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Run: Film Tension and Web Alignment Audit - Converting

Audit unwind, process, and rewind tension plus web guide alignment on converting lines to catch wrinkles, baggy lanes, edge wander, and misregistration befor...

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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.

Note (optional)

Current job or work order matches production schedule critical (required)

Verify the line is running the correct job, SKU, or work order for the audit period.

Yes No N/A

Unwind Tension and Web Feed Control

Unwind tension setpoint recorded

Record the unwind tension setpoint used for the current run.

Note (optional)

Actual unwind tension within approved operating range critical (required)

Measure actual unwind tension and compare it to the approved process range for the product.

Dancer, load cell, or brake control responding smoothly critical (required)

Check that the unwind control system responds without hunting, oscillation, or sudden tension spikes.

Yes No N/A

Web feeds without slack, flutter, or edge wander critical (required)

Observe the web path for slack, flutter, edge wander, or other instability at the unwind section.

Yes No N/A

Photo evidence (optional)

Process and Nip Tension Control

Process tension setpoint recorded

Record the process-zone tension setpoint between unwind and rewind.

Note (optional)

Actual process tension within approved operating range critical (required)

Measure the actual process tension and confirm it remains within the approved range for the material and speed.

Nip pressure and engagement are correct critical (required)

Verify nip pressure, contact, and engagement are set to the approved operating condition and are not causing slip or distortion.

Yes No N/A

No wrinkles, baggy lanes, or web distortion observed in process zone critical (required)

Inspect the web path in the process zone for wrinkles, baggy lanes, telescoping, or other visible distortion.

Yes No N/A

Photo evidence (optional)

Web Guide Alignment and Tracking

Web guide centered and aligned to reference marks critical (required)

Verify the web guide is centered and aligned to the machine reference marks or approved setup position.

Yes No N/A

Edge sensor, ultrasonic sensor, or guide feedback functioning critical (required)

Confirm the web guide sensor provides stable feedback without dropout, drift, or false correction.

Yes No N/A

Web tracking remains stable across speed changes critical (required)

Observe whether the web remains centered and stable during startup, steady-state, and speed changes.

Yes No N/A

Photo evidence (optional)

Misregistration risk indicators present

Select any indicators that could contribute to misregistration or poor web tracking.

Note (optional)

Rewind Tension and Roll Build

Rewind tension setpoint recorded

Record the rewind tension setpoint used for the current roll build.

Note (optional)

Actual rewind tension within approved operating range critical (required)

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 critical (required)

Inspect the finished roll for telescoping, starring, baggy build, or other winding defects.

Yes No N/A

Photo evidence (optional)

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