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DIECUTTING TRENDS TO CONSIDER IN THE FUTURE
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- Written by Robert Larson
To better understand how to compete and flourish in the future especially in our current time of recession and anxiety over possible terrorist actions in the USA , it is necessary to understand the forces that comprise the business environment that we all face in today’s marketplace. This article is a recap of a session that I recently presented at Print01 in Chicago, updated with the situation after September 11th.
In today’s severe competitive marketplace, it is essential that converters seek out the most efficient and low cost procedures to cut or trim component parts of their products. Diecutting can be performed from a wide range of basic diecutting techniques to sophisticated high-speed systems. Companies who invest in new systems of diecutting will increase productivity that will make a positive impact on their profit margins.
The Invisible Process:
I like to call die cutting the invisible process. Most people never see this important part of the converting process. When people ask me what I do, I tell them that I am involved in diecutting. Often a quizzical look appears on their face. I ask them if their mothers ever made cookies with a cookie cutter. Immediately, they recognize what I am talking about when I say that a cutting die is a “cookie cutter with a college degree” and is used to cut out identical parts from many soft to semi-rigid materials using a sharp edge cutting die.
Die cutting is involved in almost every aspect of our daily lives. Not a day goes by when we are not exposed to many products that have been diecut. For example, almost every product that is packaged in a paperboard or corrugated container is diecut. Your shoes, wallets, handbags, parts of your clothing are diecut. Envelops, labels, flexible printed circuit boards, medical gowns, puzzles, even helicopter blades are diecut or trimmed. Your automobile’s upholstery, dashboard, headliner, carpeting, gaskets and many more parts are diecut. I have developed what I call the never-ending lists of materials and products that are die cut. Leave me your business cards and I will send you these lists. Some far out diecutting applications include cutting and molding fish sticks; die cutting tobacco leaves for cigars and diecutting wooden toothpicks.
A Look Back in History
To better understand where we are today in diecutting and where the process may be in the future, let us take a few moments to see how the craft of diecutting developed. The basic design of a flatbed press eventually used in diecutting paper, embossing and foil stamping was originally modeled after a wooden wine press.
About 1450 AD in Germany, a gentleman called Johann Gutenberg adopted the concept of the wine press into the first printing press. His discovery changed the course of history and enabled a more modern way of recording and duplicating the written word and pictures. Another great advance was reported in 1790 was the development of the letterpress for printing was built by Adam Ramage. He substituted an iron platen and bed for the original wooden & stone parts in a press.
In 1798, Charles, the Third Earl of Stanhope, in England built the first printing press with a one-piece cast iron frame. In 1816, George Climer of Philadelphia built the all iron Columbian press. The Columbian press could make an impression with one pull of the handle. It had a platen capacity of 23” x32”. Its biggest drawback was that it took 11 different press operations and could only print one sheet of paper at a time. George Phileus Gordon introduced the Gordon press in 1851. In 1862 he developed his improved Franklin Gordon Press. This became a standard printing press in the commercial printing industry in the U.S.A. for 75 years.
The beginning of steel rule diecutting
Paralleling the development of printing is an interesting history of the development of steel rule diecutting for the graphics arts and packaging industry. Robert Gair is given credit for inventing steel rule die cutting in America in 1879. Mr. Gair was a printer and as the story is told, one day he inadvertently inserted an over height crease rule into a letter press lock-up that he was constructing. He discovered quite by error that instead of creasing the paper, as desired, he cut the paper. He ruined a whole job before he discovered the error. He is also credited with being the creator of the diecut and creased folding carton. The platen printing press therefore developed a new use in diecutting. In the printing industry there were three forms of letterpress machinery: the platen press, and the later developed cylinder press and rotary press. These two later types of printing presses also were adopted to become diecutting presses.
The development of commercial steel rule diecutting blades in North America is attributed to the J. F. Helmold Company established in 1881. Helmold was a pioneer in developing a multitude of products used in the graphic arts industry, folding cartons and corrugated containers and later in displays, gaskets and related industries. Helmold pioneered the development and production of steel rule cutting, perforating, and creasing rules and equipment to produce steel rule dies. In England, the Notting Company was also producing cutting rules for steel rule dies.
