Category: New Energy/Technology

  • How Flexo Concepts® Was Digitally Transformed

    How Flexo Concepts® Was Digitally Transformed

    digital transformationFlexo Concepts has completely transformed the way it does business.

    Digitally, that is.

    It began the way all of our projects do, with a vision – to create a digital cohesiveness throughout our company to optimize our customers’ experience with us – and a plan to make that vision a reality. Together, they led us down a 4-year path of pervasive digital transformation that reached into every corner of our company and united all of our business functions.

    “A company’s digital transformation may not be very noticeable from the outside,” said Greg Howell, Flexo Concepts’ president and de facto project leader. “If done correctly, customers won’t notice initially.  But over time they will see increasing examples of improved experiences as they engage with suppliers who are transforming.”

    Greg Howell and Phil RyanA successful digital transformation requires hard work that needs to be done inside the organization, necessitating a sustained, company-wide focus on a long-term goal and plenty of patience along the way.  A key player in the company’s transition was Flexo Concepts’ Supply and Customer Experience Manager, Phil Ryan. Together, Greg and Phil piloted a process to attack this initiative over a period of 4 years, leading to countless examples of technology being used in game-changing ways.

    From the start, Greg realized the importance of drawing ideas and buy-in from all areas of the company – not just IT or Sales where the initiative started, but also Accounting, Engineering, Operations, Marketing, Manufacturing and Customer Experience. This was important not only to generate the best ideas, but also to ensure that knowledge and capability were distributed throughout the company and not centered around a few people.  He was sure that everyone in the organization – from top to bottom and across – needed to work together for this to succeed. And so, our “Digital Transformation Team,” with representatives from each department, was born.

    Since the beginning, the team would gather every other week to communicate progress, celebrate “wins”, vet ideas, and plan next steps.  Tasks were decided upon, and members would return to their departments after each meeting with tactical to-do lists. Gradually, the assignments were moved from “to-do” status to “completed” and crossed off the list.

    digital transformationOver time, wonderful things began to happen in different parts of the organization. Tighter control over billing and collections, better cost tracking, easier multiple currency billing and simplified sales tax management were achieved in the accounting department, for example. Our engineers started using “cases,” or CRM system tickets, to manage the process of blade analysis. Manufacturing personnel came to enjoy the ease of using an on-platform shipping tool that allowed direct creation of shipments from a sales order within a single application. SOP’s and master batch records created clear, accessible guidelines for daily operation in a digital format. New inventory management automation and a centralized procurement system ensured access to accurate, up-to-the-minute levels of available product, improved cost allocation and better raw material tracking. The customer experience team began using surveys to gauge the company’s performance at not only meeting customers’ current needs, but also to get a sense of new services people would like to see from us.

    Internal and external quality issue tracking through digital cases enable us to recognize issues early, investigate them, and resolve problems as quickly as possible. Internal costs savings were realized, too, when the operations department declared “paperless status” in September 2019, eliminating over 87,000 pieces of paper and about $10,000 in related expenses annually! An order is now received, processed, manufactured, packed, shipped and invoiced using only a single piece of paper – the packing slip.

    Steve KaoThe sales and marketing teams were also rewarded with automated processes to pinpoint customers’ pain points and offer customized solutions. The integration and optimization of software systems provide quick and easy account “snapshot” analysis and tracking via personalized dashboards, providing our salespeople with all the information they need at their (keyboard-operating) fingertips. Our marketing staff has gained tools to determine the information prospective customers are looking for and deliver it to them not only when they want it, but how. A central repository offers the entire international team access to all online marketing collateral, and a Kanban process enables them to request sales support materials digitally.

    Today, we are proud to report that 100% of our business processes are in the cloud (except for a few processor-intensive applications and some local file storage). Our entire office staff company-wide has access to all job functionality via the web, facilitating remote operation on laptops, iPads, mobile phones and other devices. As a result, we now have maximum flexibility to maintain uninterrupted service to our customers despite unforeseen events that may impact our ability to operate from a central location.

    Greg sees our company’s digital transformation as a logical extension of our continuous improvement mindset and believes that you can’t really do one without the other. “Our culture has always placed an emphasis on finding ways to work smarter and leverage technology to do it. Much like continuous improvement, meaningful digital transformation is an accumulation of very small improvements done over time that come together to create large, efficient and more capable systems.”

    It began with the belief that if we could create a digital record of all our customer interactions, we could attain operational bliss and deliver amazing experiences for our customers.  And we did. For now. Because, almost by definition, digital transformation is a never-ending process with infinite room for improvement. As our ways of conducting business keep evolving, our technology capabilities grow, and our customer focus remains steadfast, there’s no doubt we will continue to “transform.”

  • Flexo Concepts Joins Local “Scallop Roll”

    Flexo Concepts Joins Local “Scallop Roll”

    Flexo Concepts Scallop Shell Plymouth, MAFlexo Concepts recently joined 29 other area businesses participating in the latest Plymouth Area Chamber of Commerce street-side art project – “The Scallop Roll.” Part of a celebration to commemorate our country’s upcoming 400-year anniversary, the project features a collection of large, fiberglass scallop-shaped forms about 4 feet tall and 3 feet wide. Company sponsors worked with local artists to come up with design concepts and paint the structures – front and back. The shells have Flexo Concepts Scallop Shell Plymouth, MAbeen installed at various locations around the downtown and waterfront areas for residents and visitors to admire, and maps are available to help people make a fun activity out of finding them as they explore the town.

    According to the Plymouth Area Chamber of Commerce, “The scallop was selected for this year’s campaign because of its symbolism for pilgrimage. Artwork of the shell can even be found on local headstones dating back as early as 1681.”

    For its design, Flexo Concepts chose a nautical theme radiating a message of acceptance and equality. The front of the shell depicts a seaside display with a rainbow-colored lighthouse at its center. The back features a quote by John Lennon, “It matters not who you love, where you love, why you love or how you love; it matters only that you love.”

