JOB CARD | ROTARY & FLAT DIE MANUFACTURING
Precision Limited
Order no: 202609-415B7668 | Page 1 of 5
Complete the relevant departmental sections before printing. Mark non-applicable fields N/A; keep all five pages together.
| 1. CUSTOMER INFORMATION | SALES |
|---|
| Customer name | WORDS WORTHY PACKAGING |
| PFI no. | 123456 |
| Order no. | 202609-415B7668 |
| Order / die type | ROTARY |
| Production no. (die) | 00122 |
| Date received | 2026-09-12 |
| Lead time (workdays) | 14 |
| Est. completion date | 2026-09-19 |
| Delivery required | 2026-09-17 |
| Quantity of die sets | 2 |
| Additional information / special instructions: |
This order is to be produced and rendered on the Bai Run machine configuration of the customer. Please check and confirm such is the case before producing.
Check the distortion and the hole scaling before producing the board. |
| Sales completed by | Daniel Tetteh |
| Date / initials | GM DT |
| 2. ARTWORK / DESIGN | GRAPHICS |
|---|
| Job name | BLUE SKIES BSP 088 |
| Drawing no. | PRC20261 | Rev. | 1 |
| CAD file name | PRC20261 - WORDS WORDY |
| Designer | PRINCE KUSAGBOR | Repeats | 2 |
| Customer approval | Yes | Date | 2026-09-12 |
| Approved by / date | 2026-09-12 |
| ATTACHMENTS RECEIVED |
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| PDF drawing | ✔ |
ArtiosCAD | |
DXF file | |
| Sample carton | |
Printed sheet | |
Reference | |
| Other attachments | Refer to Customer file in Source Folder |
| EMBOSSING INFORMATION | FLAT DIE ONLY |
|---|
| Required? | No | Quantity | |
| Embossing drawing no. | | Rev. | |
| Embossing production no. | |
| Tool - full specification | |
| Position / register ref. | |
| Embossing approved by / date | |
| Graphics completed by / date | |
| 3. CORRUGATOR BOARD INFORMATION |
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| Board construction | Single |
| Flute type | E |
| Board grade / type | |
| Board caliper (mm) | |
| Paper quality | |
| Flute direction | |
| Print / feed side | |
| Paper GSM (g/m²) - liner / flute sequence: |
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| Board sample / ref. | |
| Board / print notes and critical tolerances: |
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| Confirmed by | |
| Date / initials | |
| 4. ROTARY MOLD SPECIFICATIONS |
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| Machine / model | YKED-1224 |
| Machine spec. ref. | BAI RUN |
| Cylinder D x L (mm) | 2550 |
| Shell ID x L x T (mm) | |
| Repeat / circ. (mm) | 1132 |
| Segment° / repeats | 2 |
| Distortion (%) | |
| Cutting direction | Anti-Clockwise |
| Bolt / mounting ref. | Down |
| Diameter datum | |
| Shell stock ref. | |
| 5. CUTTING RULES |
|---|
| Straight rule - D x H x T | Straight Knife 23.80 X 1.42 |
| Arch / alternative - D x H x T | |
| Edge type | |
| Bevel | |
| Profile | |
| Length (m) | |
| Stock code | |
| Notes / location: |
|
| 6. CREASING RULES |
|---|
| Primary crease - D x H x T | Arch crease 360 X 23 X 1.42 |
| Alt. / reverse - D x H x T | |
| Top profile | |
| Creases (no.) | |
| Length (m) | |
| Counter ref. | |
| Stock code | |
| Crease & Cut pattern / order / location |
|
| 7. PERFORATION |
|---|
| Rule specification - D x H x T | Straight Perforation 5:5 |
| Cut x tie pattern (mm) | |
| Type / profile | |
| Length (m) | |
| Sections (no.) | |
| Location / ref. | |
| Stock code | |
| Other requirements: |
|
| 8. RUBBER / STRIPPING |
|---|
| Rubber full size - H x W (mm) | Rubber R50 Orange Small 380 x 300 x 17 x 20 |
| Type | |
| Hardness / scale | |
| Colour | |
| Length (m) | |
| Stock code | |
| Adhesive | |
| Stripping knives - full specification: |
|
| Rubber map ref. | |
RULE / CREASE SPECIFICATION (mm): diameter x height x thickness, in ONE field. Example: 360 x 24.5 x 1.40. Flat / straight rules without a diameter: N/A x height x thickness. Crease & Cut: e.g. 5:5 (= 5 mm x 5 mm), 3:3 or 3:2.
| RELEASE TO MANUFACTURE | PLANNING: verify the approved drawings and all relevant specifications on pages 1 to 4 |
|---|
| Prepared by | |
Technical / planning checked by | |
| Authorised by | |
Release date / signature | |
Customer and order details appear once on page 1. Pre-Laser/CNC: page 2. Knife & Creasing: page 3. Welding, Grinding & Rubbering: page 4. Final QC and materials: page 5.