The first steel rule bender to bend steel rule stock for steel rule dies was invented by Joel Welty in 1900. It was a simple machine that bent the thin ribbon die steel. Mr. John Arthur Richards, born in Newark, Ohio in 1880 learned his trade as a pressman in the printing trades. He worked for a series of printers, newspapers and printing press manufactures to include the Miehle Printing Press & Mfg. Company. On a trip to visit his brother in Fort Wayne, Indiana in 1910 he saw a man making steel rule dies in the window of the Fort Wayne Paper Box Company. He asked the man what he bent the rule with and the man pointed to a small machine saying that it was the "Multiform made across the street". Mr. Richards purchased the patent, patterns and business of the J. Welty Company from Mr. Welty's widow. That began the Richards’ family’s involvement in producing machinery and equipment for producing steel rule and steel rule blanking dies. In 1912, the J. A. Richards Company produced their first line of Multiform saws for cutting the die lines in steel rule dies. These jig saws were operated by foot power, belt drive and later by motor drive.
I have tried to describe the early beginnings of the diecutting process. In the first half of the 1900's many advances were made in the types of cutting dies produced and the types of cutting presses developed to cut out a whole array of materials and products. In the 1960's and 70's new methods of cutting soft to semi-rigid materials were developed such as laser cutting, waterjet cutting and computerized knife blade cutting. Today, cutting dies are still the mainstay and the choice of many manufacturers for cutting component parts of many products.
In 1962 William F. Ward of The Ward Machine Company developed the soft anvil rotary die cutting concept using a rotary steel rule cutting die. Up to that time manufacturers of corrugated containers used flat steel rule dies. Mr. Ward wanted to build a rotary diecutting press that would run twice as fast as a flat die cutter, could handle a corrugated sheet twice the size of a flat press and sell his press for one half the price of a flat diecutting press. The soft anvil rotary diecutting press opened a whole new avenue not only to corrugated box makers to produce specialty die cut boxes at lower unit cost, but also to many other products in the converting industry such as felt products, non-woven products and a host of other materials and products.
Also paralleling the development of diecutting in the graphic arts and packaging industries was the development of diecutting in other industries such as footwear, leather goods, gaskets, apparel and numerous other products. That is another story. You can read more about the history of diecutting in an article entitled “ History of the Diecutting Process in America” that I wrote in 1994 that is located in Reference Area under Diecutting Articles in www.dieco.com. You can also find over 100 other articles on the diecutting process.
A Whole World of Systems:
Another interesting facet of the diecutting process is the wide range of different diecutting methods and techniques in use to cut or trim many of the different products that I have described above. Today there are many options in diecutting systems including flatbed, multi-contour and rotary diecutting systems. Each of these systems have advantages and disadvantages for cutting different materials.
Few people have a detailed knowledge of the whole range of different systems including their tooling to cut different materials. In the packaging industry where paperboard and corrugated board are the materials of choice, converters use a variety of systems that are entirely different from cutting component parts for shoes, leather goods or apparel. Look at the side of a truck and you will see a large pressure sensitive vinyl graphic that most likely was cut with a heated thermal die on a thermal diecutter. Beer and wine labels are often diecut on a high pile diecutter where the die blade constantly cuts into a lower lay of labels with a die called a PMC label die. Envelopes are cut 500 sheets high using heavy duty forged or wire EDM cut dies that are a marvel in construction and sharpness. The dashboard of your automobile was cut and trimmed with cutting die sections cutting from different angles in a multi-contour cutting press system. The wonderful world of diecutting is truly diverse. If you are a cigar smoker, your tobacco wrapper leaves were die cut. Human skin is also die cut in laboratories to prepare skin grafts for surgical procedures.
Diecutting is a very simple and logical process. It is easy for me to say that having been born into the industry and being active in many types of diecutting and diemaking for almost 50 years. The diecutting process is a logical process of cutting single ply’s or multiple ply’s of material and understanding the dynamics of a blade penetrating through whatever material has to be cut. I could spend hours on that subject, but it will have to wait for another time and place.
