Advanced Cutting Systems Geared to Improving Operator Safety
By: Bruce Peterson, President, Colter & Peterson
Since its introduction 164 years ago, the guillotine paper cutter has evolved into a powerful production tool for printers and bindery operations. Paper mills and converters are also benefiting from a host of improvements that have been made to these machines during the last two decades. Advanced manufacturing techniques have enhanced the paper cutter’s affinity for precision and reliability. Electronic controls have digitized the cutters’ back-gauge control system and can now provide important production feed back. New microprocessor-based memories have enabled the cutter to literally learn the cutting sequences of dozens of jobs.
The impact of each of those advances enhances what might be the most significant improvement in paper cutting since the invention of the guillotine. It’s the use of paper handling and material processing peripherals to transform the humble cutter into a highly automated paper cutting system that can be extensively customized to optimize the ability of an operator to process any particular job at hand.
Given the guillotine cutter’s importance in the chain of production both in paper houses and printing facilities, equipment manufacturers have been working to improve the cutter’s efficiency. While the guillotine cutter has come a long way since the first machines were introduced in France in 1844, the basic structural composition of the machine remains the same.
Operator’s role radically altered
Though the basic cutting sequence has remained unchanged, the role of the operator has been radically altered, at least in facilities equipped with a state-of-the-art cutter. In the past the operator spent considerable time positioning the back-gauge for each cut. That action spots the sheet stack under the blade for a precision cut. Today, the back-gauge moves into place automatically, in most cases positioning material much faster than even the most experienced hands ever could.
Cutting efficiency is further enhanced by the higher capacity of advanced cutters. They boast both faster cycle speeds and the ability to handle thicker pile heights than their predecessors. As a result, an operator now spends much more time moving material than they do cutting. Workflow analysis studies show that in many situations, operators spend only 20% of their time cutting, while 80% of their working hours are devoted to moving material. When the new generation of electronically enhanced cutters came on-line, unaided operators simply couldn’t keep up with the productive pace of the advanced machines.
The manufacturers’ response was to develop new equipment and methods for efficiently loading (feeding) material and unloading (delivering) material to and from a guillotine. That issue remains at the top of the technical agenda being addressed by current guillotine cutting equipment suppliers. The result is the replacement of the stand-alone guillotine cutter with a cutting system that puts the guillotine machine at the center of an automated workflow chain.
Increased productivity, safety concerns
The objectives of these improved systems center on two prime considerations: increased productivity and utilization as well as safety and health concerns. Recent figures tracking increased productivity in various industries, without corresponding increases in manpower, support this observation as the direction being taken through the use of modern equipment and production techniques. The same holds true for cutting operations.
Safety and health concerns facing businesses today must be addressed. Consider the long-term well-being of an operator who works eight-hour shifts at a stand-alone cutter. He can, over the course of a day, have to lift tons of paper, almost ensuring that an injury will occur before too long. The result is an increase in the number of cases of Cumulative Trauma Disorders (CTDs). The two most widespread forms of these repetitive motion disorders are back injuries and carpel tunnel syndrome. Both are prevalent in guillotine cutting operations and each produce physical and financial pain.
Reducing strain on operators
The solution to the CTD problem facing the paper handling operation can be found in the science of ergonomics. In the case of cutting, the need exists for ways to apply modern technology, equipment and work processes together to reduce strain on the operators.
Changing the guillotine cutting operation involves several steps including taking a fresh look at existing procedures and how they can be improved. A detailed analysis of the cutting operation with time studies on current equipment provides the basis for evaluating areas of improvement. Next, there’s the evaluation of alternative equipment and procedures that can be implemented. This requires examining present procedures and seeking out and applying techniques that may not be known within the operation.
Assistance is available either through consultants or from equipment suppliers. Now as never before, equipment suppliers actively take the consultative approach in applying solutions that often prove to be the best source of advice on upgrading cutting operations.
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Bruce Peterson is President of Colter & Peterson, the largest independent distributor of paper cutters and paper handling equipment in North America. Employing more than 75 people in four locations, Colter & Peterson specializes in every facet of paper cutter and perfect binding acquisition and ownership, including maintenance and repair, machine sales, safety and productivity upgrades, surplus machines and more. Contact Bruce at (800) 932-0780 x206 or bruce@colterpeterson.com.