Created by: Admin | Created on: 2026-09-12 15:51
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MANUFACTURING & PRE-LASER / CNC RELEASE
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Doc No: PRCN / PRD / 01
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Precision Limited | Graphics / planning / laser-CNC production
Use the order and approved graphics / embossing information on page 1. Complete only the applicable die-type specifications.
| 9. FLAT MOLD SPECIFICATIONS |
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| Machine / model | |
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| Machine spec. ref. | |
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| Flat board - L x W x T (mm) | |
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| Max. board L x W | |
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| Chase / carrier ID | |
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| Plate / counter | |
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| Gripper / feed edge | |
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| Mounting / register | |
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| Board stock ref. | |
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| Flat-die notes / critical requirements: | |
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| Planning by / date | |
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|
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| 10. MANUFACTURING PROCESS / WORKFLOW TRACKING | PRODUCTION |
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| Process |
Operator |
Date |
Checked by |
Start - end |
Remarks / N/A |
| 1. Design verification / release | | | | | |
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| 2. Rotary compensation checked | | | | | |
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| 3. Laser / CNC cutting (release below) | | | | | |
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| 4. Rule bending | | | | | |
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| 5. Rule installation | | | | | |
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| 6. Welding (if specified) | | | | | |
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| 7. Grinding (if specified) | | | | | |
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| 8. Rubbering | | | | | |
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| 9. Embossing manufacture / fit (if Yes) | | | | | |
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| 10. Final assembly | | | | | |
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| 11. Quality inspection | | | | | |
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| 12. Packaging | | | | | |
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| Production completed by / date | |
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|
| 11. PRE-LASER / CNC ROUTING RELEASE | Complete BEFORE cutting the main plywood / shell |
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| GRAPHICS / PLANNING CHECKS |
Result |
LASER / CNC OPERATOR CHECKS |
Result |
| 1. Released KLD / drawing and program revision match the order; approval, units and die type are correct. |
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9. Approved plywood / shell sound, clean and aligned; clamps / vacuum secure; cutting path clear of fixtures. |
|
| 2. Record original graphic L x W and machine-output L x W; verify scale, orientation and number of repeats. |
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10. CNC home and X/Y/Z / rotary zero ('pulse position') verified; correct work origin, travel limits; no alarms. |
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| 3. ROTARY: approved KLD distortion factor, direction and diameter datum; compensation applied once only. |
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11. LASER: clean lens / nozzle, focus and stand-off. ROUTER: correct bit / collet, offsets and approved recipe. |
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| 4. ROTARY holes: approved template, pitch, size and mapping to shell; do not copy the KLD factor blindly. |
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12. Compressor ON; clean, dry air reaches the machine. Record required and actual bar with air flowing; no leaks. |
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| 5. Base: shell ID / thickness match the customer's cylinder datum; flat board L x W x T and flatness correct. |
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13. Extraction / dust collection ON and drawing well; filters clear; cooling flow / temperature within limits. |
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| 6. Layout: feed / operator side, flute / print direction, centre line, lead edge and waste areas correct. |
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14. Guards, interlocks and emergency stop checks satisfactory; no bypass; fire controls ready; operator attends. |
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| 7. Knife fit: D x H x T, line types, slots, bends, bridges / notches, joints and clearances support installation. |
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15. Correct program / tool assignments; preview or approved dry run checks size, position, depths and clamp clearance. |
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| 8. Specials: Crease & Cut pattern / order / location, perforation and embossing drawing / production no. agree. |
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16. Approved test on scrap / test zone: slot width, rule fit, depth / through-cut and hole position pass; no excess burn. |
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Use Pass / Fail / N/A. Verify against the approved drawing, machine manual and setup sheet; N/A must be justified. Record actual values below.
| Graphic size BEFORE (L x W mm) | |
Output size AFTER (L x W mm) | |
| KLD factor (%) / axis / ref. | |
Hole mapping / template ref. | |
| Origin / pulse X/Y/Z/A | |
Air required (bar) | |
| Machine ID / recipe reference | |
Air actual (bar) | |
| Test sample ID / QC notes | |
Trial slot required / actual (mm) | |
| Graphics checker / date | |
Operator / date | |
| Released by / date | |
Release status / Time | |
HOLD: do not cut the main workpiece until applicable checks pass, required readings are recorded and the release is signed.