    Anyone visiting the area is encouraged to visit the Plymouth, Massachusetts downtown waterfront to see the shells.

  • Engineering Manager John Ferris Talks about Sustainability and Going Green at Flexo Concepts

    Engineering Manager John Ferris Talks about Sustainability and Going Green at Flexo Concepts

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    What do 850 solar panels, a giant vacuum collection system, new LED lighting fixtures and a bunch of blue receptacle bins at 100 Armstrong Road in Plymouth have in common?

    They are all part of Flexo Concepts’ efforts to “go green.”

    Today we will talk with the engineering manager, the man behind the curtain, John Ferris, to find out the story behind these changes and how he is leading the way at Flexo Concepts when it comes to sustainability.

    John, tell us about some of the things Flexo Concepts has done to reduce its carbon footprint.

    For starters, Flexo Concepts installed a solar renewable energy system last year that produces 100% of the energy used by our company and the other tenants in the building. The blankproject, which included 850 panels on the roof, 40 power inverters and all materials required to connect the energy to the building and electric grid, was completed over five months. We are proud to say that our entire facility is now energy-independent!

    Also, two years ago, we equipped our entire facility with more efficient LED lighting. The scope of the project consisted of all Flexo Concepts’ manufacturing and administrative space as well as the parking lot and other common areas of the building complex. Every bulb in the office areas was exchanged for an LED lamp and all lighting equipment in the shop and common areas was replaced with new fixtures that contain LED lamps.Flexo Concepts Installs LED Lighting

    Could you describe some of the less obvious ways Flexo Concepts is leading the way in the industry with its sustainability practices?

    One of my primary responsibilities as the engineering manager is to look for ways to develop products using materials and processes that don’t have a negative impact on the environment. Our R&D team and material suppliers work closely together to create polymer doctor blade materials that not only deliver performance to printers but also offer eco-friendly options to help our customers meet their sustainability goals. One of the criteria we use to select new materials and material combinations for testing is the eco-friendliness of the polymerizing methods. For example, the main polymer used to make our TruPoint Green® doctor blade is created from carbon monoxide that’s recaptured from a steel mill. If this vapor were released into the atmosphere, it would break down into carbon dioxide which is a well-known greenhouse gas.

    Another example is the procedures we have in place to reduce, reuse and recycle waste throughout the company. Flexo Concepts recycles 100% of its manufacturing cardboard waste and has placed blue recycling bins at every desk and in common areas to collect office waste and food packaging. But, in addition to these more “typical” recycling practices, we have installed a central trim collection system in the manufacturing area to consolidate blade material waste. The system consists of a network of pipes from each point of plastic chip generation connected to a centralized suction machine. (As an added benefit, we found the system significantly reduced electricity usage by replacing the use of higher-amperage and landfill-disposable shop vacs at individual workstations.) The waste is then made available to be reused as filler by other industries.

    John, explain how this program could be adopted by other companies in the industry.

    Any company can install a solar system, LED lighting and recycling bins in their facilities. But our efforts reach beyond the bricks and mortar of our facility to the printing industry as a whole. Our customers choose plastic doctor blades in part because they help reduce their carbon footprint. Producing steel is a highly energy-intensive process that uses up large quantities of fossil fuels and releases a significant amount of greenhouse gases into the atmosphere. Producing plastic uses much less energy, emits smaller volumes of greenhouse gases, and has lower transportation requirements due to local sourcing of raw materials and its relatively lighter weight. Plastic blades, such as our TruPoint Orange® doctor blade for the tag and label market, also lasts longer than steel in the press, which results in less start-up waste and fewer order deliveries. We believe, by setting this example, we can inspire other organizations in the industry to turn to their supply chains to source more eco-friendly components.

    What is unique about your approach?

    Our desire is to not only pursue environmental responsibility for our company but also help our customers achieve their sustainability goals is what makes our approach different. To our knowledge, we are the only global doctor blade manufacturer that uses 100% solar carbon-free energy to power its entire facility and the only blade manufacturer that uses recaptured carbon monoxide as a feedstock in our products.

    While every company wants to be able to call itself “green,” we feel we have gone above and beyond to reduce energy dependence, improve efficiency, and recycle and reuse waste across our entire organization. Plastic, as a material, has developed a negative image in society due to a culture of “throwaway living,” its limited recycling and its inability to break down in the environment. As a manufacturer of plastic doctor blades in an industry that primarily uses steel (sometimes referred to as the “most recycled material on the planet”), we are working hard to change this negative image by promoting the “green” benefits of our operations and products.

    Thank you, John!

    [Read how we were awarded the “Calvin Frost Environmental Leadership Award” by the Tag and Label Manufacturers Institute in October 2018!]

    To learn about the environment impact of plastic vs. steel doctor blades:

    [Download our infographic, “The Environmental Impact of Doctor Blades”]

    [Read our white paper, “Reduce Your Carbon Footprint with Plastic Doctor Blades”]

  • Flexo Concepts®: Distinguished Exporter of TruPoint® Doctor Blades

    Flexo Concepts®: Distinguished Exporter of TruPoint® Doctor Blades

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    If a time period in a company’s history can be characterized by a single phrase, 2018 could be called the “year of the export” for Flexo Concepts.

    On the verge of wrapping up its 3rd decade of selling overseas, doing business globally is nothing new for our doctor blade manufacturing company. But 2018 has been a year to celebrate. Flexo Concepts received two high profile export awards, won its fifth export grant, and is about to onboard its third international business development manager.

    First, Flexo Concepts was named, “2018 Exporter of the Year” for Massachusetts by the U.S. Small Business Administration in April. The very next month, Flexo Concepts was recognized at the national level, receiving blankthe President’s E Award – considered the highest recognition any U.S. entity can receive for making what Secretary of Commerce Wilbur Ross calls “a significant contribution to the expansion of  exports.”

