Roll forming line records: coil, length, profile and cut tracking

A roll former turns one coil into thousands of metres of profile in a single shift, and without records the order ships on the operator’s memory alone. Short lengths, wrong gauge and a worn roll then show up at the customer’s site.

Four records cover the line. Each is one page or one screen. Each ties to the one before it by a lot number.

Start on paper if you must. The columns you choose, and the lot number carried from coil to bundle, count for more than whichever tool stores them.

When a coil arrives, log the supplier, mill heat number, coating, gauge, width and net weight. Attach the mill test certificate as a scanned file. Give the coil your own lot number and write it on the tag.

Note the condition on receipt. Edge damage, rust or a telescoped wrap should be recorded with a photo, because disputes with the steel supplier are settled by that note.

Track remaining weight after every run. A half used coil on the rack with no weight is a coil nobody dares use.

Each profile has a roll set, a pass line and a punch or notch pattern. Record the profile code, roll set number, line speed and shear setting, so that when a job repeats the setter starts from the last good record.

Cut length needs two numbers, ordered and measured. Measure the first piece, a piece at mid run and the last piece, and record all three with the tape or gauge used.

A drift of a few millimetres across a run often points to a worn encoder wheel or a slipping feed roller. Camber, bow and twist matter on long panels, so add a pass or fail for each, checked against the customer drawing and the straightedge or table used. If a roll set was reground since the last run, say so on the same line.

The run log records start time, stop time, pieces cut, scrap pieces and stop reasons. Use short codes: coil change, roll adjustment, jam, shear blade, waiting for order. After a month, the codes show where time goes.

Every bundle gets a tag with the order number, profile, length, piece count and coil lot, printed at the exit table if you can. A tag written by hand at the end of a shift is where mistakes enter.

The bundle count must tie to the run log. If the log says 480 pieces and the tags add to 470, find the ten before they ship.

Dispatch should read from bundle tags, not from the order sheet, so that only bundles which physically exist get loaded onto the truck. A short order is then visible at the gate, not after the customer calls.

Close each order by comparing ordered, produced, scrapped and shipped pieces. Differences need a reason.

Review the stop codes weekly with the shift leads, pick the top reason and fix that one, then repeat next week. Keep the old sheets, because a slow drift in blade changes or jams shows only over months.