Cutting Through The Complexity

Computerization is making cutters easier to use and helping in-plant managers deal with the steady decline in skilled operators.

For cutting machines, technological innovation seems to have reached a point past which most further improvements and features seem superfluous. Indeed, today's machines operate about as quickly, efficiently and safely as anyone can reasonably expect.

One factor, however, promises to influence the design of these machines for the foreseeable future: The lack of skilled operators to run them.

"I haven't yet spoken to a single plant manager who hasn't said it's hard to find skilled help," says David Spiel, vice president of Spiel Associates. "The only improvement to cutting machines would be to put better computers on them. There reaches a point where the actual mechanics can't be improved much further."

Spiel notes that the capabilities of cutting machines haven't changed much over the past few years, but powerful computers and computer software have made them easier to use. This reflects the increasing computer orientation of our society, as well as the fact that some segments of the work force aren't keeping pace with this trend.

"Generally, the method of cutting paper hasn't changed for eons," notes Tom Wood, regional manager for Challenge Machinery. "Today, almost all cutters are programmable to some degree. The benefit is increased productivity. A less-skilled work force necessitates more automation. The days of the apprenticeship and the journeyman are over. It's a shame."

Mark Hunt, marketing manager for Standard Finishing, says today's work force needs cutting machines that are easy to set up and operate, and that feature intelligent operator interfaces that guide the user through the setup procedure.

"These are important for safety reasons, but they also ensure that less-skilled operators can use them, since the machines are more foolproof," says Hunt.

On a basic level, increased automation can help offset lack of technological savvy in the work force by making machines more user friendly. It can also help speed production by allowing operators to program those jobs a shop does on a regular basis into the machine's computer memory; in the near future, this data transfer may be achieved via bar-code programming.

One easily overlooked advantage of automation is that, in the hands of skilled operators, it can actually open up markets that heretofore might have been closed to them.

"Increased sophistication allows people who are versed in digital printing—and these are people who are pretty computer-literate to begin with—to make a smoother transition to mechanical printing, since different parameters are involved," says Mark Pellman, sales engineer for Baum USA. "This way, they can cover more markets."

Most manufacturers of cutting machines agree that automation and programmability are fast becoming standard—and essential—features.

Challenge Machinery's Wood sums it up by citing the "green button mentality" driving the design of new equipment. "Operators want to go up to a green button and press it to make the machine work," says Wood. "They want it made as simple as possible, and also easy to program."

Don't Overdo The Bells And Whistles

With computer-assisted operation a given, what other features must in-plant managers consider when buying a new cutter? Spiel acknowledges that a certain degree of automation is essential, but he issues a caveat geared to the size of the in-plant operation itself.

"Everyone wants all the bells and whistles, but maybe 10 percent of the 25˝ cutters I sell have a computer—or need one," he says. "If you run a complicated shop that handles multiple, complex jobs, then you need a computer. But don't over-buy.

"Also, don't rule out buying used equipment that isn't inline," Spiel adds. "Sometimes, it's faster to do things offline. Some people are into the mentality of 'paper in this end, finished product out the other end,' even if such a process winds up taking more time."

William Golde, president of MBM, says that the importance of buying the proper size of cutter can't be overstated. "Is the manager going to purchase pre-cut paper, or buy larger sizes of stock to be cut down to smaller sizes?" asks Golde. "If one cuts paper only occasionally, a manual or semi-automatic model should be purchased. Consistent cutting jobs require a fully automatic and/or programmable model."

On non-programmable cutters, warns Golde, a front safety guard becomes extremely important.

Pellman says that a machine's cutting width should allow for easy rotation of even the largest stock. He also stresses the importance of selecting a cutting blade that's suitable for the type of work passing through the machine. "If you need a variety of blades, then use a variety of blades," says Pellman.

Electric Vs. Hydraulic Cutters

Pellman warns against using electric versus hydraulic cutters, especially for those plants doing a large volume of cutting work. "If you buy a small electric cutter and your business grows, it's ill-suited to your needs," he says. "You should've purchased a hydraulic cutter to begin with. Paper manufacturing is constantly changing, and there's a lot of recycled paper on the market. Some of the small electric cutters can't cope with this kind of stock."

Hunt suggests that in-plant managers buy slightly more machine than they think they'll need. "Buy ahead of yourself, because a cutter is a long-term investment," says Hunt. "Don't skimp, especially on safety features."

A cutting machine's throat capacity should slightly exceed the largest sheet one anticipates cutting, Hunt points out. Furthermore, the machine's cycle capacity should match the needs of the shop. Hunt also favors a small machine that leaves as small a "footprint" as possible.

Hunt advises buying a machine with a mechanical knife system. "Mechanical knife systems are proven most accurate," asserts Hunt. "Hydraulic systems can deliver unequal pressure, whereas the pressure is more constant with a mechanical system."

Today, it's crucial to purchase machines with the very latest in tamper-proof, state-of-the-art safety features. Machines with control systems that require an operator to activate the cutter with two switches have become an industry standard.

Some machines go a step further, using a light-beam sensor that detects the presence of an operator's hand under the cutting blade.

As the design of cutting machines has evolved, it has become increasingly difficult for operators to override their safety features. Nonetheless, in-plant managers must think a step ahead of their equipment operators so that they can purchase machinery that's as tamper-resistant as possible.

Given all the crucial points that must be considered when adding a new cutting machine, Baum USA's Pellman offers the perfect advice for those thinking of making a purchase. "Just remember that after your printing press," he says, "the cutter is the most important machine in the shop."

Safety Is In Your Hands

Almost a third of cutter injuries result from poor maintenance, and almost half are caused by human error. To help operators avoid such needless injury, Mark Hunt, marketing manager for Standard Finishing Systems, offers the following tips:

• Read the training manual carefully. On older machines, ask for safety updates from the manufacturer and check too see if modifications were made in safeguard controls.

• Check workplace conditions. Remove debris or foreign objects from the cutter area.

• To prevent clamp accidents, cover the treadle (foot pedal) with the hood.

• Never place your hands under the knife or clamp even when they're locked or turned off.

• Don't rely solely on anti-repeat devices.

• Replace missing guards before operating the machine.

• Never bypass or rewire two-handed controls. Such modifications are dangerous and illegal.

• Consult the operator's manual before changing the knife, as this can be a difficult maneuver.

• Don't leave tools on the clamp when the cutter is operating.

• Keep repairs up to date.

• Turn off the machine if you hear unusual sounds.

• Turn off the power when you are done.