The difference in die cutting systems is so diverse that individuals who are using one type of press system often have little appreciation of other die cutting systems. For example, in the printing industry, many people know of a Bobst AutoplatenÔ Flatbed Cutter/Creaser Diecutter or a hand operated Thomson or Brausse clamshell flatbed die cutter. How many of you have head about a pneumatic flatbed sliding table die cutter or clamshell hydraulic multi-contour trim press? Have you ever heard of a hydraulic flatbed swing arm clicker press? What about a label high pile die cutting press? All these different types of cutting presses are ideal for a wide range of materials, but likewise totally inappropriate for other materials. The question therefore is which is the best system to use for a particular material?
Pick the right system:
Listed below is a list of different diecutting press systems from my new resource guide entitled “International Manufacturers and Distributors of Flatbed, Multi-Contour and Rotary Die Cutting Systems” due to be published later this year by Larson WorldWide.
Die Cutting Systems by types of equipment:
Flatbed Die Cutting Systems:
Arbor Hand Operated Presses
Automatic Cutter/Creaser Die Cutting Presses
C-Frame Hydraulic Die Presses
C-Frame Pneumatic Die Presses
Clamshell Platen Die Cutting Presses - Hand fed, semi & automatic
Cylinder Die Cutting Presses
Envelope Die Cutting Presses
Full Head Hydraulic Beam Die Cutting Presses
Label High Pile Die Cutting Presses
Label Narrow Web Die Cutting Presses
Laboratory Physical Testing Die Cutters
Large Area Hydraulic Die Cutters
Large Area Pneumatic Die Cutters
Mechanical-Electronic Die Cutting Presses
Mechanical Die cutting Press Systems
Pneumatic Platen Die Presses
Progressive (Incremental) Feed Hydraulic Die Cutting Presses
Radio Frequency (R.F.) Articulating Seal & Cut Hydraulic Presses & Feed Systems
Receding Head Hydraulic Die Cutting Presses
Roller Die Cutters
Semi-automatic Cutter/Creaser Die Cutting Presses
Shuttle (Sliding) Table Hydraulic Die Cutting Presses
Shuttle (Sliding) Table Pneumatic Cutting Presses
Swing Arm (Clicker) Die Cutting Presses
Thermal Die Cutting Presses
Traveling Head Hydraulic Die Cutters
Multi-Contour Cutting & Trim Systems
Multi-contour Clamshell Cutting & Trim Systems
Multi-Contour Platen Cutting & Trim Systems
Rotary Die Cutting Systems:
Rotary Corrugated Soft Anvil Die Cutters
Rotary Hard Anvil Narrow Web (up to 20” 508mm) Die Cutters
Rotary Hard Anvil Mid-Web (20-36” 508-914mm) Die Cutters
Rotary Hard Anvil Wide-Web (over 36” 1397mm) Die Cutters
Rotary Hard Anvil File Folder Die Cutters
Rotary Hard Anvil Narrow Web Folding Carton Die Cutters
Rotary Flexo Soft Anvil Diecutters
Rotary Label Die Cutting Presses
Rotary Magnetic Cylinder Die Cutters
Rotary Narrow Web Label Die Cutters
Rotary Sheet Fed Soft Anvil Die Cutters
Rotary “Split Gap” Hard Anvil & Inter-Changeable Magnetic Cylinder Die Cutters
Rotary Web Fed Soft Anvil Die Cutters
You can see the wide range of systems available to converters to fit their particular die cutting applications. As I have mentioned before, there is a preferred diecutting solution for each type of material, but there are also alternative types of systems that can be utilized in producing desired die cut parts. Some systems with ancillary material feed systems offer improved productivity over other systems. Often, a diecutter try’s to utilize diecutting equipment that he has on hand to save the investment in a new system. Often a converting diecutter just does not know what options are available in equipment to improve productivity.
Which system to use and what type of tooling to use is often the sixty-four dollar question in the minds of many people in our industry. There is a logical and economical solution to each die cutting application. Seek out experts in the diecutting process that can recommend the appropriate diecutting system with the best diecutting tooling to cut or trim your products. The International Association of Diecutting and Diemaking (IADD) is located in Crystal Lake, IL and claim’s to be the “Definitive Resource” to the diecutting process. For more information, visit the IADD website at www.iadd.org or call the association headquarters at +1 815 455-7519 or toll free at 1-800-828-IADD (4233).
