Carton Factory Loss Analysis--Corrugating Machine Cardboard Loss

Loss is a major factor affecting the cost, loss control can be a great extent to increase the efficiency of the mouth, improve product competitiveness. The following briefly analyzes the various losses in the carton factory.

The total loss of the carton factory is simply the input amount of raw paper—the amount of finished goods put into the warehouse. For example, when the input amount of raw paper for the month should be 1 million square meters, and the finished goods storage amount is 900,000 square meters, then the total loss of the factory in the current month is (100-90) 2100,000 square meters, and the total loss rate is 10/100 x ?00%. 0%. But such total loss can only be a very general figure. As managers cannot analyze the rationality of loss from this figure, you may think that it is too high, but you cannot judge which part of the loss is too high and which part needs improvement. The loss should basically include the following loss content:

(A) Corrugated machine cardboard loss

1 bad product loss

Bad products refer to unqualified products that have been cut by a cutting machine.

Formula definition: (Fixed width x cut number) x cut length x defective cutter number

For example: Trim width 845mm Cut number 2 Cut length 800mm Defective product Number of cutters 10 knife

Defective material loss area (845 x 2) x 800 x 10/1000000 = 13.52 square meters Causes: In general, improper operation of personnel, quality problems of the base paper, poor adhesion, etc.
Improvement measures: Strengthen the management of operators and control the quality of the base paper.

2 Super product loss

Ultra-finished products refer to more qualified products that are scheduled to be discharged. For example, the number of papers that are scheduled to be shipped is 00, resulting in 105 sheets of qualified products, of which 5 are super products.

Formula definition: (Fixed width x cut number) x cut length x (good cuts - cuts cuts)

For example: Trim width 845mm Cut number 2 Cut length 800mm Good number of cuts 105 Number of knife cuts Cut number of 100 knife

Super product wastage area (845 x 2) x 800 x (105-100)/1000000 = 6.76 m 2

Causes: The number of papers on a single tile machine is too high, and the single tile machine does not accept the paper;

Improvement measures: The use of a corrugating machine production system can solve problems such as inaccurate paper feeding and paper pick-up in a single tile machine;

3 trimming loss

Trimming refers to the part of the trimming pressure line machine repaired when it is trimmed.

Formula definition: (paper - width of trim x cut number) x cut length x (good cut number + bad cut number)

For example: Paper 1750mm Width 845mm Cut Number 2 Cut Length 800mm Good Cutter Number 100 Knife Defective Product Cutter Number 10 Knife

Trimming loss area = (1750-845 x 2) x 800 x (100 + 10) / 1000000 = 5.28 square meters

Cause: Normal loss, but if it is too large, analyze the cause. For example, the order's trim width is 981mm, and the minimum trimming required for the corrugator is 20mm, then the 981mm+20mm=1001mm, just larger than 1000mm, only uses 1050mm paper to go, so the trimming width is 1050mm- 981mm=69mm, much larger than the normal edging, resulting in increased area of ​​edging loss.

Improvement measures: If it is the above reasons, you can consider such orders without trimming, use 1000mm paper to go to the back of the printing box when rolled together, can save 50mm width paper.

4 tab loss

Skip refers to the portion of paper produced when a wider web is needed to feed paper when there is a shortage of certain paper stocks. For example: The order should go 1000mm paper, but due to the lack of 1000mm base paper or other reasons, you need to use 1050mm paper, and the extra 50mm is a tab.

Formula definition: (post skipped web-scheduled web) x cut length x (good cuts + bad cuts)

For example: after skipping the web 1050mm schedule paper 1000mm cut length 800mm good product number of knives 100 knives defective product number of knives 10 knives

Tab loss area: (?050-1000) x 800 x(100+10)/?000000=4.4 square meters

Cause: The original paper is not reasonable.

Improvement measures: The department should review the purchase of raw paper and prepare the warehouse to meet the needs of customers. Try to cooperate with customers to prepare paper.

The loss of defective products and the loss of ultra products should be attributed to the loss of performance in the corrugated paperboard department. It can be used as an assessment indicator of the department to promote improvement.

(to be continued)