TECHNICAL ARTICLES

STEP-UP™ Program White Paper  (Page: 1, 2, 3)

RESEARCH CONDUCTED

The Study

As noted previously, the ET system is the most precise way to measure anilox volume and line screen, when utilized in a controlled environment. Our goal was to create a program that would improve the process, offer more accurate results, and save the customer time and money. To do so, we tested a new possible process vs. taking the ET system into a customer’s facility.

The test included taking an Echochek impression of an anilox roll at a customer’s facility, and then reading the impression using the ET system in Harper’s controlled technical laboratory. This system, if proven accurate, will be called the STEP-UP program.

The STEP-UP program would potentially eliminate the possibility of the ET system breaking down due to travel, would allow for a controlled environment in the Harper Corporation laboratory, and would provide the most precise readings to the customer. Following as the testing procedure.

Test Parameters

1. Use one ET system to read an anilox roll and an Echochek taken from the same anilox roll.
2. Test with ET systems 1 and 2.
3. Include the manufacturing tolerance in the test results.
4. Test a variety of line screens.
5. Test 100 rolls.

Objective

Use the ET system to measure the BCM from the Echochek impression and from the anilox roll, and compare the differences to determine if the new STEP-UP program gives acceptable results.

1. The technician takes a reading of the anilox roll using the ET system and records the data. This can be done in the customer's facility or in Harper's manufacturing facility.
2. Once the reading has been taken and recorded successfully, the technician takes an Echochek impression on the same anilox roll.
3. The technician sets up the ET system in a controlled environment at Harper Corporation.
4. After the set up is completed, the technician reads the Echochek with the ET system and records the data.
5. The results from both readings are combined into a spreadsheet to use to analyze.

Manufacturing Tolerance Levels

Manufacturing tolerance levels were established as a guide to determine an acceptable range of variance:

• Line Screen of 200-599 is +/- 5%
• Line Screen of 600+ is +/- 4%
  

CONCLUSIONS AND RESULTS

The technician performed the tests and recorded the data. The raw data was compiled and analyzed as the following:

• 91 data samples were taken to analyze and evaluate (100 Tests performed; 9 bad impressions)

• The number of tests per line screen are shown below.

• A BCM tolerance was calculated using the ET BCM reading to show the acceptable range of variance.

• A BCM difference was calculated by comparing the ET reading to the Echochek

• The BCM difference was compared against the BCM tolerance. If the BCM difference was below the calculated tolerance, the test was considered to be a pass. If the BCM difference was above the calculated tolerance, the test was considered to be a fail.

Following is a summary of conclusions that can be drawn from this study:

1. A greater number of tests passed than failed. This suggests that the new STEP-UP process does work.
   
2. Data with an extreme percentage difference of 10%-34.7% suggests that some piece of the test was not performed properly.

The following results came out of this study:
The primary goal of the study was to determine the viability of the STEP-UP program, which includes using the ET system to read the volume from an Echochek impression. We discovered that some of Echocheks were inconsistent and a portion of them were unreadable making it difficult and at times impossible for the ET to read the impressions. It’s important to note that a Harper Lab Technician performed all Echocheks, revealing the unpredictability of taking Echocheks. For that reason, Harper developed the Accuchek™ instrument, shown below.

New Accuchek™ Instrument Developed to
Take More Consistent Echochek Impressions

The Accuchek tool provides consistent pressure, compensates for width, and discontinues double impressions. The spring-loaded punch administers a repeatable and fixed burst or pressure every time an Echochek is taken. The tip of the punch is a circular rubber head that delivers a wide impression in the form of a circle.

Testing was conducted on the accuracy the ET provides when using the new Echochek tool to take impressions. With the human factors of error eliminated, all bad impressions that were present in the feasibility study conducted in may have been eliminated. Analysis of the test results showed a marked improvement in volume accuracy when the ET read the Echocheks taken using the Accuchek. Line screens 100 to 600 produced results similar to the feasibility study, but absent of frequent bad impression. Using the Accuchek tool the pass rate on line screens from 700-800 was 92.5%.

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