The loss of carton enterprises is a major factor affecting the cost. If the loss is controlled, it can increase the efficiency of the enterprise to a large extent and improve the competitiveness of the products. Let’s analyze the various losses in the carton factory.

To put it simply, the total loss of the carton factory is the amount of raw paper input minus the amount of finished products put into storage. For example: the monthly raw paper input should produce 1 million square meters, and the finished product storage volume is 900,000 square meters, then the total loss of the factory in the current month = (100-90) = 100,000 square meters, and the total loss rate is 10/100×100 %-10%. Such total loss can only be a very general number. However, the distribution of loss to each process will be clearer, and it will be more convenient for us to find ways and breakthroughs to reduce loss.

1. Cardboard loss of corrugator

● Waste of defective products

Defective products refer to unqualified products after being cut by a cutting machine.

Formula definition: Loss area = (trimming width × cutting number) × cutting length × number of cutting knives for defective products.

Causes: improper operation by personnel, quality problems of base paper, poor fit, etc.

● Formula definition

Loss area = (trimming width × number of cuts) × length of cut × number of cutting knives for defective products.

Causes: improper operation by personnel, quality problems of base paper, poor fit, etc.

Improvement measures: strengthen the management of operators and control the quality of raw paper.

● Super product loss

Super products refer to qualified products that exceed the predetermined amount of paper. For example, if 100 sheets of paper are scheduled to be fed, and 105 sheets of qualified products are fed, then 5 of them are super products.

Formula definition: Super product loss area = (trimming width × number of cuts) × length of cut × (number of bad cutters-number of scheduled cutters).

Causes: too much paper on the corrugator, inaccurate paper receiving on the corrugator, etc.

Improvement measures: the use of the corrugator production management system can solve the problems of inaccurate paper loading and inaccurate paper receiving on a single tile machine.

● Trimming loss

Trimming refers to the part that is trimmed when trimming the edges by the trimming and crimping machine of the tile machine.

Formula definition: Trimming loss area = (paper web-trimming width × number of cuts) × length of cut × (number of good products + number of bad products).

Cause: normal loss, but if it is too large, the cause should be analyzed. For example, if the trimming width of the order is 981 mm, and the minimum trimming width required by the corrugator is 20mm, then 981mm+20mm=1001mm, which is exactly larger than 1000mm, only use 1050mm paper to go. The edge width is 1050mm-981mm=69mm, which is much larger than the normal trimming, causing the trimming loss area to increase.

Improvement measures: If it is the above reasons, consider that the order is not trimmed, and the paper is fed with 1000mm paper. When the latter is printed and the box is rolled off, 50mm width paper can be saved, but this will be to a certain extent Reduce printing efficiency. Another countermeasure is that the sales department can take this into consideration when accepting orders, improve the order structure, and optimize the order.

● Tab loss

Tabbing refers to the part that is produced when a wider paper web is needed to feed the paper due to the shortage of the base paper of the basic paper web. For example, the order should be made of paper with a paper width of 1000mm, but due to lack of base paper of 1000mm or other reasons, the paper needs to be fed with 1050mm. The extra 50mm is a tabulation.

Formula definition: Tabbing loss area = (paper web after tabbing-scheduled paper web) × cutting length × (number of cutting knives for good products + number of cutting knives for bad products).

Reasons: unreasonable raw paper stocking or untimely purchase of raw paper by the sales department.

Countermeasures for improvement: The company’s procurement should review whether the raw paper procurement and stocking meet the needs of customers, and try to cooperate with customers in paper preparation to realize the t-mode work idea. On the other hand, the sales department must place a material demand list in advance to give the purchasing 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 cardboard production department, which can be used as the evaluation index of the department to promote improvement.

2. Printing box loss

● Additional loss

A certain amount of additional production will be added when the carton is produced due to the printing machine trial and accidents during the production of the carton.

Formula definition: Addition loss area = scheduled addition quantity × unit area of ​​carton.

Causes: large loss of the printing press, low operating level of the printing press operator, and large loss of packing in the later stage. In addition, the sales department has no control over the amount of additional orders placed. In fact, there is no need to add so much extra quantity. Too much extra quantity will lead to unnecessary overproduction. If the overproduction cannot be digested, it will become “dead inventory”, that is, overdue inventory, which is an unnecessary loss. .

Improvement measures: This item should belong to the performance loss of the printing box department, which can be used as an evaluation index of the department to promote the improvement of the quality of personnel and operation level. The sales department will strengthen the gate for the order volume, and the production of complex and simple production volume To make a difference, it is recommended to include an increase in the first article to control from the source to avoid unnecessary over- or under-production.

● Cutting loss

When the carton is produced, the part around the cardboard that is rolled off by the die-cutting machine is the edge loss.

Formula definition: Edge rolling loss area = (prepared paper area-area after rolling) × warehousing quantity.

Cause: normal loss, but the reason should be analyzed when the quantity is too large. There are also automatic, manual, and semi-automatic die-cutting machines, and the required edge rolling requirements are also different.

Improvement measures: different die cutting machines must be pre-added with corresponding edge rolling to reduce edge loss as much as possible.

● Full version trimming loss

Some carton users require no edge leakage. In order to ensure the quality, it is necessary to increase a certain area around the original carton (such as increasing by 20mm) to ensure that the rolled carton will not leak. The increased 20mm part is the full-page trimming loss.

Formula definition: full-page trimming loss area = (prepared paper area-actual carton area) × warehousing quantity.

Cause: normal loss, but when the quantity is too large, the reason should be analyzed and improved.

Loss cannot be eliminated. What we can do is to reduce loss to the lowest and most reasonable level through various methods and techniques as much as possible. Therefore, the significance of subdividing the loss in the previous section is to let the relevant processes understand whether the various 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 corrugator picks up the paper. Accurate, skip loss is too large, it may be necessary to review whether the original paper preparation is reasonable, etc.) in order to achieve the purpose of controlling and reducing loss, reducing costs, and improving product competitiveness, and can formulate evaluation indicators for various departments according to various losses. Reward the good and punish the bad, and increase the enthusiasm of operators to reduce losses.

Post time: Mar-10-2021