Cutting Edge Article – Rule Processing – Automate or Evaporate 2022

Automate or Evaporate! What to look for in your next rule bender purchase.

Here we are, early 2022 with manufacturing facing many unique challenges every day. One of the biggest challenges is shorter lead times with a smaller work force. One of the best ways to address this issue is with automation. In the last few years there have been some innovation with rule processing that can improve your productivity. The purchase of a new rule bender is typically a 15-to-20 year investment. This purchase should have the ability to enhance the work you are doing today and allow you the flexibility to change with your business down the road. What is the next opportunity awaiting you?

There are many reasons to purchase a new bender from faster processing/bending speeds, new or improved options as well as tax incentives. Another consideration in looking at a new bender is the change over time for different options, for example, the time it takes to switch from bending 2 PT to 3 PT or changing cartridges.

Capabilities

Types of cutting and creasing rule to be processed, bevel, height and pointage is very important to know when discussing machine options. Typically, when it comes to punching/bridging rule the clearances for the bender tooling is most commonly 2 & 3 PT or 3 & 4 PT. 

How the machine handles the rule is also a consideration that should be discussed as well. Cut first and bend last is one way to process rule, this is where the length of rule is cut first then goes through the processor and is bent last before dropping out of the machine. 

The other method is for the rule to be processed and bent first while still attached to the coil then is cut as at the end of the machine. Typically this is done with a scissor tool. There are pros and cons to both methods so be sure to consider this when looking at a bender. In the interest of saving money and rule, one question to ask, how much rule is wasted between each piece of processed rule? Another area to look at on a new bender would be the processing speed. How fast and accurately is the rule running through the machine, how fast and accurately is it bending? With changes in technology this is one area where improvements in design and software can make a huge impact on speed and accuracy. Flexibility of the machine, today you might only be bending/processing 2 PT rule. If you need to add capabilities of 3 PT or 4 PT rule later, how difficult would that be? 

Options

With the latest innovations in die making and automation, different options can help save a huge amount of time and money as well as offer better accuracy and repeatability. 

Depending on the industry you are serving, there is the potential that the rule will need to be nicked. The benefit of nicking in the bender offers a consistent placement and consistent nick depth compared to other manual methods. In most cases nicking on the bender will also save a considerable amount of time. Compared with the old-fashioned nicking chisel where the rule is smashed, removing material is the best way to nick cutting rule. This can be done with either grinding or punching the rule on the bender. Since punching is done similar to the bridging process, this is faster than grinding. However, with the latest innovations grinding nicks may allow for a deeper nick when needed at a very high speed.

Broaching is another opportunity to improve the quality of the die and is fully automated in the bender. Broaching is the process of scraping or grinding the side of the rule to a depth just short of the bevel to allow the rule to bend a small radius but still maintain cutting strength. This is done for a number of reasons, to prevent the rule from cracking and to prevent the rule from actually getting taller in the radius area. When bending a tight radius without a broach there is the potential that the rule gets a little higher in the radius causing added makeready time and excessive die wear. This is especially important if you are using the die for kiss cutting. Another use for broaching is in the case of a miterless joint, instead of using a miter at the end of a piece of rule, the piece that it is joining can be broached instead. With available technology the ability to “broach at the end of a piece” offers Die Makers a consistent angle at the end of the rule along with the miter eliminating hours of dangerous hand grinding. 

Today you may also find a rule bender that is capable of making Perf Rule and Cut/Crease Combo rule with punching process similar to the nicking process. The ability to make Perf rule in the bender can save money and time as well as help reduce your inventory and lead times. The other benefit is that it will allow you to make custom perf rule with different cut and skip lengths if needed. With opening features in cartons and boxes getting more intricate this option could be especially important to you and your customers lead times. 

With steel counter plates becoming more popular every day, the need for round top crease/combo rule is a common requirement. This allows for creasing in the channel while the cutting on top of the plate. Punching a dove tail cut that allows Die Makers to puzzle fit cut and crease rule together is not new technology, this has been done with off-line equipment for years with varying results. If you need Perf, Combo or Dovetail options, you should ask if these options are available.

