The crux of the hottest carton loss and its radica

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The crux of carton loss and its radical cure

the loss of carton enterprises is a major factor affecting costs. If the loss is well controlled, it can greatly increase the efficiency of enterprises and improve the competitiveness of products. Let's analyze various losses in the carton factory

the total loss of the carton factory is simply the input of base paper minus the storage of finished products. For example, if the input volume of base paper in the current month should be 1million square meters and the warehousing volume of finished products is 900000 square meters, then the total loss of the factory in the current month = (100-90) = 100000 square meters, and the total loss rate is 10/100 × 100%-10%。 Such total loss can only be a very general figure. However, the allocation of losses to each process will be clearer, and it will be more convenient for us to find out the methods and breakthroughs to reduce losses

corrugated machine paperboard loss

defective product loss: defective products refer to unqualified products cut by the cutting machine

formula definition: loss area = (trimming width × Cut) × Cut length × Number of defective product cutters

causes: improper operation by personnel, quality problems of base paper, poor fitting, etc

improvement countermeasures: strengthen the management of operators and control the quality of base paper

over production loss: over production refers to the qualified products with more than the predetermined paper quantity. For example, if 100 sheets of paper are scheduled to be delivered, and 105 sheets of qualified products are delivered, then 5 of them are super products

formula definition: loss area of super product = (trimming width × Cut) × Cut length × (number of bad cutters - number of scheduled cutters)

causes: too much paper on the corrugating machine, inaccurate paper connection of the corrugating machine, etc

improvement countermeasures: using the corrugated machine production management system can solve the problems of inaccurate paper loading and inaccurate paper receiving on a single corrugated machine

trimming loss: trimming refers to the part repaired by the trimming and crimping machine of the re tile machine

formula definition: trimming loss area = (paper web - trimming width × Cut) × Cut length × (number of good products + number of bad products)

cause: normal loss, but if you want the later operation to be more safe, stable and accurate, if it is too large, you should analyze the cause. For example, if the trimming width of the order is 981 mm, and the minimum trimming width required by the corrugating machine is 20mm, then 981mm+20mm=1001mm, which is exactly greater than 1000mm, only 1050mm paper can be used, so the trimming width is 1050mm-981mm = 69mm, which is much larger than the normal trimming, resulting in the increase of trimming loss area

improvement countermeasures: if it is for the above reasons, it can be considered that such orders do not repair the beautiful edge, use 1000mm paper to run the paper, and roll it off when it comes to the rear section of the printing box, which can save 50mm wide paper, 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 the order

skip loss: skip refers to the part produced when a wider sheet of paper needs to be used to run due to the shortage of base paper of the basic sheet. For example, the order should use 1000mm paper, but due to the lack of 1000mm base paper or other reasons, 1050mm paper needs to be used, and the extra 50mm belongs to skip

formula definition: skip loss area = (skip Web - scheduled WEB) × Cut length × (number of good products + number of bad products)

cause: unreasonable preparation of base paper or delayed purchase of base paper by the sales department

improvement countermeasures: the company's procurement should review whether the base paper procurement and stock preparation meet the needs of customers, try to cooperate with customers to prepare paper, and realize the working idea of T-mode. On the other hand, the sales department must issue the material requisition in advance and give the purchasing department a procurement cycle to ensure that the base paper is accurate and 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, which can be used as the evaluation index of the Department to promote improvement

loss cannot be eliminated. What we can do is to reduce the loss to the lowest and most reasonable level through various ways and techniques as far as possible. Therefore, the significance of subdividing the losses above is to let all relevant processes know whether the losses are reasonable, whether there is room for improvement and what needs to be improved (for example, if the loss of super products is too large, it may be necessary to review whether the corrugated machine is accurate to receive paper, if the skip loss is too large, it may be necessary to review whether the base paper preparation is reasonable, etc.), so as to achieve the purpose of controlling and reducing losses, reducing costs, and improving product competitiveness, And according to various losses to develop assessment indicators for each department, reward the good and punish the bad, and improve the enthusiasm of operators to reduce losses

loss of printing cartons

loss of processing volume: due to the trial run of the printing machine and accidents during the production of cartons, certain losses will inevitably occur, so a certain amount of processing volume of self-developed new materials will be added during order scheduling

formula definition: additive quantity loss area = scheduled additive quantity × Carton unit area

causes: large loss of printing machine, low operation level of printing machine operators, and large packing loss in the rear section. In addition, the order addition quantity of the sales department is not controlled. In fact, there is no need to add so much additive quantity, and excessive additive quantity will lead to unnecessary overstock. If the overstock cannot be digested, it will become "dead stock", that is, overstock, which is also an unnecessary loss

improvement countermeasures: this item should belong to the performance loss of the printing and box making department, which can be used as the evaluation index of the Department to promote the improvement of personnel quality and operation level. The sales department should strengthen the gate in terms of order addition quantity, and the addition quantity of complex production and simple production should be different. It is suggested to include the addition quantity in the first article, and control it from the source, so as to avoid unnecessary over or under production

edging loss: in the production of cartons, the part around the cardboard rolled out by the die-cutting machine, that is, edging loss

formula definition: edge rolling loss area = (paper preparation area - area after rolling) × Stock in quantity

cause: normal loss, but if the quantity is too large, the cause should be analyzed. There are also fully automatic, manual and semi-automatic die-cutting machines, which require different requirements for edging

improvement countermeasures: different die cutting machines must pre add corresponding edging to reduce edging loss as much as possible

full page trimming loss: some carton users require that the edges should not leak white. In order to ensure the quality, it is necessary to increase a certain area around the original carton (such as 20mm) to ensure that the rolled carton will not leak white. The increased 20mm part is the full plate trimming loss

formula definition: full plate trimming loss area = (paper preparation area - actual carton area) × Stock in quantity

cause: normal loss, but if the quantity is too large, the cause should be analyzed and improved

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