    In November, Flexo Concepts received notification that it was awarded funding for the fifth time through the Massachusetts State Trade Expansion Program (STEP) to facilitate long-term export growth. When allocating the grant, the Massachusetts Export Center chooses companies based on their demonstrated commitment to boost exports, create jobs and impact the economy.

    blankAnd now, the company is adding to its team of overseas sales representatives fully dedicated to international business development and service.

    Flexo Concepts understands the importance of having salespeople in the field who understand the regional markets, speak the native languages and are intimately familiar with local cultures and business practices. Soon Arnoud de Jong will join Bernat Ferrete (based in Spain) and Steve Kao (based in Taiwan) in promoting the TruPoint line of doctor blades globally. Arnoud will be based in his home country, the Netherlands, and brings a wide range of strategic capabilities to his new role – a good sense for the European flexo industry, strong marketing background and proficient language skills in his native Dutch, English and German.

    The activities of the international business development managers are fortified by support from back home – Flexo Concepts’ headquarters in Plymouth, Massachusetts. The company actively participates in foreign trade associations and regularly exhibits at key trade events around the world. To localize its selling, the company’s marketing department provides translated versions of its sales tools and promotional materials – brochures, installation guides,  email campaigns, blogs, white papers, infographics, ads, training documents, etc. – and recently launched Spanish and Chinese versions of its blankwebsite (with French and German to follow in 2019).

    Behind the scenes, developing and executing a successful international business model is a whole-company team effort. From navigating the intricacies of international accounting, to mastering the complexities of shipping and logistics and maintaining compliance with foreign regulations, every department is involved.

    But, while “internationalizing” the business has been (and will continue to be) one of our biggest challenges, it will surely also remain one of our biggest rewards. Exports have grown from 17% of revenues in 1991 to over 40% today. We maintain OEM relationships and distribution on every (habitable) continent, and our current customer base spans 50+ countries worldwide. The recognition we have received in 2018 celebrates our efforts over the past 30 years to advance the global flexo printing industry.

    And we’re pretty darn proud of it.

  • Manufacturing Manager Adam Yock Talks about Plant Safety at Flexo Concepts

    Manufacturing Manager Adam Yock Talks about Plant Safety at Flexo Concepts

    Adam Yock Flexo Concepts Plant SafetyOne of Flexo Concepts’ most important cultural values relates to its people and keeping them safe is one of its highest priorities. For this reason, the company has established a “Safety Team” and protocols throughout the building to create and maintain a safe environment for its employees.

    Today we will talk with Manufacturing Manager Adam Yock to learn more about what Flexo Concepts does to keep workers safe.

    Adam, can you tell us about the Safety Team and their responsibilities?

    The Safety Team consists of five members from the production staff who meet on a regular basis to review the overall safety of the premises and address any areas of concern. As the manufacturing manager, I perform random safety audits to identify risks and make suggestion tickets available for employees to communicate any safety concerns they may have. The tickets are posted on a master board in the shop, tracked through our CRM system and attended to by the Safety Team. Safety tickets receive immediate attention and take priority over ideas for needed repairs or continuous improvement posted on the board.

    What are some of the safety measures you have in place in the manufacturing area?

    flexo concepts manufacturing

    On the manufacturing floor, there is a wide variety of safety equipment available to protect workers from injuries. All our machines are guarded at the cutters to keep operators from being hurt and prevent loose pieces of blade scrap from flying into the air. Ear plugs or muffs are worn by employees running the blade cutting equipment to protect from the loud machine noise. There are anti-slip mats throughout the shop and anti-fatigue mats in all blade fabrication areas. Bench heights are kept at a comfortable height that allows the operators to work without being hunched over, and windows have been installed in doors entering/exiting the shop to prevent someone from being hit by a door being opened from the opposite side.

    The company purchased flow racks for the storage of raw material to reduce the need for workers to bend when picking material, and an automated conveyor system makes it easy to move heavy boxes from the production lines to the shipping area. Flexo Concepts also installed a Dura-Vac central trim collection system to gather and dispose of manufacturing waste, eliminating the need to physically remove blade scrap from the workstations.

    We also use 5S practices which not only drive efficiency but also a continuously tidy and safer shop environment. The company has structured, documented procedures and shop floor workforce training programs in place to ensure that blade fabrication, order fulfillment and scrap removal are done properly and safely. All manufacturing employees are formally trained and certified in the proper use of forklift equipment.

    How do you communicate safety procedures with your employees?

    Safety procedures are communicated through monthly team meetings, quarterly company meetings, building-wide notices and training events. Evacuation procedures and instructions specific to each department are posted throughout the facility. Also, the Safety Team sends out safety tip sheets to all employees before each major holiday to help protect them and their families from accidents at home.

    Do guidelines change and evolve over time, and if so, how?

    flexo concepts doctor blade manufacturing supplier

    Flexo Concepts takes pride in being proactive when it comes to safety. Our company stays in compliance with Osha guidelines and has outsourced the management of some of our safety initiatives to vendors. Through contracts with providers such as CINTAS and Yankee Sprinkler, our equipment specifications and instructions are continuously monitored and kept up to date. For example, Cintas has installed a first aid station in our shop, including AED technology with on-site monthly service to maintain the device. Yankee Sprinkler is under an annual contract with Flexo Concepts to maintain our fire protection system. Both companies provide regular training for our staff on the proper use of this equipment.

    How successful has your company been with plant safety?

    Flexo Concepts continues to be very successful with its safety protocol as indicated by our low injury rates and minimal lost-time accidents. Since establishing a Safety Team dedicated to this important aspect of our business, the number of accidents that occur in our building has been reduced to almost zero. We are proud of our great track record and feel confident that the safety systems and procedures we have in place will keep it that way!

