February 21, 2017

Manufacturing Conference & Expo 2017

BOPP Film Lolita Plant Report

Jame Wong
Topics

1. 80 microns Yield Improvement.

2. PL25 Yield Improvement with Six Sigma Project.
3. Clear Film Profile Flatness Control Improvement.

10
Section I White Film Summary Table

Sec. 1 Extrusion Internal Customer

Film Output Qty Reject Qty Complaint Issues
Year Yield (lbs.) Qty (lbs.)
Type (lbs.)
2015 1. PCS80 2,554,761 81.27% 135,861 0 Profile-
2016 2. YCL80 1,867,154 86.83% 52,021 0 Flatness
2015 1. PL25 3,798,539 86.36% 44,413 427 Web
2016 2. PL25 3,567,647 90.05% 22,677 13,958 Breaks

11
 YCL80 versus PCS80 Extrusion Performance

Product Yield Days of Cut back ** Web

Year Remarks
Type (%) Production to clean Breaks
Worst scenario:
2015 PCS80 81.27% 44 77 101 2.0 hrs. then cut
back to clean die lip.
Best scenario:
2016* YCL80 86.83% 28 37 34 13.0 hrs. then cut
back to clean die lip.
*YCL80 production started at March 2016.
** Web breaks = Total of PRS Breaks, TD, MD splits.

YCL80 N40057A on core layer only; No matte resin on skin (flame side)

12
YCL80 Yield Lost Analysis
Choppy Profile
Root Cause :
Quality Rejects (Profile Issues)
Measurex die bolt mapping
misalignment.
IR source of the Measurex
decay.
Plate-out on die lip which will
cause
Lumps, Holes and Web Breaks
Scrap generated from
Coming up after cut back
cleaning
Working profile during start-up.

13
YCL80 Countermeasures
Countermeasures:
Improve flatness quality:
Die bolt mapping alignment by Measurex
Technician.
Suggest to change the IR source of the
Measurex.
Reduce plate-out on the die lip:
Optimizing Process conditions.
Better formulation compared to PCS80.
Reduce Scraps
Training on Operators to improve their
skills.
Start-up Checklists.
Die Build-up
14
PL25 Web Breaks Summary Table

Product Days of Total of Total of PRS

Year Yield (%)
Type Production MD/TD Splits Breaks
230 85
2015 PL25 86.36% 93
(2.47 per day) (0.91 per day)
117 63
2016 PL25 90.05% 96
(1.22 per day) (0.66 per day)

15
PL25 Yield & Output Quantity before Six Sigma Project
PL25 Annual Jun-May : Yield & Quantity
100% 10

95% 8

90% 6

85% 4

80% 2

75% 0
2012 June - 2013 May 2013 June - 2014 May 2014 June - 2015 May 2015 June - 2016 May
Qty 5,557,896 5,530,060 4,827,978 3,262,920
Ext 88.24% 88.75% 85.50% 87.73%
Slit 95.46% 95.46% 96.06% 96.34%
Overall 84.24% 84.72% 82.14% 84.52%

16
PL25 Yield & Output Quantity with Six Sigma Project

100% 600
Quanty Yield 2015 June ~ 2016 May 6 Sigma Target 91.34%

95% 500

90% 400

85% 300

80% 200

75% 100

70% 0

17
PL25 Yield Improvement on Six Sigma Project

Root Cause : Countermeasure :

Scraps Generated Reduce Scraps
Work instructions & Trainings
Web Breaks Web Breaks
Settings Optimize SOCs for better quality
Process products and stable operability
of the lines.
Equipment
Checklist to ensure proper
Operator Skills equipment function.
Raw Material Work with operators to improve
their skills.
N40057A cause visual issues
(shiners), and high frequency
Raw Material
of web breaks. Incoming raw material checking
and segregation.

18
Clear Film Flatness Control Improvement XE02, XE03

Root Cause Profile Scanner Countermeasures:

NDC:
Frame Upgraded
Instability of X,Y, Z directions
on scanner, causing bad fixed had replaced.
sample reading. Software Upgraded
Software issue Eliminated most of the human
measurement.
Measurement needed to key
Auto die bolt mapping is verified
in to the system. by manual bump test.
Sporadic system failures.
System over adjusting the
profile.

19
 February 21, 2017

Lolita Site
Vertical Packaging 2017

Presented by John Bauerle

 In 2016 we learned of Vertical Packaging through
our Tennessee partners. We were challenged by
Homer to prepare the Lolita site for the same type of
packaging as a cost savings project.
Todd Socha, Steve McGrew, Dion Smith, and
myself visited the plant to learn about the equipment
and operational practices used for this project.