A look at tooling
Should you use a flatbed or rotary steel rule die, a hard anvil rotary die, a chemically etched die that adheres to a magnetic cylinder, a forged or edge hardened clicker or high die or a heated thermal die in your operations? Should you use “into or “onto” diecutting using different types of tooling? Is your production run a short run for a limited time period or a long run cutting millions of identical parts? What is the tolerance of the parts to be cut? Can the parts be cut to a commercial tolerance of +/- 0.015” (1/64” or .381mm) or do the parts have to be very accurate to +/- 0. 005” (.127mm)? Is the material flexible, compressible or rigid? Does the material change dimension after diecutting? Does the material change dimensionally in different degrees of humidity? What about the cost of the tooling? How long dies it take a die to set-up (to make-ready) on a press? What is the cost to maintain the sharpness of the cutting edge? These are but a few of the considerations to determine in selecting the proper tooling to make a diecutting press operated to it maximum efficiency and productivity.
Unfortunately, many converters do not use the best type of tooling in their diecutting press systems to obtain maximum productivity. I have seen numerous instances where either due to inexperience or lack of vision in tooling options, that a company accepts using tooling that is inappropriate or inadequate for the job.
In many cases, the purchasing department has been given the edict from management to save money on tooling to reduce costs. In too many cases, I have observed that individuals sourcing die cutting tooling for their diecutting operations have little or no appreciation of the complexities of the diecutting process. They buy at the lowest quoted price tooling. The people on the production line suffer from using less than desirable tooling, the dies may need more set-up times on the press and the press operates at less than optimum speeds. When a die fails for one reason or another, down time on the press almost always exceeds (many times over) the small initial savings in the cost of the tooling.
A number of years ago, I did a joint study on the typical costs of producing a folding carton job. My associate and I considered all the costs of materials, tooling, equipment, overhead, printing etc. What we discovered was that the cost of the tooling in all cases accounted for less than 1% of the total cost of the job. The cost of the tooling per cut piece was so small that it would go out three decimal points, in other words negligible. In fact, most diecutters do not figure in the cost of tooling into a job because it is so small. In the packaging industry, especially in folding cartons and corrugated boxes, packaging converters have a mania for “nickel and diming” tooling providers to save that last cent of expense. Instead of seeking out the best tooling providers to improve production, they often seek out the cheapest source of supply. One instance of downtime to fix or repair a die costs many times the savings on that die.
I could do on and on with this topic, but for now, please understand that cutting corners on the cost of tooling in most cases is strategic error that costs a company more money than it saves. Unfortunately, many companies in the converting and packaging industry are penny wise and pound-foolish as our British compatriots have coined the phrase.
Setting some guidelines:
Before we look at the future, let’s identify some common needs or situations common in our industry today:
1. Faster through put of materials in the die cutting operation.
Today productivity is the name of the game. In the diecutting process, the number of cycles per minute of a press is important, but often the functions of material handling take up more time. The up and down action of a diecutting press is but one factor in productivity. How long does it take feed and take off the diecut parts from the press area? How much time is wasted in setting up a job? How much material has be ruined to get the press up and running properly? How often does a die have to be replaced in the production cycle to resharpen the blades or fix a tube or cutout? How often is there a problem with the stripper material to eject the part from the die?
Today, we are experiencing more and shorter runs as diecutters meet the demands of the just-in-time production environment. This means many more set up’s of jobs during the day. This is where minimal set-up times become crucial in maximizing productivity during a shift of operations. Delays cost money. Innovative set up procedures with preparing the tooling before it goes into the press are more important today than ever. You will see more and more diecutting systems with “quick change” tooling systems come into the marketplace.
Bobst introduced their new Sprintera automatic platen press system at Drupa last spring in Germany. This sophisticated automated system can diecut up to 12,000 sheets of material per hour. That is assuming that a converter has all the best tooling produced and installed in the press and operators are trained to ensure maximum productivity. More common are a number of automatic platen presses for paperboard and corrugated board that can operate in the 8,000 to 9,000 sheets per hour range. Of that class of automatic die cutters, I think it could be said that many, if not most companies never attain the 9,000 sheets per hour maximum productivity of a press. They normally operate in the 6,000 to 7,000 sheets per hour range, sometimes a little over 5,000 sheets per hour.
