Flexo Tooling

Overview#

The Flexo Tooling set of Estimate Types is custom-made for the Flexographic Tooling industry. Products include:

• Rotary Die
• Flexible Die
• Print Cylinder
• Anvil Rollers
• Magnetic Cylinders
• Gears
• Anilox Roller
• Rubber Roller
• Sprocket Punch Unit

The Die Trace Image for Rotary and Flexible Dies is available in the Data Pipeline = Items_Flexo and the filed name is IMAGE.

Die layout images can be emailed from the Estimating Form by clicking the Images button (visible when Rotary or Flexible Dies are selected). Options are:

• Email die layout (.emf): this file can be emailed to customers.
• Email die layout (.asc): this file can be imported into BESgrav engraving software.

Settings#

Several General Settings are required for this model to work correctly – in the Flexo Tooling group.

Machine#

In all these Estimates, you can (optionally) select a Machine from the list of Machines that are linked to the Customer. When a machine is selected, the gear information is populated from the selected machine.

Override - Materials and Services#

Functionality is provided to override the Materials and Services by checking the Override checkboxes on the Form tab.

Outsourced#

When the Outsourced checkbox is checked, several fields are enabled for you to input the Supplier Price and the Currency which is then inserted as an item in the converted local currency. The Adjustment can also be set on the Input Form and it is added as an overall adjustment.

Common fields - Rotary and Flexible Dies#

• Machine: A lookup of Flexo machines that are linked to the Customer. It's an optional field that can automatically populate the Module field when it is selected.
• Module & Teeth (No. of gear teeth) – Determines the Cylinder Diameter.
• Drawing No & URL: Use the URL to open a drawing uploaded to a cloud drive. Click the Open button (Web icon) to open/download the drawing.

Label#

• Shape: The dimension fields that appear depend on the Shape that is selected.
• Qty – Across: Must be captured.
• Qty – Around & Min: The Qty Around is calculated according to the Repeat Length, Depth of the Label and Minimum gap (Min field – Default = 3)

Perforations#

• Cut, Tie and Qty Across and Qty Around.
• Qty = No. of Perforations

Die#

• Machine: Select the Die-cutter Type = Rotary, Semi-Rotary and Flat.
• Hardening: Select from Items where the Code contains HARDENING. The selected item is added to the BoM under components SER_CYL... and SER_GEAR.
• Application: How the die will be used (e.g. Kiss Cut or Through Cut).
• Material: The Material and Liner that will be cut.
• Coating: How the Die needs to be coated. (Optional)

Engrave (Customer Reference)#

Enter the Customer's Reference Numbers that need to be engraved on the Die. It is added to the Estimate Description by default.

Rotary Dies / Sprocket Punch Unit / Underscore Unit#

Rotary Dies consist of two components: The Gear and the Cylinder. An Assembly is added for both the Gear and the Cylinder and each Assembly will include the Materials and Services that are required.

Gear#

• Checkbox: When a Gear is not required (unchecked), you need to enter the Repeat Length manually.
• OD: Calculated from the Module and Teeth
• Width: Enter the Total Width of the Gear (if the Gear is checked)

Cylinder#

• Diameter: Calculated from the Module and Teeth
• Total Length: Capture the Total Length from the drawing supplied.

Material - Cylinder#

• Grade: Select the Material Grade.
• Margin: Enter the Margin that must be added to the Total Length of the Cylinder.
• Length: Calculated: Total Length of the Cylinder + Margin

Material - Gear#

• Grade: Select the Material Grade.
• Margin: Enter the Margin that must be added to the Total Width of the Gear.
• Length: Calculated: Total Width of the Gear + Margin

BoM selection#

Components for the Gear and the Cylinder need to be created in Items and must contain a Materials and Services Assembly as follows:

Gear (Code: RD_GEAR)

• Services: (Code: SER_GEAR) Must be an Assembly that contains the Services required to manufacture a Gear.
• Materials: (Code: MAT_GEAR) – Can be a custom Assembly.

Cylinder (Codes: RD_CYL (4, 5 & 6 Star); RD_CYL_3STAR (3 Star))

• Services: (Code: SER_CYL) Must be an Assembly that contains the Services required to manufacture a Gear.
• Materials: (Code: MAT_CYL) – Can be a custom Assembly.

Recondition#

The Rotary Die, Magnetic Cylinder, Anvil Roller, Print Cylinder and Rubber Roller product types can be reconditioned. When the Recondition checkbox is checked, several fields are hidden and the Description is updated. In addition, an Actual field appears in the Cylinder section to capture the actual Pitch Diameter which needs to be measured. If the difference between the Actual and Theoretical Diameter is more than 0.2 mm, a QC Alert is raised. The Final Diameter is calculated from the Actual Pitch Diameter if a value is entered.

BoM Selection#

Flexible Dies#

The Flexible Die estimate allows for outsourcing and in-house manufacture.

