Digging Deeper, Part IV

For the moment, we have one final look at the Light Green Machine Institute’s inaugural projects, this month we want to look at the complex problem of width vs. speed optimization, which primarily is a discussion around new machines, but can come into play in some rebuild scenarios.  

But first, thank you for your inputs thus far.

Now, on to width vs. speed.  When setting design parameters for a new machine, the width of the machine (in multiples of widths of downstream converting and printing equipment) versus the speed of the machine is such a complex question that it has likely never been optimized using engineering and mathematical principles.

Unlike our previous discussions of inaugural projects where we asked what’s left to be done, in this case we can emphatically state that everything is left to be done. It is simply too complex a problem to have ever been given more than a cursory look.

We expect work on this problem to be broken into “bite size chunks” and proceed with a number of iterations over a long period of time. It simply does not lend itself to a quick or obvious solution.

Here are some of the challenges to be considered as we think about optimizing this problem…

Machine roll widths vs. diameters necessary to maintain stable cross section parameters.

The effect of the first issue on bearing size and lubrication system design.

Stopping and starting inertias and their effects on acceleration and braking.

Motor, cable, and starter sizes.

Building foundations.

Building width and concomitant conditioning requirements.

Steam and condensate service to the machine.

Optimization of crew sizes.

Optimization of maintenance activities.

Roll cover life.

Optimization of CAPEX vs. OPEX at a given rate of return.

A question in summary that can demonstrate the problem I am sure you have never considered: What is the relationship between the size and quantity of motor starters to machine width and speed? If you think about it for a moment you can see there is indeed such a relationship to optimize.

Again, here is what we want you, the reader, to think about. We want you to consider stepping up to the challenge of committee membership in the Light Green Machine Institute. This challenge is not only articulating the issues as we have done above (and this is just the beginning, there are many more issues), but helping form real solutions compelling for all to implement. For instance, as mentioned above, those with years of experience can solve these problems easily.  What is the documented solution, in the form of protocols, best practices, and/or standards, that one can be assured will be implemented without question to solve such issues? How do we express the arguments and formulate solutions that will pass all temporary holds on maintenance spending, value engineering and other such actions to produce sustainable, long-term results regardless of the temporary economizing program of the day?

As an industry, we may compete against one another, but in the bigger world, we compete against using our products versus other materials or elimination. This starts with efficiently doing everything we do as aided by proven protocols, practices and standards produced by LGMI. And this can only be produced and accepted by the industry when experienced minds collectively work together within the LGMI framework.

Are you ready for the challenge?

So, again, we would like your responses to this month’s newsletter.

Let us know if you are interested in working on the Width vs Spead Team with a simple response to this newsletter, something like, “Yes, I am excited about Width vs Speed.”

Thank you very much for your participation.  

Of special note...

In a few months, we will be moving this column to the Light Green Machine Institute website. There is not much there right now, but you might as well get signed up and start thinking about moving over there. It is at www.lightgreenmachine.institute.