Delamination and Tunneling Defect Log

Inspection log for laminated roll defects including delamination, tunneling, and bubbles, with suspected cause documentation and corrective actions focused on adhesive performance and tension settings.

Inspection Context

• Inspection date and time recorded
• Line, machine, or roll identifier documented
• Product, substrate, and laminate structure identified
• Inspector name and shift recorded
• Inspection stage confirmed
• Reference work order, batch, or lot number recorded
• Relevant SOP or control plan referenced

Defect Identification

• Delamination present
  Visible separation of bonded layers, edge lift, or loss of adhesion between laminate plies.
• Tunneling present
  Channeling, raised lanes, or air paths running through the roll structure.
• Bubble or blister defects present
• Wrinkles, waviness, or telescoping present
• Defect severity rated
• Defect location on roll recorded
  Record edge, center, lead end, tail end, or measured web position.
• Approximate defect length or affected area recorded

Suspected Cause Review

• Adhesive mix ratio or coat weight out of target
  Check for under-application, over-application, incorrect mix ratio, or uneven adhesive distribution.
• Web tension or rewind tension out of target
  Check for excessive, uneven, or fluctuating tension that could contribute to tunneling or layer separation.
• Nip pressure, dwell, or lamination temperature out of target
• Substrate moisture, contamination, or surface energy issue suspected
• Roll handling, storage, or curing time issue suspected
• Most likely root cause selected

Corrective Action and Containment

• Affected roll placed on hold or quarantined
  Non-conforming material must be clearly identified and prevented from use or shipment.
• Immediate process adjustment made
• Corrective action documented with owner and due date
• Rework, scrap, or customer notification decision recorded
• Follow-up verification scheduled

Evidence and Attestation

• Photo evidence attached for defect and affected area
• Measurement or gauge reading recorded if applicable
• Inspector attestation completed