Static in coating, printing and converting operations causes injury and waste. I estimate that global static losses in 2014 were $800M USD and on our current path, I project these losses will exceed $1B by 2020. Manufacturers would benefit financially from reducing these losses by increasing their internal static control expertise. Controlling static in web conveyance lines is challenging because operations are complex and static problems are often intermittent. I make 11 recommendations for effectively managing static. First, devote -2% of work hours to control static in operations where static is important such as film casting, coating/printing, and converting. Additional recommendations include performing static surveys to qualify lines for service after being down for maintenance, assessing static in Management of Change procedures, and building internal expertise when drawing on external resources to solve persistent static problems that threaten product quality and manufacturing output.
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