Flexo Tooling
Overview
The Flexo Tooling set of Estimate Types are custom made for the Flexographic Tooling industry. Products include:
Rotary Die
Flexible Die
Print Cylinder
Anvil Rollers
Magnetic Cylinders
Gears
Anilox Roller
Rubber Roller
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 include:
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
A number of General Settings are required for this model to work correctly.
The Default Assembly settings are used to select the Item which contains the BoM and Services. (Not Active yet)
Default Assembly - Gear
Default Assembly - Gear (Recondition)
Default Assembly - Print Cylinder
Default Assembly - Print Cylinder (Recondition)
Default Assembly - Rotary Die
Default Assembly - Rotary Die (Recondition)
Default Assembly - Flexible Die
Default Assembly - Flexible Die (Recondition)
Default Assembly - Anvil Roller
Default Assembly - Anvil Roller (Recondition)
Default Assembly - Magnetic
Default Assembly - Magnetic (Recondition)
Lookup list - Application
Lookup list - Material Type
Lookup list - Material
Lookup list - Coating
Machine
In all these Estimates, you are able to (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.
Note: When the following fields are changed, the Input is overwritten: Product, Quality and Outsourced
Outsourced
When the Outsourced checkbox is checked, a number of 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 - This is 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 - The URL can be used to open a drawing that has been uploaded to a cloud drive. Click the Open button (Web icon) to open/download the drawing)
Label
Shape - The dimension fields are displayed according to 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, eg. Kiss Cut, Through cut, etc.
Material - The Material and Liner that will be cut.
Coating - How the Die needs to be coated. (Optional)
Engrave (Customer Reference)
Allows you to 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
Rotary Dies consist of two components: The Gear and the Cylinder. A Component will be added for both the Gear and the Cylinder and each Component 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 Component as follows:
Gear (Code: RD_GEAR )
Services - (Code: SER_GEAR) This must be a Component that contains the Services required to manufacture a Gear
Materials - (Code: MAT_GEAR) - This can be a custom component.
Cylinder (Codes: RD_CYL (5&6 Star); RD_CYL_3STAR (3 Star))
Services - (Code: SER_CYL) This must be a Component that contains the Services required to manufacture a Gear
Materials - (Code: MAT_CYL) - This can be a custom Component.
Recondition
The Rotary Die, Magnetic Cylinder, Anvil Roller, Print Cylinder and Rubber Roller product types can be reconditioned. When the Recondition checkbox is checked, a number of fields are hidden and the Description is updated. In addition, an Actual field is displayed 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 0.2mm, a QC Alert is raised. The Final Diameter is calculated from the Actual Pitch Diameter, if a value has been entered.
BoM Selection
Rotary Die (Code: RD_RECON) - Contains Services only
Magnetic Cylinder (Code: MD_RECON) - Contains Services only
Anvil Roller (Code: A_RECON) - Contains Services only.
Print Cylinder (Code: P_RECON) - Contains Services only.
Gear (Code: G_RECON) - Contains Services only.
Rubber Roller (Code: RR_RECON) - Contains Services only.
Flexible Dies
The Flexible Die estimate allows for outsourcing and in-house manufacture.
Supplier & Ref - Select a Supplier and enter their reference - eg. 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 - will be applied to all sides of the Die to calculate the required plate size. Default = 90mm
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 > Item Category for Flexible Dies Material (eg... ) - This setting identifies the Item Category from which the die plates are selected. 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 Component as follows:
Gear (Code: RD_GEAR)
Services - (Code: SER_GEAR) This must be a Component that contains the Services required to manufacture a Gear
Materials - (Code: MAT_GEAR) - This can be a custom component.
Cylinder (Codes: P_CYL)
Services - (Code: SER_CYL) This must be a Component that contains the Services required to manufacture a Gear
Materials - (Code: MAT_CYL) - This can be a custom Component.
Rubber Roller
BoM selection
Components for the Gear and the Cylinder need to be created in Items and must contain a Materials and Services Component as follows:
Gear (Code: RD_GEAR)
Services - (Code: SER_GEAR) This must be a Component that contains the Services required to manufacture a Gear
Materials - (Code: MAT_GEAR) - This can be a custom component.
Cylinder (Codes: RR_CYL)
Services - (Code: SER_CYL) This must be a Component that contains the Services required to manufacture a Gear
Materials - (Code: MAT_CYL) - This can be a custom Component.
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 Component as follows:
Gear (Code: AR_GEAR)
Services - (Code: SER_GEAR) This must be a Component that contains the Services required to manufacture a Gear
Materials - (Code: MAT_GEAR) - This can be a custom component.
Cylinder (Codes: RD_CYL)
Services - (Code: SER_CYL) This must be a Component that contains the Services required to manufacture a Gear
Materials - (Code: MAT_CYL) - This can be a custom Component.
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 Component as follows:
Gear (Code: RD_GEAR)
Services - (Code: SER_GEAR) This must be a Component that contains the Services required to manufacture a Gear
Materials - (Code: MAT_GEAR) - This can be a custom component.
Cylinder (Standard) - (Codes: A_CYL)
Services - (Code: SER_CYL) This must be a Component that contains the Services required to manufacture a Gear
Materials - (Code: MAT_CYL) - This can be a custom Component.
Cylinder (Stepped) - (Codes: A_STEP_CYL)
Services - (Code: SER_CYL) This must be a Component that contains the Services required to manufacture a Gear
Materials - (Code: MAT_CYL) - This can be a custom Component.
Magnetic Cylinders
BoM selection
Components for the Gear, Cylinder and the Bearers need to be created in Items and must contain a Materials and Services Component as follows:
Gear (Code: RD_GEAR)
Services - (Code: SER_GEAR) This must be a Component that contains the Services required to manufacture a Gear
Materials - (Code: MAT_GEAR) - This can be a custom component.
Cylinder
Services - (Code: MD_CYL) This must be a Component that contains the Services required to manufacture a Gear
Materials - (Code: MAT_CYL) - This can be a custom Component.
Bearers
Services - (Code: MD_BEARER) This must be a Component that contains the Services required to manufacture a Gear
Materials - (Code: MAT_BEARER) - This can be a custom Component.
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 on the Transaction Item which is a Flexo Tooling estimate and select Quality Check.
Enter the dimensions that correspond to the drawing. eg. A, B, C, etc.
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.