    To learn about how using plastic doctor blades can improve safety and reduce costs in your pressroom:

    [Read our white paper, “The [Hidden] Costs of Using Steel Doctor Blades”]

  • Safety First: Discover Why Plastic Doctor Blades Are Preferred over Steel

    Safety First: Discover Why Plastic Doctor Blades Are Preferred over Steel

    blankEveryone agrees that plastic doctor blades are safer than steel. But why exactly is this true? The answer lies in the fundamental differences between the two materials: steel blades are harder and sharper than plastic blades. While this is commonly understood, the reason becomes clear when we examine the molecular structures of these materials.

    What Does It Mean to Be Sharp?

    Steel and plastic materials (and all matter) are comprised of small particles. As a doctor blade wears, the material is removed in clusters of particulate which can be no smaller than the basic particle size of the material. So, the finest tip on a blade can only be as wide as one particle. And since plastic particles are larger than steel particles, a plastic blade worn to its finest point will be wider than steel. This combined with the fact that plastic is inherently softer than steel, results in a plastic blade edge that is less “sharp” than steel and safer to handle.

    Ink Metering with Plastic Bladesblank

    Given this information, one might wonder if plastic blades can wipe as effectively as a steel blade. The answer is some can, and some can’t. UHMW plastic for example is perfect for applying ink or coating in applications where graphic difficulty is limited.  But it is too soft for applications involving high screen anilox rolls or precise metering requirements where a fine contact area is required.

    Thanks to next-generation polymers like Delrin, Polyether Ether Ketone (PEEK), or glass/Kevlar reinforced materials, there are compositions that are rigid enough to support a fine contact area similar to that of steel. The bonus is these blades are plastic, so they are inherently softer and do not develop a dangerous cutting edge risking injury to press operators.

    Making the Switch

    Next-generation polymer doctor blades offer the performance of steel blades while providing the safety of plastic blades. The combination of advanced materials and innovative profile (MicroTip, bevel, etc.) design enables these safe doctor blades to perform in demanding applications previously dominated by steel. Substituting a next-generation polymer doctor blade for steel is a great way to produce a high-quality product while maintaining a safe work environment.

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  • In Safe Hands with Polymer Doctor Blades Blog Series Part 2 “Steel Doctor Blade Risk Management”

    In Safe Hands with Polymer Doctor Blades Blog Series Part 2 “Steel Doctor Blade Risk Management”

    blankWorkplace hazards are present in almost every industry, and the printing industry is no exception. A press operator faces many dangers at work every day. One of the greatest is the risk of serious lacerations to his hands if he’s using steel doctor blades. He is exposed to being cut anytime he’s handling them – installing or removing them from the press, cleaning them, disposing them and when changing end seals. The blades are especially dangerous when being replaced – their edges become honed through contact with the anilox roll as they wear, leaving razor-sharp tips that can cause serious cuts.

    Fortunately, printers have a variety of options to reduce or eliminate the risk of injuries from steel doctor blades without sacrificing print quality.

    Wear personal protective equipment

    blankWhen worn correctly, cut-resistant gloves can prevent injuries to operators when using steel blades. However, the U.S. Bureau of Labor Statistics 2012 figures show that about 70% of lost-time hand injuries occur on workers who aren’t wearing gloves. The remaining 30% are wearing gloves at the time of the accident, but the gloves are inadequate, damaged or the wrong type for the job. It goes to show, the steel doctor blade risk of serious lacerations to a press operator’s hands doesn’t just go away with wearing protective gloves.

    Establish occupational health and safety programs

    Companies with safety and health management programs reduce their injury and illness costs by an estimated 20-40% according to the Occupational Safety and Health Administration (OSHA). In fact, an ASSE white paper by OSHA’s Office of Regulatory Analysis suggests that companies that implement effective safety and health programs can expect a return of $4 to $6 for every $1 invested. These programs lead to improved productivity and employee well-being in addition to reducing injury-related direct and indirect costs. Training employees and documenting handling procedures can also be beneficial in reducing the doctor blade risk of lacerations. In the pressroom, operators should be taught how to minimize their exposure to the risks from steel doctor blades by following standard protocols – for example by keeping blades in their protective packaging until they are ready to be installed and not changing blades on a machine while it’s running.

    Switch to plastic doctor blades

    The above options will certainly lower the risk of getting cut by steel blades but switching to plastic doctor blades will completely eliminate this doctor blade risk. Plastic materials are inherently softer and less sharp than steel. Even when plastic blades are worn, their edges are not sharp enough to cut a press operator.

    Unlike in the past, a printer producing high-quality graphics now has the option of choosing a plastic blade for its safety benefits. Next generation polymer blades with MicroTip® technology can compete with the metering performance of steel in even the most demanding graphics applications while retaining the safety benefits of traditional plastic.

    Next generation polymers with MicroTip®

    blankToday’s advanced polymer material is stiffer than traditional plastic and can support a precisely engineered MicroTip edge. This tip design allows the blade to achieve and maintain a fine contact area with the anilox roll comparable to a steel blade. Next generation polymer blades are able to effectively meter line screens up to 2000 LPI or 785 L/cm and produce graphics of the highest quality. The MicroTip has a long and steady wear period which reduces the frequency of blade changes and delivers consistent ink film thickness for the duration of the print job.

    Today’s printers have more options than ever to improve workplace safety. Protective gear and safety programs will no doubt reduce the risk of injuries from steel doctor blades. But if you want to completely eliminate these injuries, then completely eliminate steel blades from your pressroom. Switch to next generation polymer blades and get the best of both worlds – high performance metering and safety.

    Look for part three of our In Safe Hands with Polymer Doctor Blades Blog Series – “Not the Sharpest Blade in the Pressroom.”