Machine-specific settings only. Do not change pulse calibration, compensation or air settings without authorisation. Never bypass safeguards.
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PRE-KNIFE & PRE-CREASING INSTALLATION RELEASES
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Doc No: PRCN / PRD / 03
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Complete BEFORE installing rules into the main plywood / rotary shell. This release belongs to the single customer order identified on page 1; keep all four pages together. Record approved and measured values. HOLD for any unresolved failure.
| A. PRE-KNIFE INSTALLATION RELEASE | CUTTING / PERFORATING RULES |
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CUTTING-RULE SCHEDULE | Enter every rule family; list arch and straight rules separately.
| Item |
Function / location |
Orientation |
Approved height (mm) |
Actual height (mm) |
Thickness (mm / pt) |
Projection (mm) |
Back-curve dia. (mm) |
Edge / bevel / tooth |
TPI / pitch |
Grade / hardness |
Status |
| 1 | Contour / external cut | Arch | | | | | | | | | |
| 2 | Slots / internal cut | Straight | | | | | | | | | |
| 3 | Perforation / tear line | Arch | | | | | | | | | |
| 4 | Other critical rule | Straight | | | | | | | | | |
KNIFE INSPECTION | Confirm dimensions with calibrated equipment and compare against the approved drawing, rule order and machine cutting-circle specification.
| 1 |
Correct rule type, function, profile and quantity match the approved key-line / die-line drawing. |
Evidence / value | |
Result | |
| 2 |
Rule height and thickness are within the approved tolerance; no mixed or unidentified stock. |
Evidence / value | |
Result | |
| 3 |
Arch-rule back curvature matches the approved rule-back diameter and seats without springing or tilt. |
Evidence / value | |
Result | |
| 4 |
Straight rule is straight; joints, bridges, nicks, notches and reliefs are correctly located and sound. |
Evidence / value | |
Result | |
| 5 |
Cutting-tip diameter / cutting circle is compatible with cylinder, shell thickness and anvil condition. |
Evidence / value | |
Result | |
| 6 |
Edges are sharp, clean and undamaged; no corrosion, burrs, cracks, twists or unsafe projections. |
Evidence / value | |
Result | |
| Nonconformance / deviation | |
| Disposition / corrective action | |
|---|
| Reinspection result | |
RELEASE / HOLD | |
Authorized by | |
Date / signature | |
| B. PRE-CREASING BLADE INSTALLATION RELEASE | CREASING RULES / COUNTER OR MATRIX |
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Use the same page-1 order and approved drawing. Verify blade geometry against actual board construction, flute direction, press system and approved counter / matrix. HOLD if the crease system is incompatible.
CREASING-BLADE SCHEDULE | List arch and straight blades separately where applicable.
| Item |
Function / location |
Orientation |
Approved height (mm) |
Actual height (mm) |
Thickness (mm / pt) |
Projection (mm) |
Top profile / radius |
Back-curve dia. (mm) |
Counter width (mm) |
Counter depth (mm) |
Status |
| 1 | Main fold / score | Arch | | | | | | | | | |
| 2 | Flap fold / score | Straight | | | | | | | | | |
| 3 | Double score / special | Arch | | | | | | | | | |
| 4 | Other critical crease | Straight | | | | | | | | | |
CREASE-SYSTEM & BOARD PARAMETERS | APPROVED / ACTUAL
CREASING INSPECTION | Verify dimensions, condition, seating and expected fold performance before installation.
| 1 |
Creasing locations, lengths, interruptions and flute direction match the approved drawing. |
Evidence / value | |
Result | |
| 2 |
Blade height, thickness, top profile / radius and projection match the approved rule specification. |
Evidence / value | |
Result | |
| 3 |
Arch curvature or straightness is correct; blade seats fully without rocking, tilt or forced fitting. |
Evidence / value | |
Result | |
| 4 |
Counter / matrix width, depth and alignment are compatible with board caliper and crease geometry. |
Evidence / value | |
Result | |
| 5 |
Joints, bridges, ends and clearances are clean, secure and free from burrs, cracks or damage. |
Evidence / value | |
Result | |
| 6 |
Trial strip or documented setup check confirms acceptable fold with no liner cracking or flute collapse. |
Evidence / value | |
Result | |
| Nonconformance / deviation | |
| Disposition / corrective action | |
|---|
| Reinspection result | |
RELEASE / HOLD | |
Authorized by | |
Date / signature | |
| PAGE-3 CONTROL: the knife and creasing releases must be completed before welding and grinding on page 4. Any FAIL places the job on HOLD. |
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| Prepared / inspected by | Date / signature |
Planning / technical check | Date / signature |
| Production authorization | RELEASE / HOLD |
Supervisor authorization | Date / signature |
Record measuring-tool identification and calibration status in the evidence fields. Do not use machine pressure to compensate for incorrect rule height, shell diameter, cutting circle, blade profile or counter geometry. Continue to Welding and Grinding on page 4.