Why does this happen? A few answers could be in less than adequate tooling and in inexperienced (less than 100% trained) operators. How a steel rule die is rubbered can have a dramatic influence on how fast a die can run in a press. New waterjet cut rubber ejectors in steel rule dies can improve productivity dramatically. By using the best-designed and constructed tooling, it is often possible to increase productivity 5%, 10% or more per job. Then it may be possible to get one or more jobs on a press per shift. This all adds to increased profitability in the diecutting department.
One more time let me revert back to my favorite subject of the cost of tooling. Diecutting converters should seek out tooling providers who understand their diecutting systems and know how to provide tooling to maximize the productivity of their equipment. Often, you will not find these suppliers when sending out quotes and buying on the lowest bid. A new philosophy of partnering with tooling vendors has to be understood. Today some of the largest packaging companies look at partnering as the tooling provider offering them the lowest price for the best tooling systems. This misguided one-way strategy most often just does not work and does not encourage true partnering of interests to maintain a good profit margin of both the supplier and customer.
2. Minimizing Set-up Times.
Today, pressures are on converters to turn around orders in an ever-faster basis at less cost. Tooling providers also are under the gun to provide tooling to meet their customers (the converter) to meet their schedules. Minimizing set-up times between jobs is a prime consideration today. Reducing make-ready times is essential. Tooling has to be prepared and tested off the press. When the tooling package is put into the press, the time taken for the operation must be short and fast. No longer can a diecutting manager allow 4 to six hours of make-ready time for a job. Set-up times now must be accomplished in minutes. The difference between a profit and a loss can often be counted in the time it takes to set up a job. Yes, press speed is an important element, but minimal set-up time is equally important.
Diecutting press operators must have the tooling and training to minimize press set-up times. Compare two converting companies diecutting the same like material and product on the same type of diecutting press. One is very profitable, the other cannot figure out how to improve their production. In which camp does your company fall?
3. Improved tooling and methods to accomplish the two items above.
No matter if you are diecutting folding cartons or gaskets, shoe vamps or cigar wrappers, or presentation folders, there are suppliers who understand your business and your diecutting situations. Management must seek out these suppliers and open up a dialog, a communications channel to discuss the diecutting operations and determine the best solutions to improve productivity and profitability. I am not talking in a cloud of theory. There is a cost-effective solution to every diecutting application.
Sometimes it is a challenge to discover that right person or supplier that can offer solutions. Improved tooling comes about only after a converter and a tooling supplier understands the whole situation. Improved tooling solutions that improve productivity do not come with the cheapest price. Often it makes sense to pay a little more for tooling especially when you have developed a relationship with a vendor who understands your business. Your tooling supplier should be a valued asset to your company’s goal to attain the highest productivity and profitability in your diecutting operations.
4. Training of press operators and managers
You can have the most advanced diecutting equipment; the best in cutting die tooling and yet not meet productivity goals for one simple factor. . . less than 100% equipment operators and management personnel. I have seen many instances in diecutting operations where press operators need more training or have not been properly trained to perform their jobs. In many cases, operators are put on machines with little or no organized training. On the job training often is a quickie course on how to run the machine. As I have mention previously, the main difference between two companies productivity and profitability often lies in which company has the best trained (and experienced) people.
Training comes in man forms. Scheduled formal training can provide employees with the nut and bolts of knowledge to do their job better. On the job training assisted by knowledgeable supervisory personnel can fine-tune a persons skills. Exposure to new techniques in seminars, educational conferences and trade shows can expose personnel to many things that may not be available in plant. Yes, training is an essential element of production. Unfortunately, adequate training is “the missing link” in many companies. Training is not a cost to a business, but an investment.
Diecutting Trends in the Future:
Now we come to what could be called the meat of this presentation. This is where I, as a diecutting guru am supposed to tell you all the good things of what the future holds for you your diecutting operations. Well folks, I will try to address several positive and negative trends that I see affecting your business in the future:
1. Global Outsourcing & Shifting of Production
I sold my diemaking and diecutting business in 1984. At that time in the shoe, apparel, leather goods, sporting goods areas, I experienced the loss of business to outsourcing of products off shore to Asia and Central America. I guess I got out at a good time. In 1986, I started my new informational-based company providing information and resources to the diecutting process. Fifteen years later I have seen many shifts within the diecutting process.
