Film Tension and Web Alignment Audit - Converting

Inspection template for auditing unwind, nip, and rewind tension plus web guide alignment on converting lines to help prevent wrinkles, baggy lanes, and misregistration.

Audit Details and Line Identification

• Line, machine, and station identified
  Record the converting line name/number, machine ID, and the specific unwind, process, or rewind station being audited.
• Product and substrate identified
  Record product name, substrate type, width, and roll/core details relevant to the audit.
• Date, shift, and operator recorded
  Capture the audit date/time and note the shift and primary operator or setup technician.
• Current job or work order matches production schedule
  Verify the line is running the correct job, SKU, or work order for the audit period.

Unwind Tension and Web Feed Control

• Unwind tension setpoint recorded
  Record the unwind tension setpoint used for the current run.
• Actual unwind tension within approved operating range
  Measure actual unwind tension and compare it to the approved process range for the product.
• Dancer, load cell, or brake control responding smoothly
  Check that the unwind control system responds without hunting, oscillation, or sudden tension spikes.
• Web feeds without slack, flutter, or edge wander
  Observe the web path for slack, flutter, edge wander, or other instability at the unwind section.

Process and Nip Tension Control

• Process tension setpoint recorded
  Record the process-zone tension setpoint between unwind and rewind.
• Actual process tension within approved operating range
  Measure the actual process tension and confirm it remains within the approved range for the material and speed.
• Nip pressure and engagement are correct
  Verify nip pressure, contact, and engagement are set to the approved operating condition and are not causing slip or distortion.
• No wrinkles, baggy lanes, or web distortion observed in process zone
  Inspect the web path in the process zone for wrinkles, baggy lanes, telescoping, or other visible distortion.

Web Guide Alignment and Tracking

• Web guide centered and aligned to reference marks
  Verify the web guide is centered and aligned to the machine reference marks or approved setup position.
• Edge sensor, ultrasonic sensor, or guide feedback functioning
  Confirm the web guide sensor provides stable feedback without dropout, drift, or false correction.
• Web tracking remains stable across speed changes
  Observe whether the web remains centered and stable during startup, steady-state, and speed changes.
• Misregistration risk indicators present
  Select any indicators that could contribute to misregistration or poor web tracking.

Rewind Tension and Roll Build

• Rewind tension setpoint recorded
  Record the rewind tension setpoint used for the current roll build.
• Actual rewind tension within approved operating range
  Measure actual rewind tension and confirm it is within the approved range for the product and roll diameter.
• Finished roll shows no telescoping, starring, or baggy build
  Inspect the finished roll for telescoping, starring, baggy build, or other winding defects.