Patterns of DMM.

Direct to Machine Monitoring (DMM) provides a porthole into the cost and performance drivers of the converting processes.

The DMM graph shown below demonstrates the time and material loss that often occurs post shift change. Shift changes carry a wealth of challenges, many of which can lead to lost time and materials. Most data collection systems camouflage post shift change material losses by classifying them as registration trouble, die problems or anilox adjustments. The graphics of a DMM system can show you or, more important, your operators the cost of post shift change "tweaking" and a possible re-setup of the press. Surprisingly, it can be your top operators that are guilty of this habit. Once operators understand the cost of their actions, they can begin to explore alternatives in handing off a running press with the objective of providing the relief operator a greater level of confidence in the current press settings.

The DMM display provides the cost, material length and time for adjustments made post shift change. In the example below the time lost was small, only a few minutes, but material costs were significant: $65.91.

Note: The average converter runs good product less than 40 percent of any production shift, so saving minutes or even seconds in setup, roll changes and in shift changeover will offer significant gains in overall productivity. Combine this with gains made through material utilization and conservation techniques and your bottom line improvement will be notable. For more information on "DMM Patters to watch for," send your request to [e-mail].

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