    Part 1: Numbers That Add Insults to Doctor Blade Injuries – Read about the frequency of hand injuries in the workplace and their impact on a company’s bottom line

    Request a Free TruPoint Doctor Blade Sample
  • In Safe Hands with Polymer Doctor Blades Blog Series Part 1 “Numbers That Add Insults to Doctor Blade Injuries”

    In Safe Hands with Polymer Doctor Blades Blog Series Part 1 “Numbers That Add Insults to Doctor Blade Injuries”

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    OSHA reports, “Businesses spend $170 billion a year on costs associated with occupational injuries and illnesses.” Also, “Employers pay almost $1 billion per week for direct workers’ compensation costs alone.” These statements by themselves are alarming. But even more concerning is the fact that these costs are “expenditures that come straight out of company profits.”

    It’s not hard to imagine how traumatic it can be to experience (or even witness) an accident at work. But what not many people think about is the frequency that these injuries occur and the impact they can have on a company’s bottom line.

    It’s true that government regulations have helped keep workers safer. But on-the-job accidents continue to be a big problem for many businesses – and the printing industry is no exception. In the pressroom, some of the most common accidents are cuts and lacerations that occur when operators are handling steel doctor blades. Their edges are incredibly sharp, and machinists need to be extremely careful when installing and removing them from the press to avoid seriously injuring their hands.

    Hand injuries in numbers

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    According to the U.S. Center for Disease Control and Prevention, hand injuries account for 1,080,000 emergency department visits by workers every year in the U.S. (Industrial Safety & Hygiene News, May 1, 2015). In fact, hand injuries ranked second in number after back strains, sprains and other work injuries to the torso in 2015, as reported by the U.S. Bureau of Labor Statistics (U.S. BLS), and close to 20% of all workplace injuries involved cuts and lacerations to the hand and fingers.

    Some other statistics assign dollars to these injuries. The U.S. BLS informs us that hand and wrist accidents, the most expensive of all emergency department injuries, cost $740 million every year; the average hand injury claim now exceeds $6,000, with each lost-time workers’ compensation claim totaling just under $7,500.

    Hidden costs of hand injuries

    Equally significant are the indirect costs associated with work-related injuries. A study published in the Journal of Bone and Joint Surgery indicates that productivity costs due to absenteeism contributed more to the total costs of hand and wrist injuries (56%) than did directly related health-care costs. The U.S. BLS recorded 124,540 on-the-job hand injuries in 2015 that resulted in recordable missed work time of 5 days each. These and other secondary costs – machine downtime, equipment repairs, training of replacement employees, accident investigation, implementation of preventive measures, not to mention bad publicity – contribute to the already steep costs of workplace injuries.

    Like many companies, printers pay a high price for on-the-job injuries. Some of these costs directly affect profits while others have an impact on operations and employee well-being that’s harder to quantify. One thing is certain though – as OSHA cautions, “In today’s business environment, these costs can be the difference between operating in the black and running in the red.”

    Look for part two of our In Safe Hands with Polymer Doctor Blades Blog Series – “Steel Doctor Blade Risk Management” to learn about ways to reduce or eliminate these risks.

  • The Spectrum of Culture: From Employee to Customer

    The Spectrum of Culture: From Employee to Customer

    blankThe Cultural Spectrum

    As printers, or as suppliers to printers, we obsess in the pursuit of perfection– perhaps in no area with so much focus as on the spectrum of color. The perfect color match, the lowest Delta E, correct ink density and a flawless alignment of parts and plates from station to station. All to deliver the exact hues our customers demand. But there is a different spectrum that is perhaps even more difficult to master, and for which alignment is even more critical: the Cultural Spectrum.

    People, and the culture they share, are the true core of our businesses. The owners and leaders of the organization who direct our businesses; the employees designing our packaging, running our presses; the vendors and partners supplying us with the tools we need to get the job done; our audience, the manufacturers buying our packagingthese people are all part of a complex cultural spectrum. Each group has its own standards and expectations, its own motivations, and its own collective personality.

    Most people, when asked about their company’s culture, are unlikely to think in terms of this entire spectrum and may miss the opportunity to drive greater success. Seeking to create a culture that recognizes and fosters alignment across all of these interdependent work groups is a challenging path, but one with great rewards. We’d like to share with you the story of how our team identified the elements of its own spectrum, as well as the steps we took to pursue alignment across the spectrum.

    Our Culture Journey

    Spectrum of Culture FTA Forum 2018 Phil Ryan Rachel Acevedo
    Rachel Acevedo and Phil Ryan of Flexo Concepts speak on The Spectrum of Culture at the 2018 FTA Forum.

    In 2015, our company, Flexo Concepts, felt a need to work on and improve our culture. But what does that even mean? To us, we wanted to improve employee retention and satisfaction, but really had no idea how to get started. To help us, we engaged a cultural consultant and embarked on a journey so much bigger than just building employee morale. It started with one of those intensive 360° reviews typically done of individuals by persons from every part of their work sphere. For us though, it was a 360° review of our entire business. Customers of all sizes were interviewed to learn the market’s perception of our business. We also went about privately interviewing every single one of our employees—the owners, the guys running our equipment, our accounting team, engineers, customer support—everyone!

    The result of this process was not just the most complete view of our business we have ever had. We understood our customers better. We learned firsthand about their perception of our brand, our strengths and our weaknesses and then used a simple Venn diagram to map our capabilities and also those of our competition against the wants and needs of our customers. The areas where our business uniquely supported the customer expectations were defined as our “Points of Distinction” [PODs]. We worked with this information to create a new focus and strategy for the business. For example, one of our PODs is centered around innovation. To grow this strength, we constructed an R&D lab specifically to support application testing and the development of new polymers.

    While the PODs gave us a tactical roadmap, we had more work to do to understand and develop our culture. The cultural consultants had helped us to collect and compile information, but for the next 6 months we worked on our own to further grow the concepts. This process was done by way of a biweekly meeting held with the entire management staff. All departments worked together, taking a ground-up approach to write our Vision, Mission and Promise statements.  It’s an exercise many organizations go through, but one we took a fanatical approach toward. We had a rule in these meetings that no one was ever to leave in silent disagreement. To say one thing during the meeting, but to act out of synch in the day-to-day would completely undermine the process and would not foster alignment.