Several months ago, I was speaking to a major producer of steel rule die tooling. He had recently gone to a toy store to by his grand child a toy. To his horror, he discovered that almost all of the products came from somewhere outside of the USA even though they carried famous American brand names. Likewise all the packaging came from where the products were made. Where were the “Made in the USA” products? He had just realized, as I did in the 80’s, that our customers business has been moving to distant lands. How will he cope with that situation? Will he have the vision to seek out new product lines to supplement or expand his business for the loss of business that he is currently experiencing? This situation will require many tooling providers and printing and packaging companies to re-evaluated their businesses to maintain their livelihood in the future.
Today this is a global phenomenon not only affecting only North America but also Europe and yes, Japan and Asia. In one of my trips to Southeast Asia, I was in a packaging company in Bangkok, Thailand. The owner was complaining about his loss of business to China. In Europe and Japan, companies are experiencing a similar shift, an outsourcing of production to other cheaper areas of production. It still is strange to see a Japanese product like Sony or Panasonic with made in Singapore or Thailand on the packaging and products. We are all affected by this shift in production. One solution may be to follow your customers to their new bases of production. This is a difficult decision for many homebodies who would never consider moving to a foreign place to set up shop.
2. The “Recession”
If you have not heard, the press is telling us we are in a recession. Daily we hear of new layoffs as large and small companies downsize to adjust to market conditions. The consumer does not yet seem to have heard of the recession, as spending is still strong. Companies can take two roads in a downturn. First they can draw inward, cut expenses and hunker down to survive the recession hoping for better days. The second option, probably for the more visionary companies is to invest in new systems and methods to improve productivity. My company did just that in the 80’s during a major downturn. We invested in a new computer controlled EDM machining system. It tool us a year to go through the learning curve of how to use this piece of equipment When the economy recovered (as it will this time) we were in position to take on new business that we could not handle before. We could then produce some of our products more efficiently that we did in the past. This slowdown will pass in time. When it does, will your company be in a better position to accept business on a more profitable playing field?
3. The Internet
My, how this is changing business. Recently while talking to an industry supplier of materials to make steel rule dies, a comment was made that in Denver, Colorado, for example, the printing business was in a slump therefore fewer steel rule dies were being made which means that less diecutting is probably being done. The reasoning, this person suggested for this situation, was told was the Internet. Let me explain the thought process.
I maintain a large on-line resource and information marketplace with over 2000 industry vendors to the diecutting process, plus embossing and foil stamping. The Dieco Marketplace in www.dieco.com also has links to over 600 websites in the diecutting process. My industry supplier associated told me that they had recently had printed a new sales catalog at a price of approx. $ 14.00 each. That catalog was out of date as soon as a new product or new development occurred. On their website, they could keep all information updated and current. Many more people could view their information and download pertinent information. This has to have an effect on commercial printers as more and more companies go on-line and more and more people seek out resource on-line. This is another shifting of information from the printed word to the electronic word.
4. Consolidation of major converting players in the packaging industry.
Who is on first base today? What is the latest name of that company producing folding cartons or corrugated boxes down the street? Who was bought out by whom? How many factories will be closed down in the realignment of production capabilities. How many of those operations had their internal diecutting operations that required die cutting tooling? This is a causing a definite change in the marketplace. Those tooling providers who used to service many factories of a large folding carton company, fir example, are finding it harder to keep busy, to maintain their workflow of orders. It is another indication of our “I want it this instant” mentality where we do not want to wait for the snail mail to arrive with a catalog several days later. We want it now!
5. Over Supply of Tooling Providers
A little over 5 years ago, I had over 1800 diemaking companies in my database in North America. At that time I predicted that in 5 years, 25% of those companies would disappear. In the fall of 2000, I checked my database again and found only about 1300 diemaking tooling providers, a 27% drop in the numbers. I now predict that in the upcoming 5 years, we will see a further 25 to 35% reduction in cutting die tooling provider companies.
The survivor companies will be larger and more automated in their manufacturing of cutting die tooling. Those companies that fell through the safety net in most cases just could not remain profitable, could not adapt to the changing competitive marketplace or did not have the vision to invest in the future to minimize labor costs and increase the productivity of each employee. Is your company going to be a survivor or a statistic?