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WELDING, GRINDING & RUBBERING RELEASES
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Doc No: PRCN / PRD / 04
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Complete after the Pre-Creasing Release on page 3 and before final quality control. This page belongs to the single customer order identified on page 1. HOLD the job for any loose joint, protruding sharp tip, undocumented special weld, defective grinding or nonconforming rubbering.
| C. WELDING & GRINDING RELEASE | ALL RULE JOINTS MUST BE SECURE |
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Mandatory standard: weld every cutting-rule and creasing-rule joint specified by the factory process so it cannot open in production. Grind and smooth every protruding rule tip, weld bead, burr and sharp end without damaging the cutting edge, crease profile, rule height or shell / plywood.
| Welding process / WPS | |
Welder / ID | |
Consumable / batch | |
Equipment / setting ref. | |
Date | |
| Special weld? | |
Written special-weld instruction ref. | |
Drawing / exact location | |
Authorized by | |
WELD-JOINT REGISTER | A "special weld" must be written, located and authorized. Examples include welding a short cutting- or creasing-rule piece so it cannot lift or come out.
| No. |
Joint / exact location |
Rule type |
Joint type |
Standard / special |
Special-weld instruction / drawing ref. |
Method / setting |
Welder / date |
Result |
| 1 | | | | | | | | |
| 2 | | | | | | | | |
| 3 | | | | | | | | |
| 4 | | | | | | | | |
WELDING & GRINDING INSPECTION
| 1 |
Every required cutting- and creasing-rule joint is welded, closed and mechanically secure; no joint can open during production. |
Evidence / value | |
Result | |
| 2 |
Every short or small rule piece that could lift or come out is retained by an authorized special weld with a written reference and exact location. |
Evidence / value | |
Result | |
| 3 |
Welds have adequate fusion and restraint with no crack, porosity, burn-through, excessive bead, rule distortion or heat damage. |
Evidence / value | |
Result | |
| 4 |
All protruding tips, weld beads, burrs and sharp ends are ground flush, rounded or smooth enough for safe handling and die operation. |
Evidence / value | |
Result | |
| 5 |
Grinding has not reduced rule height, damaged the cutting edge / crease crown, weakened joints, scorched plywood or contacted the shell. |
Evidence / value | |
Result | |
| 6 |
Finished joints are clean, stable and visually acceptable; loose metal and grinding debris have been removed before rubbering. |
Evidence / value | |
Result | |
| Nonconformance / corrective action | | Reinspection result | |
|---|
| Welding / grinding inspector | Date / signature |
RELEASE / HOLD | |
Authorized by | |
Date / signature | |
| D. RUBBERING RELEASE | FUNCTION, PLACEMENT, BONDING & APPEARANCE |
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Complete after welding and grinding have passed. Rubber selection and placement must follow the approved rubber map, board grade, rule function and machine requirements. Rubber must strip reliably and present clean, consistent workmanship.
| Rubber map / revision | |
Rubber type / profile | |
Hardness / scale | |
Adhesive / batch | |
Date | |
| Nominal H x W (mm) | |
Height above rule (mm) | |
Rule clearance (mm) | |
Colour / identification | |
Prepared by | |
RUBBER SCHEDULE | Record different hardnesses, profiles and functional zones separately.
