Carton business loss is a major factor affecting the cost, loss control is good, can greatly increase the efficiency of enterprises, improve product competitiveness. Let us analyze the various losses in the carton factory.
The total loss of the carton plant is simply the amount of raw paper input minus the finished goods. For example, when the original paper input amount should be 1 million square meters and the finished product storage amount is 900,000 square meters, then the total loss of the factory in the month = (100-90) = 100,000 square meters, and the total loss rate is 10/100 x 100 %-10%. This total loss can only be a very general number. However, the loss will be more clearly and clearly assigned to each process, and it will also make it easier for us to find ways and breakthroughs to reduce losses.
Corrugated board cardboard loss
Loss of defective products: Defective products are those that have been cut by a cutting machine.
Formula definition: loss area = (repair width × cut number) × cut length × defective product number of knife.
Causes: Improper operation of personnel, quality problems of base paper, poor fit, etc.
Improvement measures: Enhance operator management and control the quality of the base paper.
Loss of super products: Ultra products refer to more qualified products that are scheduled to run. For example, 100 papers are scheduled to be fed, resulting in 105 sheets of qualified products, of which 5 are super products.
The formula is defined as: loss area of ​​the super product = (repair width × cut number) × cut length × (number of defective cutters - number of cutting cutters).
The reason is: the amount of paper on the corrugator is too high, and the corrugator is inaccurate on the paper.
Improvement measures: The use of a corrugating machine production management system can solve problems such as inaccurate paper feeding and inaccurate sheet-feeding in single-tile machines.
Trimming Loss: Trimming refers to the part of the trimming pressure line trimmed by the resurfacing machine when it is trimmed.
Formula definition: trimming loss area = (paper - trim width × cut) × cut length × (good cut + defective number of cut knives).
Cause: Normal loss, but if it is too large, analyze the cause. For example, orders with a width of 981 mm in width are trimmed, and the width of the blanking machine needs to be at least 20 mm. Then 981 mm+20 mm=1001 mm, which is just larger than 1000 mm, only uses 1050 mm paper. The width of the edge is 1050mm-981mm=69mm, which is much larger than the normal edge trimming, resulting in an increase in the trimming loss area.
Improvement measures: If it is the above reasons, you can consider such orders are not edging, use 1000mm paper to go paper, to the back of the printing box together rolled off, can save 50mm width paper, but this will to some extent Reduce printing efficiency. Another countermeasure is that the sales department can take this into account in order to undertake orders, improve order structure, and optimize orders.
Tab skip loss: Tab skip refers to the portion of the base paper that is lacking in the basic paper web, which needs to be produced when the paper is fed through a wider web. For example, the order should go through 1000mm paper, but due to the lack of 1000mm base paper or other reasons, it needs to use 1050mm, and the extra 50mm is a tab.
Formula definition: tab loss area = (post-span paper-schedule) × cut length × (good knife number + defective knife number).
Reasons: Raw paper is not properly prepared or the sales department's original paper procurement is not timely.
Improvement measures: The company's procurement should review the purchase of raw paper and prepare the warehouse to meet the needs of customers. Try to cooperate with the customer to prepare paper and realize the working pattern of t-model. On the other hand, the sales department must advance the material demand list and give the procurement department a procurement cycle to ensure that the base paper is accurately placed. The loss of defective products and the loss of ultra products should be attributed to the loss of performance of the corrugated board production department. It can be used as an assessment indicator of the department to promote improvement.
Losses can not be eliminated. What we can do is to reduce losses to the lowest possible and most reasonable through various methods and techniques. Therefore, the purpose of subdividing the loss is to let each relevant process understand whether the various losses are reasonable, whether there is room for improvement and what needs to be improved (for example, excessive consumption of ultra products may require review of the connection of the corrugator Accurate, excessive loss of tab grid, may need to review the original paper is reasonable, etc., in order to achieve control and reduce losses, reduce costs, improve product competitiveness, and based on various losses to various departments to develop assessment indicators, Rewards are rewarded and rewarded, which increases the enthusiasm of operators to reduce losses.
Loss of printing box plus processing loss: As the carton in the production of the printing machine test machine, accidents and other circumstances, will inevitably produce a certain amount of loss, so in the order schedule will add a certain amount of additional processing.
The formula is defined as: adding consumption loss area = scheduling plus quantity × carton unit area.
The reason for this is the large loss of printing presses, the low level of operator's operation of the printing press, and the large loss of packing in the back section. In addition, there is no control over the amount of sales orders placed by the sales department. In fact, there is no need to add so much quantity. Excessive quantity of system will lead to unnecessary super system. If the system is indigestible, it will become a "dead inventory", that is, it will be overstock and it is an unnecessary loss. .
Improvement measures: This item should be the performance loss of the printing box department, which can be used as an assessment indicator of the department, promote the improvement of personnel quality and operation level, strengthen the gates for the sales department to increase the number of orders, and make the production of complex and simple production. To be different, it is recommended that the first piece be included in the amount of increase, from the source control, to avoid unnecessary overshoot or underproduction.
Rolling edge loss: During the production of the carton, the peripheral part of the cardboard which is rolled off by the die cutter is the edge loss.
Formula definition: rolling loss area = (spared area - area after rolling) × number of warehouses.
Cause: Normal loss, but the number should be analyzed. There are also automatic, manual, semi-automatic die cutting machines, and the required edge requirements are also different.
Improvement measures: Different die-cutting machines must be pre-added with corresponding edge-rolling to reduce the edge-loss as much as possible.
Full version trimming losses: Some cartons require no edge leakage. In order to ensure quality, it is necessary to add a certain area (such as an increase of 20mm) to the circumference of the original carton to ensure that the rolled out carton does not leak out. The increased 20mm part is the full-page trimming loss.
Formula definition: full version trimming loss area = (spare area - actual box area) × number of warehouses.
Cause: Normal loss, but the amount should be analyzed and improved.