning OperatorStarts the clock OperatorStart at Rewind, load new plate into correct stations. OperatorSet and register print starting at the rewind end (parallel processing) OperatorMatch plates with 1st color to with 1/8" OperatorPush idle and begin to make final adjustments. OperatorGradually increase speed and make necessary adjustments OperatorPlace flag in master or splice on the turret (finisher responsibility for turret) OperatorStop the clock and record set up time OperatorLog previous job information onto Press Sheet OperatorFill out QUALITY check approval for new job OperatorMonitor QUALITY HelperPRE SET UP activities HelperChange Paper (if needed) HelperChange ink and aniloxes (if needed) HelperStart at unwind, load new plate into correct stations HelperSet and register print starting at the unwind end (parallel processing) HelperMatch plates with 1st color to with 1/8" HelperPush idle and begin to make final adjustments. HelperGradually increase speed and make necessary adjustments HelperMove on to POST SET UP activities FinisherPRE SET UP activities FinisherRemove finished master and put new core on rewind FinisherRemove wsate matrix FinisherRelease RD score knives FinisherChange die FinisherChange camera settings FinisherRegister DIE to PRINT FinisherStart waste martix FinisherSet RD score Knives FinisherMove on to POST SET UP activities SET UP TIME CERTIFICATION WASTE COUNT Brian S. Hurst VP Manufacturing PASS/FAIL

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. YLDO | TLMI CONVERTER MEETING By developing and implementing this practice we have been able to increase up time and reduce waste. -Up time has increased: A 55% improvement has been achieved on set up times. -Make ready waste has decreased: A 63% improvement has been achieved in waste reduction. One Best Way Results

© Copyright 2012 Tag and Label Manufacturers Institute, Inc. All Rights Reserved. Title of Presentation | Presenters Name TLMI: Partnering to Grow Through Knowledge and Education Thank you!