The crux of carton loss and its cure

The loss of the carton enterprise is a major factor affecting the cost. If the loss is well controlled, it can increase the company's efficiency and improve the competitiveness of the product to a large extent. The following is a general analysis of the various losses of the carton factory.

The total loss of a carton factory is simply the amount of raw paper input minus the amount of finished product storage. For example: the input amount of base paper in that month should be 1 million square meters, and the storage of finished products is 900,000 square meters, then the total loss of the factory in that month = (100-90) = 100,000 square meters, the total loss rate is 10/100 × 100 % -10%. This total loss can only be a very general figure. However, the distribution of losses to each process will be more clear, and it will be easier for us to find methods and breakthroughs to reduce losses.

Corrugated cardboard loss

1. Loss of defective products: defective products refer to unqualified products cut by a cutting machine.

Formula definition: Loss area = (trimming width × number of cuts) × length of cut × number of defective cutters Causes: improper operation of personnel, quality problems of base paper, poor fit, etc.

Improving countermeasures: Strengthen the management of operators and control the quality of base paper.

2. Excessive product loss: Excessive product refers to the qualified product with more than the scheduled paper feed. For example, if 100 papers are scheduled to be fed, and 105 papers are passed, then 5 of them are super products.

Formula definition: Area of ​​excess product loss = (cut width × number of cuts) × length of cut × (number of bad cutters-number of scheduled cutters) Causes: excessive paper load on corrugating machine, inaccurate paper receiving on corrugating machine, etc.

Improving countermeasures: The use of corrugated machine production management system can solve the problems of inaccurate paper quantity and inaccurate paper receiving on single-watt machine. 3. Trimming loss: Trimming refers to the part that is repaired when the trimming and crimping machine of the tiler is trimmed.

Formula definition: trimming loss area = (paper width-trimming width × number of cuts) × cutting length × (good product cutting number + bad product cutting knife number) Cause: Normal loss, but if it is too large, the cause should be analyzed. For example: the order width is 981

mm paper width, and the minimum trimming width required by the corrugating machine is 20mm, then 981 mm + 20mm = 1001 mm, which is exactly greater than 1000mm, only 1050mm paper is used for walking, then the trimming width is 1050mm-981mm = 69mm, which is much larger than normal trimming, resulting in increased trimming loss area.

Improving countermeasures: If it is the above reason, you can consider such an order without trimming, use 1000mm paper to feed the paper, and roll it together when printing the box at the later stage, which can save 50mm

Paper with a wide width, but this will reduce the printing efficiency to a certain extent. Another countermeasure is that the sales department can take this into account when accepting orders, improve the order structure, and optimize orders. 4. Grid skip: Grid skip refers to the part that occurs when a wider paper web is used to feed the paper due to a shortage of base paper. For example, the order should go 1000mm

The paper of the paper web, but due to the lack of 1000mm of base paper or other reasons, it needs to use 1050mm to feed the paper, and the extra 50mm is a tab.

Formula definition: Area of ​​grid loss = (Paper width after grid-Scheduled paper width) × Cutting length × (Number of good-quality cutters + Number of bad-quality cutters)

Causes: Unreasonable preparation of raw paper or untimely purchase of raw paper in the sales department.

Improving countermeasures: The company's procurement should review whether the original paper purchases and stock preparation meet the customer's needs, and try to match the customer's paper preparation to achieve the T-mode working idea. On the other hand, the sales department must place a material demand list in advance and give the procurement department a procurement cycle to ensure that the original paper is in place. Among them, the loss of defective products and the loss of super products should belong to the performance loss of the corrugated board production department, and can be used as the department's assessment index to promote improvement.

Loss cannot be eliminated. What we can do is to reduce the loss to the lowest and most reasonable through various methods and techniques as much as possible. Therefore, the significance of subdividing the loss in the above is to let each related process know whether the various losses are reasonable, whether there is room for improvement and what needs to be improved (for example: excessive product loss is too large, you may need to review whether the corrugated machine is receiving paper Accurate, excessive grid loss, it may be necessary to review whether the original paper preparation is reasonable, etc.), in order to achieve the purpose of controlling and reducing losses, reducing costs, and improving product competitiveness, and can set assessment indicators for various departments according to various losses, Rewarding good and punishing bad, and improving the enthusiasm of operators to reduce losses.

Printing box loss

1. Loss of additive volume: due to the printing press testing and accidents during the production of carton, certain loss will inevitably occur, so a certain amount of additive volume will be added when the order is scheduled.

Definition of formula: Lost area of ​​additive amount = scheduled additive amount × carton unit area

There are many reasons, such as: large loss of printing press, low level of operation of printing press operators, and large loss of packaging in the rear section. In addition, the sales department has no control over the additional orders. In fact, there is no need to add so much extra amount. Excessive extra amount will lead to unnecessary over-production. If over-production cannot be digested, it will become "dead inventory", that is, over-time inventory, which is also an unnecessary loss. . Improving countermeasures: This item should belong to the performance loss of the printing box department. It can be used as the department's assessment indicator to promote the improvement of personnel quality and operation level. To make a difference, it is recommended to add the amount in the first article, and control from the source to avoid unnecessary over-production or under-production.

2. Edge curling loss: In the production of carton, the peripheral part of the cardboard rolled away by the die-cutting machine is the edge curling loss.

Formula definition: Rolling edge loss area = (paper preparation area-area after rolling) × storage quantity

Cause: Normal wear and tear, but the reason should be analyzed when the number is too large. There are also automatic, manual and semi-automatic die-cutting machines, which require different edge rolling requirements. Therefore, different die-cutting machines must be pre-added with corresponding edge trimming to reduce edge trimming loss as much as possible. 3. Full version trimming loss: some carton users require that the edges should not be white. In order to ensure the quality, it is necessary to increase the area around the original carton by a certain area (such as an increase of 20mm) to ensure that the rolled carton will not leak. The increased 20mm part is the full edge trimming loss.

Formula definition: full-edged trimming loss area = (paper preparation area-actual carton area) × storage quantity

Cause: Normal wear and tear, but when the number is too large, the cause should be analyzed and improved

It has been proved by practice that under the scientific management model, the loss can be controlled. As long as the enterprise adopts a reasonable solution, the loss will no longer be the permanent pain of the enterprise. [next]

Solutions to current problems in production

1. Loss issues

The problem of loss is the most important problem in production at present. Too much loss not only affects the company's costs, but also weakens the company's overall competitiveness. The following sixteen words can bluntly indicate the direction of efforts for each process, that is, "full participation, standard operation, focus on quality, reduce loss".

2. On-site IE improvement to eliminate production waste

Wasted work should not happen, and it should be resolved in time if found. It mainly includes seven kinds of waste, excess, waiting, handling, processing, inventory, action, and defective products.

To eliminate waste, we must first have the attitude of "change from me, improve by me", each process starts from its own reality, abandons the conservative concept, and negates the bad phenomenon. "Infinite", don't be complacent with small achievements.

3. LEAN production method

(1) Meaning: The words are literally interpreted as thin and fat-free, that is, without any waste, the most suitable production method.

In the past, the production method allowed a small amount of defects and a certain amount of safety stock, but the LEAN production method did not accept defects and inventory, and eliminated all businesses with no added value.

(2) The necessity is mainly the improvement in the following three aspects:

â‘ Improvement of management system (system);

â‘¡Improvement of production environment;

â‘¢ Consumers demand diversified quality.

(3) Features of LEAN production method:

â‘  Emphasize the personal ability of employees;

â‘¡Pay attention to SPEED (speed);

â‘¢Strict quality management;

â‘£ Waste ZERO (to eliminate waste).

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