• Supplier & Ref: Select a Supplier and enter their reference – e.g. a Quotation No.
• Cost & Currency: Enter the quoted price and select the Currency in which the Supplier is quoting.
• Selling Price: The Selling Price can be set using an Adj. %, Adj. Amount or by entering a Selling Price.

Fields#

• Margin: Is applied to all sides of the Die to calculate the required plate size. Default = 90 mm.
• Height: The Total Height of the Flexible Die when complete – from the top of the blade to the bottom of the plate.
• Thickness: The Thickness of the Plate after etching.
• Angle: Manual selection of 60/70/90 degrees

BoM Selection#

• Code: SER_FD: Contains Services for Outsourced Dies.
• Code: SER_FLEX: Contains Services for in-house manufacture.

Settings#

General Settings > Flexo Tooling > Flexo - Item Category for Flexible Dies Material (e.g. = 2, in (1,2,3)): This setting identifies the Item Category from which the die plates are selected. The Material must be loaded with a Unit of sq.m.

Print Cylinders#

BoM selection#

Components for the Gear and the Cylinder need to be created in Items and must contain a Materials and Services Assembly as follows:

Gear (Code: RD_GEAR)

• Services: (Code: SER_GEAR) Must be an Assembly that contains the Services required to manufacture a Gear.
• Materials: (Code: MAT_GEAR) – Can be a custom Assembly.

Cylinder (Codes: P_CYL)

• Services: (Code: SER_CYL) Must be an Assembly that contains the Services required to manufacture a Gear.
• Materials: (Code: MAT_CYL) – Can be a custom Assembly.

Rubber Roller#

BoM selection#

Components for the Gear and the Cylinder need to be created in Items and must contain a Materials and Services Assembly as follows:

Gear (Code: RD_GEAR)

• Services: (Code: SER_GEAR) Must be an Assembly that contains the Services required to manufacture a Gear.
• Materials: (Code: MAT_GEAR) – Can be a custom Assembly.

Cylinder (Codes: RR_CYL)

• Services: (Code: SER_CYL) Must be an Assembly that contains the Services required to manufacture a Gear.
• Materials: (Code: MAT_CYL) – Can be a custom Assembly.

Anilox Roller#

The Anilox Roller is designed to transfer a precise amount of ink from the ink reservoir to the printing plate. The surface is engraved with thousands of tiny cells that are responsible for carrying the ink.

BoM selection#

Components for the Gear and the Cylinder need to be created in Items and must contain a Materials and Services Assembly as follows:

Gear (Code: AR_GEAR)

• Services: (Code: SER_GEAR) Must be an Assembly that contains the Services required to manufacture a Gear.
• Materials: (Code: MAT_GEAR) – Can be a custom Assembly.

Cylinder (Codes: RD_CYL)

• Services: (Code: SER_CYL) Must be an Assembly that contains the Services required to manufacture a Gear.
• Materials: (Code: MAT_CYL) – Can be a custom Assembly.

Anvil Rollers#

The Anvil Roller is a hard, smooth Cylinder that works in conjunction with the Rotary Die. As the Substrate (material being printed on) passes through the press, it goes between the Rotary Die and the Anvil Roller.

BoM selection#

Components for the Gear and the Cylinder need to be created in Items and must contain a Materials and Services Assembly as follows:

Gear (Code: RD_GEAR)

• Services: (Code: SER_GEAR) Must be an Assembly that contains the Services required to manufacture a Gear.
• Materials: (Code: MAT_GEAR) – Can be a custom Assembly.

Cylinder (Standard) – (Codes: A_CYL)

• Services: (Code: SER_CYL) Must be an Assembly that contains the Services required to manufacture a Gear.
• Materials: (Code: MAT_CYL) – Can be a custom Assembly.

Cylinder (Stepped) – (Codes: A_STEP_CYL)

• Services: (Code: SER_CYL) Must be an Assembly that contains the Services required to manufacture a Gear.
• Materials: (Code: MAT_CYL) – Can be a custom Assembly.

Magnetic Cylinders#

BoM selection#

Components for the Gear, Cylinder and Bearers need to be created in Items and must contain a Materials and Services Assembly as follows:

Gear (Code: RD_GEAR)

• Services: (Code: SER_GEAR) Must be an Assembly that contains the Services required to manufacture a Gear.
• Materials: (Code: MAT_GEAR) – Can be a custom Assembly.

Cylinder

• Services: (Code: MD_CYL) Must be an Assembly that contains the Services required to manufacture a Gear.
• Materials: (Code: MAT_CYL) – Can be a custom Assembly.

Bearers 

Quality Checks (End Control)#

The Quality Check provides a product-specific form against which you can record the actual dimensions of the finished product. To open, right-click the Transaction Item which is a Flexo Tooling estimate and select Quality Check.

Enter the Dimensions that correspond to the drawing (e.g. A, B and C).

Add Notes for explanations.

When the Quality Check is complete, click the Approve button to add the name of the User and the Date and to make the form read-only.

Click the Reset button to make changes.