6. Commodity Tooling Problem
Today many diecutting converting companies look at diecutting tooling as a commodity product, to buy at the cheapest price. Many diemaking companies today are selling their dies for less money than 10 years ago. With increasing costs each year, how can they afford to stay in business?
This is not a healthy situation for the diemaker or the converting diecutter. Now you may say it is to the advantage of the converting diecutter to save money buying his or her tooling cheaper. This in most cases, it just isn’t so. Cutting die tooling providers cannot continue to invest in their operations to improve their products to better serve their customers while getting less for their products. Profit margins will dwindle to a degree that even the best of tooling providers lose their ability to provide excellent service, be innovative in new cutting die tooling technology or be able to be that important source of training, knowledge and support for their customers.
Diecutting converting companies have to acknowledge that if they want quality tooling and support from their tooling providers, they have to change their mindsets of buying cheap. They have to realize that quality tooling has a definite impact on their productivity and profitability and if their suppliers are “sick” or unprofitable, then they the diecutting converting customer must shoulder a part of the blame if they maintain their “buy cheap” mentality.
7. Changes or Improvements in Base Materials
Everyday, new materials are being developed to produce new and improved products. Each of these new materials creates a diecutting and tooling challenge within the diecutting process. I recall (I am from the Mrs. Robinson generation) when plastics were invented with a whole new generation of products. Today there are literally thousands of varieties of plastics in the marketplace place. Composite materials are being created almost daily to replace older types of materials.
In the folding carton industry now more dramatic change is taking place than that of thin corrugated min-flute boards taking over where paperboard used to be the king. Plastic corrugated materials are also a viable alternative to paperboard based corrugated materials. Today recycled paper based and plastic materials poise challenges in diecutting and creasing. The challenge of setting a good crease in paperboard that has been recycled several times is an ever ending problem. In China, I saw corrugated board that was so bad that you could not glue flaps of a box together, you had to staple the box together. China today is importing more and more virgin and recycled board from North America. What new materials will eventually replace paper and paperboard as our forests dwindle in size?
8. Loss of our base of Skilled Labor
In Europe, there is a well-organized apprentership program to nurture a new generation of skilled employees in many industries. This is not the case in North America. Call this a short sightedness of American business or a reluctance to invest in the future. Is it that we as North American’s are so infatuated with this months P& L statement and profits that the “cost” of an apprentership or mentoring program is just not within the realm of business.
A common complaint that I hear from managers in many diecutting operations is that they have lost their skills base of old time employees. How they used to do things the best way in many cases has slip by them. They no longer have the personnel that can keep their presses running at top efficiency. Newer younger employees just don’t have the experience or skills of the older more experienced staff that has moved on to new positions or to a new company. I was recently in a diemaking facility in New York City where I saw an old timer who was mentoring to a younger employee. It was the job of the older veteran to teach the younger one all his “tricks of the trade”. Now, can we say that is an expense or an investment to a company? To many shortsighted companies it is an expense. To the company with a vision of the future, it is an investment. The bottom line in this matter is that if we do not perpetuate our base of skills from one generation to the next, our future profitability will be in question.
9. Flatbed to Rotary in Diecutting
I see a shift in diecutting from flatbed to rotary diecutting in many parts of the converting process. Yes, there will always be a definite place for flatbed diecutting. It is still the preferred method in cutting many materials. On the other hand, many diecutting converters are realizing that cost efficiencies that can be realized in converting to rotary diecutting.
One area where this is evident is in the use of chemically milled dies for both rotary and flat operations. A thin chemically etched & machined die can be quickly wrapped around a magnetic cylinder. There is a very fast set up time from job to job. If a material can be web fed from a roll, it is an ideal candidate for this type of diecutting. Today, we see more and more folding carton operations going the route of the flexible magnetic die. In the label industry, the flexible die is often a good cost effective alternative to hard anvil rotary tooling.
10. Newer, More Efficient, Safer Diecutting Systems
I mentioned the Bobst Sprintera automatic diecutting and creasing system. This is one example where press manufacturers are innovating to produce more productive systems. A whole new generation of semi-automatic diecutting press systems are now available for the graphics arts and packaging industries to replace much older hand fed platen clamshell type presses. New cutting press safety standards for manual hand fed diecutting presses are a clear signal that diecutters with these older type presses have the option to add required safety features or invest in newer, safer and more productive diecutting systems.
