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Problem with Square parts from Edgebander

12/8/17       
John Garth Member

I have worked in three fabrication companies now and there have always been intermittent challenges with parts not being square coming off the edgebander. They all have pre-mill stations. I believe it is mostly, if not completely operator error when loading the parts not flush to the fence. When doing as many parts as we do I can see where some percentage of the parts will be mishandled. Although, in an effort to reduce rework I am looking for ideas or solutions that my help us ensure square parts 100% of the time.
As an example, is there an attachment or jig that any of you have used to create a moving 90 degree fence to help hold the parts true to the fence of the equipment?
thanks for your help,

12/8/17       #2: Problem with Square parts from Edge ...
Stuart Douglas

No Jig, just operators that aren't stoned or hungover.

We've been through 3 edgebanders in my career, two with pre-milling stations. You are describing operator error. Operators need to be cognizant of each operation, each time. Get complacent and the work suffers. Simple as that. The only piece that an operator should struggle with is something long and narrow, like banding the end of a back-splash. Even in that instance, if you match the approach speed with the conveyor speed and keep the infeed fence waxed (SlipIt, Bostik, wax) then parts should be 100%. The edgebander can be a sleeping pill for large jobs, but just like anything else in the shop this is what separates us from the chimps.

12/8/17       #3: Problem with Square parts from Edge ...
Chad R  Member

Website: http://www.northwayind.com

Are your parts square going to the edgebander?

12/8/17       #4: Problem with Square parts from Edge ...
John Garth Member

Chad R.,
The parts are square for the most part. Parts are measured and checked for square post cutting and pre-banding. I do not believe this is always happening. Basically the reason for my question. I would like to dumb down the edgebanding process as we run thousands of parts. This would also help us to understand more quickly where the squareness issues are occurring for accountability purposes.

Hey Stuart,
I agree with your appraisal of the situation. You are on the money and follow the procedures noted for the most part. The challenge specific to our company is not only do we do thousands of parts normally, but the schedule expands to tens of thousands of parts for 3 months out of the year. We double our capacity, with primarily temp labor, so dumbing down the process to chimp labor would be helpful. Also, you can only imagine what the cost of rework is to the milling department for 2 or 3 boards when they are running thousands.

12/8/17       #5: Problem with Square parts from Edge ...
Stuart Douglas

I would make a cheat sheet. Print it on heavy card stock and laminate it and hang it by the bander control. Step by step, with benchmarks for acceptability and a team leaders name @ the top who checks the parts periodically. You'd be amazed how effective this simple piece of paper is. The hardest part is setting the protocol in writing.

It is JUST AS IMPORTANT to have the person tailing to be as competent as the person feeding. The feeder can't see how the finished board comes out without taking a walk. If the pair of operators are both trained to run, then they can switch positions to prevent brain fatigue.

We run hundreds of thousands of parts a year and while this process seems simple to someone in the biz, if you are using temp labor, then you will likely have to accept a certain percentage of rework. I have veteran guys here that haven't (wont) been able to pickup competency on our newest machine, I can't imagine bringing in someone super green. Good Luck!

12/8/17       #6: Problem with Square parts from Edge ...
John Garth Member

Thanks for the help Stuart.

12/8/17       #7: Problem with Square parts from Edge ...
Chad R  Member

Website: http://www.northwayind.com

We don't normally have a problem with squareness either, but we mainly use our double sided for squaring. We do have a squaring fence mounted on one of our Homags though. It works well when it is used.


View higher quality, full size image (2219 X 1801)

12/8/17       #8: Problem with Square parts from Edge ...
Stuart Douglas

Thats neat, Chad. I've never seen a squaring arm on a machine like that.

12/8/17       #9: Problem with Square parts from Edge ...
John Garth Member

I had not seen a squaring arm either. Why I asked. Assuming the arm came from Stiles?

12/8/17       #10: Problem with Square parts from Edge ...
Chad R  Member

Website: http://www.northwayind.com

Yeah from Stiles. I have seen them on IMA's also. Its in the Homag edgebander brochures also.


View higher quality, full size image (1741 X 1625)

https://www.stilesmachinery.com/files/assets/files/1503075157_98-450-00149.pdf

12/8/17       #11: Problem with Square parts from Edge ...
John Garth Member

Thanks for the information Chad!

12/24/17       #12: Problem with Square parts from Edge ...
Lee Johnson  Member

I have worked on many machines with pre-milling units and have seen this problem before. If it is an inconsistent issue, i.e. it occurs on some panels but not on others, then I believe some panels are "slipping" outwardly on the track. One way to check this is to mark the front of an 6" x18" panel then pre-mill one 18" side. Flip it over and run the opposite 18" side with the front still at the same end. If your panel is slipping on the conveyor track then your panel will now measure wider at one end: something like a parallelogram. To correct this issue call me at 803 517 4131 for free advice. There are several things that can cause this and I'm too slow of typist to give them all to you here.

2/23/18       #13: Problem with Square parts from Edge ...
Todd

Not meant to be sexist but have you staffed the job with women. Often women are more process and detail oriented than men. I knew a fellow that had a painting and finishing and he ended up almost entirely hiring women because they did a better job on that type of work. Now maybe someone has or can do a study on this topic for their PHD thesis...


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