    People, Trust, Accountability and Performance

    Another product of these meetings was a clear definition of our values, organized around four pillars—People, Trust, Accountability and Performance. These values closed the loop of a sort of “corporate operating system,” which we were ready to roll out not just to our organization, but to the rest of the spectrum as well. The efforts to understand and align ourselves to our audience were a good start, but we felt a more blankholistic approach would be more effective. To achieve this, we did more than work with our own staff; we reached out to our key vendors as well and educated them on our corporate values. We met with them to find common ground in our values and to get them to understand not just our needs, but the needs of our customers. We felt our own transformation would do little good without the support of our partners. Some suppliers got weeded out in the process, but our supply chain is as strong now as it has ever been.

    With leadership, employees, and our upstream support network now closely aligned, we had to circle back to the final group: the audience. A strong, progressive and uplifting culture is a great asset for an organization, and we wanted to communicate it to our customers—especially because they had been so key in shaping the changes we made. To do this, we boosted our social media presence, opened our business for employee-led tours and started sharing our story: the day-in-day-out ways our culture shapes our business and our interactions with each customer; the journey of continuous improvement that we want our customers to enjoy and benefit from as much as we have.

    After a year and a half of work, we found ourselves with the improved culture we had sought, and it extended beyond the sphere of ourselves and our employees. We feel

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    our culture and values are bigger than ourselves because our Vision and Mission are bigger than ourselves and they require more than what just the people in our building can provide. We recognize that our aspirations require a big-picture perspective, one aligned across the whole spectrum. It is not an impossible task, and though it is one that never ends, it also is one which never stops paying back. We would encourage any team looking to repeat this work for themselves to ask:

    • Who is in your Cultural Spectrum?
    • Does your Culture value what your Spectrum values?
    • Is your Culture aligned through the Spectrum?

    If you attempt to honestly and thoughtfully answer these questions, your own cultural reinvention will have already begun!

  • The Environmental Impact of Doctor Blades

    The Environmental Impact of Doctor Blades

    Generally, printers choose plastic or steel doctor blades according to their graphic requirements (or maybe blade life or safety).  But, all else being equal, choosing the eco-friendlier material can help you reduce your facility’s carbon footprint.

    This infographic compares the environmental impact of the two most common doctor blade materials: steel and plastic. For printers looking for innovative ways to reduce their carbon footprint, this infographic may help you better understand the impact your choice in doctor blade could have on the planet. Take a look and complete the form to download the PDF.

    environmental impact doctor blades
  • Doctor Blade Installation

    Doctor Blade Installation

    Back to the basics with this doctor blade installation and best practice infographic, created by Flexo Concepts. This infographic is a simple 3-step guide to proper TruPoint doctor blade installation in a chambered ink system. We also offer helpful insight on the ideal blade orientation and blade pressure to prolong doctor blade life and ensure effective ink metering.

    Complete the form to download this infographic – with this download, you will also have an option at the bottom of the graphic to print the installation guide on standard letter size or poster size paper. This graphic is a great resource to print and post by your press operators to facilitate accurate doctor blade installations.

    3 Keys to Success Doctor Blade Installation Guide
  • Doctor Blade Quality through Tight Manufacturing Control

    Doctor Blade Quality through Tight Manufacturing Control

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    From the moment raw material enters our building, Flexo Concepts® measures, analyzes and controls every step of the process of turning the polymer stock into high-precision, performance doctor blades.

    Our Doctor Blade Innovation Lab is where ideas are born and developed by our R&D department. But it is our manufacturing folks who are responsible for bringing the concepts to life on the production line.

    Quality control is a core value of our manufacturing team. Being able to execute blade fabrication day after day with high precision and repeatability is critical to our customers’ success. Printers have to be able to trust that every shipment of our TruPoint® doctor blades will deliver consistent performance – every time, in every application.

    Tight tolerances and high dimensional standards

    We establish and strictly maintain tight tolerances on all our cutting, beveling and finishing machines and set high dimensional standards for our doctor blades. To make sure our products meet these requirements, Flexo Concepts’ quality assurance team uses certain measurement techniques and analytical tools. Among them is statistical process control, or SPC, a method for managing and monitoring a process using data analysis.

    10-Point inspection

    We also apply a 10-point inspection, where blade material and tip table dimensions are measured in real time at various points in the manufacturing cycle. We certify:

        • Material thickness
        • Material width
        • Material cupping
        • Material camber (deviation from a straight edge)
        • Tip table height
        • Tip table thickness
        • Tip table width
        • Tip table length
        • Tip table depth
        • RA value (surface roughness)

    Our engineers plot their measurements on a graph to see if they fall within pre-set tolerance limits. If there is a variance, the process is tightened up, and any deficient product is thrown away. This rigorous inspection system cuts down on variability in the manufacturing process and protects against blade irregularities.

    Track and trace

    To bolster our quality program, we track and trace every aspect of production: from raw material, to operator, to machine, to boxed shipment. If there is an issue down the line, our staff is able to easily go back and pinpoint the problem and correct it right away.

    Flexo Concepts wants to help its customers be the most efficient organizations in their industry, and that starts with delivering products that they can count on. It’s important to us that our doctor blades increase the performance, quality and output of the printing press, its operator and the company as a whole. By putting systems in place to guarantee the consistent production of superior doctor blades, we make sure that our customers get exactly what they expect so their customers get exactly what they expect.

  • The World’s Most Innovative Doctor Blade Company

    The World’s Most Innovative Doctor Blade Company

     

    Flexo Concepts About Us

    Flexo Concepts® wants to be the world’s most innovative doctor blade company.

    How are we going to do it? By creating products, services and a brand experience that inspire.

    Products that inspire

    We start by crafting superior products and designs.