Another process that is needed for making dies for use with steel counter plates is the clipping back of the crease ends. There are many ways to achieve this manually or possibly with a surface grinder. If you do this on a regular basis this is another area to ask your machine vendor about. Quickly producing pieces of crease with a consistent clip back can be very important. Processed in the bender this a very accurate and fast process.

Another option in some rule benders is the option to scribe identifying numbers or letters on individual pieces of rule. Putting an identifying mark on each piece of rule can be invaluable. This can help when spare pieces of rule are made and sent to the die cutter. Given to a trained machine operator with ruling map can help them quickly replace a piece of rule that may have been smashed in the cutting process. In many cases the software in the bender will create a ruling map and number the pieces automatically. When looking at a new machine, you may want to ask how easy it is to create a ruling map and if scribing is an option.

With new opportunities that your sales department might present to you, it is important to know if you are able to equip your machine with different options or capabilities down the road. As your needs change is your bender able to change with you?

Don’t forget rotary benders

For the rotary Die Maker, there are also considerations to think about besides simply bridging, bending and cutting rule. To start, can the machine handle different diameters without issue? Can you change to a different diameter quickly and easily? With all the different heights of rule used in rotary cutting think about all the different perf and combo rule configurations, then all the different heights for each. Being able to make combo and special perf with the bender is a game changer. If you are making EVOL style dies, can the bender punch the gate hole for the ejection lever? Laser Crease is also something to consider, can your machine easily process the various types of Laser Crease.

Software

Another key area to consider is the software and flexibility of the software long term. Not only for the machine to run but also updates to the operating software for security as well. Consider the computer and software that comes with your bender. What file types does it operate on? Which file type is recommended for better processing? What operating software is being used? What happens when Windows does another upgrade? Or worse yet what happens when Windows stops supporting one of their older versions? 

In some cases, multiple machines may be networked to a single computer. This is something that may allow for a change in the Diemaking process or workflow. Having one person operate multiple machines from a single location can be a huge process improvement. 

Another area relating to the software is the calibration process. How long does it take to calibrate the machine? How much rule is used in the calibration process?

Installation and Training

If you are purchasing a new piece of equipment, there are considerations with the install process and the initial training. It is a good idea to have a plan around the installation of the machine and initial training. Understanding what is required from you prior to the machine being delivered and installed is the first step, typically electrical, network and air requirements. Location of the machine is key as well, the opportunity of changing processes or workflow with new equipment installs. Understanding the time to install the machine and amount of training that is also included is very important. It is also a good time to ask what type of support is available after installation, is there phone support, can a technician log into your computer to help diagnose an issue or help in any way?

Service and Support

Understanding what will be needed down the road with regards to preventative maintenance and parts. Your vendor should also be able to suggest a recommended amount of time or use on a machine before a PM is needed. It is a good idea to stay on top of the maintenance to prevent unwanted down time because of a worn part. Knowing who will be doing the PM and where the parts are sourced from is also good information to have, there may also be spare parts to keep on hand to also prevent unwanted down time. Some parts may also need to be sharpened, it is good to know where this can be done and the turnaround time for the sharpening. Can a technician help remotely by dialing in to the machine to help keep you going?

Seeing and evaluating equipment

There are a few different ways to find the right machine for the job. One is to attend the IADD Odyssey where you will find a variety of equipment on display and in operation. In some cases, there are opportunities to test the equipment in your facility for a period of time to see how it will work inside your business with your process. 

Planning for the payment and the future

If the need is there but cost is a concern, it may be time to discuss the tax benefits with your accountant. Currently the Section 179 tax benefit is still in place to help businesses invest in capital equipment. What kind of monthly payment can you afford? Typically, you can acquire equipment with little money down, with an affordable monthly payment. This creates an easy way to scale up your company as you grow. What is best for your business going forward? You can’t go wrong with doing more with less so… automate.