Coil handling equipment is fairly simple and low tech, and generally is purchased as part of an entire slitting or cut-to-length installation.
As such, uncoilers, recoilers, downenders, coil cars, turnstiles, etc, typically get little attention; unless they fail to do the job.
High speed operations in particular require efficient handling at the front and back end of the lines.
Well designed coil loading installation, uncoilers and recoilers can save time in setup and labor and can reduce scrap.
Remember every second, minute counts in this industry …. TIME IS MONEY!
While the biggest gains in coil processing come from increasing actual processing time, the proper staging of both full and partial coils can provide more flexibility with operation lines.
Proper staging is achieved through the use of such equipment as uncoilers, recoilers, upenders, downenders, turnstiles, coil staging racks, coil cars and reels.
In order to take a step forward you first need to take a step back and analyze what you already have and what you are working with.
The main areas to consider when it comes to coil handling are; the range of coil weights, outer and inner diameter’s of the coil, stock minute, stock thicknesses, material types, and feed accuracies required.
Coil Handling and packaging lines and equipment are the same for both ferrous and nonferrous material.
Heavier coils require more massive equipment as compared to smaller or lighter rolls.
Soft copper and brass coils require lighter duty, but slightly more refined, pieces of equipment to reduce coil damage caused by handling and conveying.
Fabricators that currently do not have any handling equipment should consider getting started.
Those that have some equipment might consider adding more equipment to increase efficiency.
Equipment such as c-hooks, jib crane, etc.
For those companies with high labor costs or demands for extreme quality (or both), proper coil handling and packaging can enhance production, safety, and earnings.
When purchasing a new processing line, service center operators says, look for a supplier with a good reputation, and don't take the coil handling equipment for granted.
By increasing efficiency most of the time you also reduce or eliminate human contact with the slit coils. In turn this helps reduce cuts, back injuries, and hernias.
Overall increasing safety.
The more sophisticated system you are working with (i.e. automatic lines) the less you need to spend on safety precautions as these are a priority for fully automated lines.
The operator is able to control the entire line from a booth overseeing the process.
With semi automatic lines you are not only introducing the human element reducing precision but you are also increasing safety risks.
Now let us give you a rough outline as far as the labour input goes in these various processes.
When coils are completely strapped on a turnstile and removed by a 'C' hook and jib crane for placement onto skids, two men will handle one slit coil every 3 minutes.
This is for a Manually operated line.
When coils are downended, banded semi-automatically and stacked with manual grab and jib cranes, two men will handle one slit coil every 1.5 min.
When a completely automated packaging line is installed and used with automatic stacker, order sorting, skid banding and weight facilities, two three men will handle 350 - 500 coils per shift.
The output is greatly depended on labor requirements of the line, the equipment purchased in addition to the layout of the workspace.
The equation is simple THE GREATER HUMAN CONTACT > EFFICIENCY/SAFETY
This does not mean that you should eliminate all of your labour and put in stellar machines, no!
In the end everything comes down to what you have to work with.
If you have the ability and lay out for machinery upgrades, then by all means upgrade away.
But for some people that is not efficient for them.
In those cases an approach to the current processes and systems should be taken.
Analyze the time intervals for the processing of one coil, once a benchmark is established efficiency upgrading may begin!!!
There are different factors when it comes to efficiency but the bottom line is always the same....
SAVE MONEY, REDUCE TIME, INCREASE PROFIT.
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