To many diecutting converters this is seen as a painful, somewhat unnecessary situation. They have been using the older presses for many years, often without accidents and now they are faced with new investments in equipment in a marketplace where they feel they cannot afford the luxury of new equipment.
This same scenario too place in the shoe, apparel and leather trade’s years ago when OSHA instituted the two-hand trip requirement on die cutting presses. Today, many of the older more inefficient type presses are history and newer, safer systems are the mainstay in many diecutting operations.
Cutting press manufacturers will keep innovating with refinements in systems to make them more productive, increase the through put of sheets or feet per minute of materials, incorporate quick change tooling systems and improve material handling systems or options on die cutting systems. I think you will see more semi-automatic and automatic systems coming onto the marketplace.
11. Training of Diecutting Personnel
I have talked about this topic already. Just to re-emphasize, this area, the best trained and educated workforce will be a decisive advantage in allowing a diecutting converter to be more competitive than his less savvy competitor.
12. Transfer of knowledge from the old timers to the new people
I think that we will see more mentoring programs in companies. Management will realize that they have to transfer the knowledge base and experience of older employees to younger upcoming employees. This is a definite investment in productive and efficient operations. Those companies that so not realize the value of mentoring will lose their skills and productivity.
13. Alternatives to Diecutting for Small Production Runs
Ever hear of digital diecutting or a production samplemaking table? These systems are not traditional diecutting as we know it, but they are appropriate in many cases as an alternative to traditional diecutting especially in cases where low to medium number of parts are needed. Both are accomplished on an X-Y flatbed table. Many of us know of samplemaking systems used to produce samples of corrugated and paperboard design for folding cartons or corrugated boxes, even foam inserts for packaging. These tables will evolve into production type machines with automatic loading and take off stations.
In Japan, I have seen several samplemaking systems that have been turned into production stations, cutting out a continuous line of corrugated parts or foam inserts. This form of production cutting system will grow as samplemaker producers evolve their systems from single samples to capabilities to produce small to medium lots of identical items.
Digital diecutting is becoming well accepted in the graphic arts industry where it is necessary to cut parts to close registration of printed paper or paperboard materials. The system can optically register onto a line or cross hairs on a sheet. This type of cutting is a logical solution in cutting small to medium lots of parts. At some point it becomes more economical to diecut the parts.
14. Productivity, Productivity & more increased Productivity
Those companies who succeed in the future will be the ones who can squeeze the last bit of productivity out of people in their operations. This does not mean overworking people, but using their talents and time more efficiently. By providing people with intelligent working systems that work better, faster and saves time, companies will be able to retain or increase their competitive position in the converting process. How do you compete against a person in Asia that makes $ .15 an hour? By using the best trained most productive workforce. In 2000, it is now reported that productivity in the United States increase 2.5%. That means that our workforce is working more efficiently and smarter. We have to keep up that pace in the future.
This new era of productivity will come at a high cost of investment in labor saving machines and systems. Fast, more intelligent die cutting systems. Equipment will have built in Internet diagnostic systems that connect the operator directly to the service technician all in real time. Training will be done on-line while a machine is operating. Maintenance services will be automated. Cutting die tooling providers will also have to invest in automatic manufacturing systems to produce better tooling more economically. Again diemakers have to transform their labor force from a handcraft basis to an engineered based workforce.
Yes, we are in for many changes. It is my hope that many visionary companies evolve into more productive operations. Unfortunately, some will not and they will be the casualties of this new ultra productivity era. We are about to experience many changes in the diecutting process. Will you be here in 5 years to relish the sweet smell of success (or survival)?
In summary
I have discussed a lot of information in this article. I hope that elements of that information can assist your diecutting operations to become more efficient and productive. Take many little steps in integrating ideas and new methods. Seek out advice on how you can upgrade your diecutting operations to reach new levels of productivity. Discover how to integrate newly developed materials into your product line to improve your products. Learn how to efficiently die cut those materials. Better appreciate the role of your tooling providers as valued partners in your overall goal to improve profitability that your require to maintain that competitive edge in the marketplace.