21
 Project Investment Cost

BOPP 1 BOPP 2
No. Item Cost No. Item Cost
1 Cascade Clamp (big) $12,869 1 Cascade Clamp (big) $12,869
2 Cascade Clamp (small) $10,995 2 Cascade Clamp (small) $10,995

3 IT equipment $5,500 3 IT equipment $5,550

(computer, scanner, printer) (computer, scanner, printer)
4 Vertical Wrapper $12,728 4 Vertical Wrapper $12,728
5 Table and Cradles $4,695 5 Table and Cradles $4,762
6 Extra Cradle $1,517 6 Guard for Vertical Wrapper $1,000
7 Guard for Vertical Wrapper $1,000
Total $49,304 Total $47,853

Total = $97,157
22
 Equipment Needed

Forklift with clamping device Packaging table

Stretch wrap machine

Label printing station

23
 3 Steps taken in the Packing Area

Step
#1 Step
Step #3
#2

It takes 3 minutes to remove a roll from the slitter cart and pack.
24
 Forklift and Stretch Wrap BOPP 1 - January 9

This process takes 5 minutes to remove a roll

from the packing area, stretch wrap, and label.
25
 BOPP 2 February 14

26
 Stretch Wrap

We use EPB115 stretch wrap.

(same as our horizontal packaging)

use 210 ft of stretch wrap. (cost of

cents per roll.

170 ft of stretch wrap. (cost of

cents per roll)

27
 Packaging and Freight Savings

28
 Packaging and Freight Savings

29
 Feb. 21, 2016

Section III
Improvement Projects
2016
Presented by Kevin Ku
5 Year Yield Trend

31
Extrusion Yield lost Analysis

32
Improvement for Change Over
Optimize product sequence to minimize change over frequency.
Plan ahead for each change over.
Recycle drained resins during change over.
Change over fly to minimize base sheet.
Improve operating and profile adjustment skill.

Improvement for Web Breaks

Training - Improve operation skill
Improve web breaks troubleshooting skill
Equipment - Check MDO NIP impression routinely
Make sure fife guide is set properly
XE05 chain/clip overhaul at Nov. 2016
Modified PRS edge trim chute
Aux#3 auto thread-up function
Cleanness - New set of breaker plates for less chance of carbon formation inside screen changer
Maintain breaker plate in clean condition/Confirm cleanness prior to push plate

33
Improvement for Web Breaks

34
2016 Top 5 Quality Reject @ 8M Slitting

250,000

200,000

150,000

100,000

50,000

0
Flatness Unstretched poly Scratches creases Impressions

-50,000

2015 2,016 Improved

35
Improvement for Flatness
Profile adjustment SOP and training, Die Bolt Mapping study.
XE05 die bolts control system and software upgrade.
Inspected XE05 scanner system.
In-shop dies rebuild to remove internal build up.
Resurfaced die at vendor site to reduce build up , 2 done 1 to go
Cut back to clean
die lip and air knife
as need.

36
VA Profile 2 Sigma trend

Cut back Cut back

clean Cut back
clean
clean
Cut back
c/o to CT40

34 hr 35 hr 33 hr

VA18T run at XE06 @ June 2016.

37
 Improvement for Un-stretched Poly
Hourly inspection for early sign of defect
Enforce cut back and clean practice
Changed out air knife blower and re-gap air knife lip
Clean exhaust blower & roof filter during PM
Redesigned exhaust hood on going
Formula improvement on going
MDO preheat Temp influence and cast sheet temp study on going.

38
Improvement for Scratches
Setup MDO rolls clean SOP
Setup scratches troubleshooting SOP
Improved water bath water quality
Prevent water carry over
from water bath
Fife guide movement response
Formula modification : On VA
replaced TOTAL 6575

39
 Feb. 21, 2016

Section IV Metallizers
2016 Performance &
Improvement Projects
Presented by Tao Chang
2017 Continuous Improvement

Continue VA film type air knife lip buildup reduction

Foremost blending system upgrade
Resurface the last die
Resolve MDO roll temperature variance issue
Scanner scan accuracy improvement by vendor
Contact roll upgrade to help pulling film flat before wind
Improve operability of SCP12, BTP18
Find out sustainable Anti-fog (AF30~50) line conditions

40
Improvement for Scratches
Setup MDO rolls clean SOP
Setup scratches troubleshooting SOP
Improved water bath water quality
Prevent water carry over
from water bath
Fife guide movement response
Formula modification : On VA
replaced TOTAL 6575

39
 Improvement for Un-stretched Poly
Hourly inspection for early sign of defect
Enforce cut back and clean practice
Changed out air knife blower and re-gap air knife lip
Clean exhaust blower & roof filter during PM
Redesigned exhaust hood on going
Formula improvement on going
MDO preheat Temp influence and cast sheet temp study on going.