    Our salespeople “have their finger on the pulse” of the industry. They are well-versed in flexography and stay up on market trends. When they report back printers’ needs and challenges, our engineers get right to work.

    We partner closely with the world’s most advanced material suppliers and perfect designs in our state-of-the-art doctor blade innovation lab. New blade concepts are subjected to rigorous internal benchmark analysis and then sent out for advanced third-party testing with customers, industry associates, material labs and OEMs before being released to the market. Our premium, solution-based portfolio of innovative products ensures that customers have blades that meet their exact needs. Combinations of materials and tips present a large range of options so that blades can be customized for specific applications.

    blankBut we don’t stop there. Our culture of “continuous improvement” compels us to keep moving forward. Whether it’s experimenting with an interesting new material or working tirelessly to perfect the geometry of a new tip, we never rest. The same goes for our manufacturing processes. We regularly invest in new (oftentimes custom) equipment so we can produce our blades swiftly and efficiently while maintaining high standards of quality.

    Services that inspire

    We make doing business with us easy for our customers so they can focus on their businesses. As trusted advisors, our highly-trained salespeople and customer experience reps help printers find the best solutions, even if it means sometimes recommending a competitor’s product. Wait, what?? It’s true.

    Providing support before, during and after each sale is important to us. Our company understands that printers need flexibility from their partners; we pride ourselves on providing quick responses, short lead times, inventory management programs and expedited shipments (even second-day or overnight guaranteed deliveries for those times that receiving blades ASAP is critical!).

     A brand experience that inspires

    Flexo Concepts wants to be the professor that’s helpful, collaborative and innovative, as well as the uncle who’s friendly, unconventional, guiding and cool. We promise to build meaningful relationships through exceptional experiences. We want our customers to feel comfortable working with us and trust us to have their best interests in mind. Having always been “different” as a niche manufacturer in the industry, we’re comfortable blazing our own trail – trying new things and coming up with unique innovations that set us apart from other doctor blade manufacturers.

    Flexo Concepts works hard to consistently deliver products, services and a brand experience that inspire. It’s not just our understanding of the market’s needs, highly-focused R&D efforts, ground-breaking blade technology, sales “consultants” and adaptive support services. It’s also a culture throughout our organization that makes us always try to be better. These are the things that will make us the world’s most innovative doctor blade company.

     

  • How to Prevent Anilox Roll Scoring

    How to Prevent Anilox Roll Scoring

    blankAnilox roll scoring poses a challenge for many printers, evident when a shiny line encircles the roll, indicating a groove or “scoring” of the anilox roll. If you are a printer this means dark lines in your print – especially when printing solids. If you are applying a coating, it’s even more important to reduce scoring since most coatings are clear, and heavy coating lines are hard to detect.

    Once scored, an anilox roll can often be used selectively, working around the score lines. But at some point, the roll needs to be reengraved and depending on size and finish, comes with a significant cost.

    Scoring often arises from debris trapped between the doctor blade and the anilox roll. Common sources include particles from steel doctor blades, dried ink build-up, or coating particles in the fluid delivery system. To minimize or eliminate anilox scoring, consider the following practblankices:

    1. Maintain Good Housekeeping:  

    • Prevent dried ink or coating from accumulating on the anilox rolls and related components within the ink delivery system
    • Use filtration in the fluid delivery system to remove dried, hard debris during prolonged production runs.

    2. Implement Magnets: 

    • If using metal doctor blades, add high-strength magnets to the fluid delivery system to capture steel particulates.
    • Maintain minimal pressure between the doctor blade & anilox roll when using steel blades to avoid entrapment of dried particulates.

    3. Optimize Mechanical Setup:  

    • Ensure level and parallel alignment of the doctor blade chamber or single blade holder with the anilox roll.
    • Misalignment can lead to excessive pressure needed to engage the doctor blade, this will bend the blade and increase chances for particle entrapment.

    4. Use Plastic Containment Blades:  

    • Consider using a plastic (polyester) doctor blade for the containment blade on enclosed chambers.
    • This change cuts steel doctor blade usage (and particulate) in half, reducing the chances for scoring to occur.

    5. Switch to Polymer Doctor Blades: 

    • Explore transitioning to plastic or polymer doctor blades to eliminate steel from your system.
    • Polymer doctor blades have advanced dramatically in terms of stiffness, edge smoothness, blade life, and durability for long production runs and offer metering quality that meets or exceeds steel.

    In conclusion, anilox scoring is permanent damage commonly caused by debris between the doctor blade and the anilox roll, resulting in a defective product. Minimize anilox scoring and save unnecessary engraving costs by filtering inks or coatings and using magnets with metal doctor blades. Alternatively, you can switch to plastic doctor blades to potentially eliminate the problem altogether.

    Request a Free TruPoint Doctor Blade Sample
  • Kanban 101

    Kanban 101

    Kanban

    In today’s competitive marketplace, manufacturers are looking for ways to improve efficiency and wring costs out of the production process. By adopting lean manufacturing concepts, companies can eliminate waste and operate more efficiently. One way to do this is to implement kanban, a Japanese inventory scheduling system that promotes just-in-time production by delivering parts on an as-needed basis.

    In a kanban system, the production process is seen as a “chain,” where each “process” becomes the supplier for the next (“downstream”) process in the sequence and a customer to the previous (“upstream”) process. This approach extends all the way to a company’s external suppliers and customers. It optimizes production flow and minimizes inventory levels by directing the supply of parts and components to workers exactly when and where they need them.

    The advantages of using a kanban system include:

    • Lower inventory costs
    • Quicker response to changes in demand
    • Increased productivity and efficiency
    • Reduced waste

    Kanban Origins

    Kanban originated in Japan in the mid-20th century by Toyota looking to increase the efficiency of its factories. Its engineers were inspired by the inventory replenishment process used by supermarkets. They observed that customers purchase only the items and quantities they need, and store employees restock their shelves with only as much product as they expect to sell. This began an important distinction between a “push” system of manufacturing and a demand-based or “pull” system.