| No. |
Function / location |
Material / profile |
Shore / scale |
H x W (mm) |
Rule clearance |
Length / qty. |
Adhesive / batch |
Colour / code |
Status |
| 1 | Cutting-rule ejection | | | | | | | | |
| 2 | Creasing / folding zone | | | | | | | | |
| 3 | Slots / narrow waste | | | | | | | | |
| 4 | Large waste / stripping | | | | | | | | |
| 5 | Special application | | | | | | | | |
RUBBERING INSPECTION
| 1 |
Surface is clean, dry and prepared; adhesive is compatible, within life and applied without contamination or excessive squeeze-out. |
Evidence / value | |
Result | |
| 2 |
Rubber type, profile, Shore scale / hardness, height, width and clearance match the approved specification for each functional zone. |
Evidence / value | |
Result | |
| 3 |
Rubber is straight, evenly spaced and securely bonded; ends and joints are square, closed, neat and positioned away from critical rule joints. |
Evidence / value | |
Result | |
| 4 |
Cutting edges, crease crowns, perforation gaps, nicks, special welds and inspection points remain unobstructed and identifiable. |
Evidence / value | |
Result | |
| 5 |
Ejection / stripping action is adequate without board marking, crushing, excessive pressure or interference with folding and waste removal. |
Evidence / value | |
Result | |
| 6 |
Finished die is clean, symmetrical and visually acceptable: consistent colour / material use, no loose pieces, torn foam, gaps or adhesive stains. |
Evidence / value | |
Result | |
| Nonconformance / corrective action | | Reinspection result | |
|---|
| Rubbering inspector | Date / signature |
RELEASE / HOLD | |
Authorized by | |
Date / signature | |
| PAGE-4 RELEASE CONTROL: Welding and grinding must pass before rubbering. Rubbering must pass before Final Quality Control. A special weld without a written reference and exact location is an automatic HOLD. |
|---|
| Production authorization | RELEASE / HOLD |
Supervisor authorization | Date / signature |
Safety: isolate equipment before inspection or correction. Remove grinding debris and confirm no hot work, sharp projection, loose rule or loose rubber remains before the die proceeds.
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FINAL QUALITY CONTROL & MATERIALS USAGE
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Doc No: PRCN / PRD / 05
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| DIMENSIONAL INSPECTION |
FUNCTIONAL INSPECTION |
PHYSICAL INSPECTION |
FINAL APPROVAL |
| Check point | Value / result |
Check point | Pass / Fail / N/A |
Condition / workmanship | Result |
Complete after inspection | |
| Machine / drawing verified | |
Sample cut performed | |
Shell / board condition | |
QC name / signature | |
| Working width verified | |
Creasing / fold test | |
Welded joints / grinding | |
Approval date | |
| Cylinder repeat / flatness | |
Ejection / stripping test | |
Rubber bonding / neatness | |
Status | |
| Distortion / compensation verified | |
Perforation pattern / test | |
Mounting / labels | |
Completed sets | |
| Shell or flat-board fit | |
Feed / print-to-cut register | |
Protection / packaging | |
Rework reference | |
| Rule D x H x T verified | |
Waste clearance verified | |
General workmanship | |
Packaging released | |
| Critical dimensions / tolerances | |
Layout / repeats verified | |
Comments / rework reference | |
Final remarks | |
Record measured values and evidence. Explain every failure, rework and variance below. Final QC approval is separate from the material-balance check.
| 12. MATERIAL ISSUE, USAGE & RETURNS | STORES / PRODUCTION |
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| Record date | |
Finished die sets | |
Production completed | |
One line per material / specification / batch. Issued includes extras; Returned is reusable stock; Used excludes scrap. Enter 0 for none. Identify welding consumables, abrasives, adhesives, rubber, embossing and Crease & Cut stock clearly.
| No. |
Material / component |
Full specification / grade |
Stock code / batch |
Unit |
Issued |
Returned |
Used in job |
Scrap / waste |
Balance (auto) |
| 1 | | | | | | | | | |
| 2 | | | | | | | | | |
| 3 | | | | | | | | | |
| 4 | | | | | | | | | |
| 5 | | | | | | | | | |
| 6 | | | | | | | | | |
| 7 | | | | | | | | | |
| 8 | | | | | | | | | |
| 9 | | | | | | | | | |
| 10 | | | | | | | | | |
| 11 | | | | | | | | | |
| 12 | | | | | | | | | |
| 13 | | | | | | | | | |
| 14 | | | | | | | | | |
| 15 | | | | | | | | | |
| 16 | | | | | | | | | |
| 17 | | | | | | | | | |
| 18 | | | | | | | | | |
Balance = Issued - Returned - Used in job - Scrap (3 decimals). Reconcile each line to zero; do not total unlike units.
ID = missing material / specification / stock / unit; QTY = missing or non-numeric quantity; NEG = negative quantity. Explain variances below. Balanced cells are not QC approval.
| NON-CONFORMANCE / REWORK / MATERIAL VARIANCES | Give item or line no., action, owner and recheck result |
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| PRODUCTION - recorded by / date | |
STORES - verified by / date | |
| SUPERVISOR - signature / date | |
FACTORY MANAGER - signature / date | |
| Inventory posted by / date | |
Additional issue / return reference | |
Keep all five pages and the approved drawings together. No release with unresolved QC failures, material discrepancies or unsigned required approvals.