38
VA Profile 2 Sigma trend

Cut back Cut back

clean Cut back
clean
clean
Cut back
c/o to CT40

34 hr 35 hr 33 hr

VA18T run at XE06 @ June 2016.

37
Improvement for Flatness
Profile adjustment SOP and training, Die Bolt Mapping study.
XE05 die bolts control system and software upgrade.
Inspected XE05 scanner system.
In-shop dies rebuild to remove internal build up.
Resurfaced die at vendor site to reduce build up , 2 done 1 to go
Cut back to clean
die lip and air knife
as need.

36
2016 Top 5 Quality Reject @ 8M Slitting

250,000

200,000

150,000

100,000

50,000

0
Flatness Unstretched poly Scratches creases Impressions

-50,000

2015 2,016 Improved

35
Improvement for Web Breaks

34
Improvement for Change Over
Optimize product sequence to minimize change over frequency.
Plan ahead for each change over.
Recycle drained resins during change over.
Change over fly to minimize base sheet.
Improve operating and profile adjustment skill.

Improvement for Web Breaks

Training - Improve operation skill
Improve web breaks troubleshooting skill
Equipment - Check MDO NIP impression routinely
Make sure fife guide is set properly
XE05 chain/clip overhaul at Nov. 2016
Modified PRS edge trim chute
Aux#3 auto thread-up function
Cleanness - New set of breaker plates for less chance of carbon formation inside screen changer
Maintain breaker plate in clean condition/Confirm cleanness prior to push plate

33
Extrusion Yield lost Analysis

32
5 Year Yield Trend

31
 Feb. 21, 2016

Section III
Improvement Projects
2016
Presented by Kevin Ku
 Packaging and Freight Savings

29
 Packaging and Freight Savings

28
 Stretch Wrap

We use EPB115 stretch wrap.

(same as our horizontal packaging)

use 210 ft of stretch wrap. (cost of

cents per roll.

170 ft of stretch wrap. (cost of

cents per roll)

27
 BOPP 2 February 14

26
 Forklift and Stretch Wrap BOPP 1 - January 9

This process takes 5 minutes to remove a roll

from the packing area, stretch wrap, and label.
25
 3 Steps taken in the Packing Area

Step
#1 Step
Step #3
#2

It takes 3 minutes to remove a roll from the slitter cart and pack.
24
 Equipment Needed

Forklift with clamping device Packaging table

Stretch wrap machine

Label printing station

23
 Project Investment Cost

BOPP 1 BOPP 2
No. Item Cost No. Item Cost
1 Cascade Clamp (big) $12,869 1 Cascade Clamp (big) $12,869
2 Cascade Clamp (small) $10,995 2 Cascade Clamp (small) $10,995

3 IT equipment $5,500 3 IT equipment $5,550

(computer, scanner, printer) (computer, scanner, printer)
4 Vertical Wrapper $12,728 4 Vertical Wrapper $12,728
5 Table and Cradles $4,695 5 Table and Cradles $4,762
6 Extra Cradle $1,517 6 Guard for Vertical Wrapper $1,000
7 Guard for Vertical Wrapper $1,000
Total $49,304 Total $47,853

Total = $97,157
22
 In 2016 we learned of Vertical Packaging through
our Tennessee partners. We were challenged by
Homer to prepare the Lolita site for the same type of
packaging as a cost savings project.
Todd Socha, Steve McGrew, Dion Smith, and
myself visited the plant to learn about the equipment
and operational practices used for this project.

21
 February 21, 2017

Lolita Site
Vertical Packaging 2017

Presented by John Bauerle

Clear Film Flatness Control Improvement XE02, XE03

Root Cause Profile Scanner Countermeasures:

NDC:
Frame Upgraded
Instability of X,Y, Z directions
on scanner, causing bad fixed had replaced.
sample reading. Software Upgraded
Software issue Eliminated most of the human
measurement.
Measurement needed to key
Auto die bolt mapping is verified
in to the system. by manual bump test.
Sporadic system failures.
System over adjusting the
profile.

19