    Push vs. Pull Inventory Control Systems

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    With traditional push manufacturing systems, companies produce what they think their customers will order and make items to stock in batches. While there are economies of scale, the downside is that inventory costs are high and companies can end up overproducing if sales forecasts are incorrect. Excess inventory ties up working capital, increases storage costs and exposes the company to the risk of parts becoming obsolete.

    A pull strategy, on the other hand, ties production directly to actual customer demand so there is little risk of overproduction and little excess inventory. Tasks in the production process are completed when requested by the next process down the line so parts or components are “pulled” into production only when needed. With a pull system of inventory management, a company may find itself slow to respond to a sudden increase in demand but very little capital is tied up in excess parts and storage.

    Kanban Cards

    kanban_cardIn order to facilitate its just-in-time manufacturing system, Toyota instituted a method using cards in its factories called “kanban” (a Japanese word combining “kan” for card and “ban” for signal). The cards, called “kanbans,” contain information about how to replenish each component used in production. By moving a kanban, an employee can signal when more parts are needed by an upstream process, prompting the production or purchase of these additional parts. Each kanban conveys all information required to replace the item such as the part name, number and description as well as the quantity to be produced and any other information about how the replenishment should take place. When delivering a kanban, the employee will write the date the order is initiated or “dropped” and when the parts are needed. The card is placed in a kanban rack to be retrieved along with the container by the appropriate person in the upstream process. Once replenished, the bin containing the new parts and kanban card are returned to their original location.

    Six Elements of Kanban

     

    The following principles are fundamental to a kanban system:

    1. Downstream processes always pull from upstream processes
    2. Upstream processes produce only when instructed
    3. Defects are never passed on to the next station
    4. Kanban cards are attached to part containers and no item is moved without a kanban
    5. Production is leveled throughout the system to prevent bottlenecks
    6. There is continuous fine-tuning of the kanbans in the production process

    The success of kanban as an inventory control system depends on its execution.  Adopting this system requires well-defined, documented procedures and training so employees are clear about every step, because a disruption in the process may lead to out-of-stocks and delays in filling customer orders. If executed properly, this is an excellent tool used to facilitate just-in-time manufacturing by eliminating waste and inefficiency from the production process.

     

  • The Right End Seals Will Prevent Leaks in Your Doctor Blade Chamber System

    The Right End Seals Will Prevent Leaks in Your Doctor Blade Chamber System

    End SealsIn an enclosed doctor blade chamber  system, the job of the end seals is to keep the coating or ink from leaking out of the ends of the chamber.  Selecting the right end seals for your application is critical to achieve proper doctor blade seating and prevent leaks.  If used correctly, these inexpensive consumables will ensure graphic quality and save a printer thousands of dollars in waste, downtime and replacement of other press parts due to premature wear.

    Problems That Result from Failed End Seals

    • Chamber leaks and mess
    • Poor graphic quality and ink/coating waste
    • Excessive doctor blade wear
    • Premature anilox roller wear and scoring
    • Press downtime

    Why Chamber Leaks Occur

    While there are other causes of chamber leaks, failed end seals are responsible for the lion’s share.  It is important to use an end seal material that is compatible with the type of ink or coating being used, the length of the run and the press speed.  Good seal design for a proper fit is also critical to ensure that end seals contain the liquid within the confines of the chamber.  Incorrect end seal size and shape will leave gaps for fluid to leak out of the ends.  If the seals aren’t sufficiently lubricated, the increased friction against the anilox roller will cause buildup and leaking.  Enlist the help of your end seal supplier to work through these issues and make sure that you are using the correct end seals for your application.

    When a chamber is leaking, a press operator will often try to fix the problem by increasing the load pressure instead of looking for the cause of the leak.  End seal leaks should never be resolved by increasing chamber pressure.  The additional pressure increases friction between the doctor blade and the anilox roll and causes both to wear prematurely.  Paying a little extra attention when installing doctor blades and end seals can prevent many leaks from occurring in the first place.  After installing new end seals, a press operator should evaluate the chamber and confirm that there is a snug end seal fit with no gaps or distortion.  The doctor blade should have some upward pressure to form an adequate seal, but not so much that it requires extra loading pressure to make contact with the anilox roller in the middle of the blade.

    End Seal Materials for Chamber  Systems

    There are various end seal materials which range in abrasion resistance, durability and solvent resistance.  Again, your end seal supplier is a good resource to help you determine the best material for your application:

      1. Foam seals are the most common and the least expensive type of end seals.  This material generally does not perform as well as other materials and may not be a good choice for long runs, higher press speeds and certain fluid chemistries.  There can also be a lot of variation in the density of the material which can range from super firm to more malleable.

     

      1. Neoprene or rubber seals offer longer life compared to foam seals.  They are compatible with aqueous and UV coatings & inks so they don’t have to be changed out between jobs.  However, these seals do not seat well due to the coefficient of friction between the material and the anilox roller surface.

     

    1. Pre-soaked felt end seals are a superior solution for resolving leaks.  These end seals are oversized for a snug fit and pre-soaked in petroleum to reduce friction and prevent  buildup.  Felt end seals are compatible with all ink and coating types, provide a tighter seal and typically last longer than rubber and foam seals.  Keeping felt seals lubricated with seal grease is key to their superior performance and longer life.  Felt end seals tend to dry out after the anilox  system is flushed with detergents and water.  Applying seal grease to the radius portion of the seals after flushing the system will ensure a tight fit and extend the life of the seals by reducing friction.

    Choosing the right seal material and design for your application and replacing end seals when necessary will help ensure that they do their job of keeping inks and coatings from leaking out of the chamber.  Better yet, the right seals will allow for proper doctor blade seating and a predictable and even transfer of fluid from the anilox roller to the blanket.  Despite their small cost, end seals have the power to save thousands of dollars in waste and downtime.