Carton Factory Production Loss Analysis

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

The total loss of the carton factory, simply put, is the amount of raw paper input to a finished product. For example, when the original paper input volume should be 10 million square meters, and the finished product storage volume is 90,000 square meters, then the total factory loss of the month = (1 OO - 9 O) = 10 million square meters, and the total loss rate is 10/1 O0×1OO%= 1O%. But such total loss can only be a very general figure.

As managers cannot analyze the rationality of the 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:

Corrugated board cardboard loss

Bad product loss

Bad products refer to unqualified products that have been cut by a cutting machine.
Formula definition: (Width of trim X number of cuts) X cut length X Defective number of cutters Example: Cut width 845mm Cut number 2 Cut length 800mm Defective number of cutters 1O Knife defective Consumption area = (845 X 2) X 800 X 10/1000000 = 13.52 square meters Causes • Under normal circumstances, improper personnel operations, quality of the base paper, poor bonding, etc. Improvement Measures Strengthen the management of operators and control the quality of the base paper.

Super product loss

Ultra-finished products refer to more qualified products that are scheduled to be discharged. For example: It is planned to take 100 sheets of paper, resulting in 105 sheets of qualified products, of which 5 sheets are ultra products.
Formula definition: (Fixed width X cut number) X cut length X (good cut knife number one schedule cut knife number)
For example, trim width 845mm cut number 2 cut length 800mm good product number of cutters 1O5 knife schedule cut number of cutters 100% consumption area of ​​knife super product = (845 X 2) X 800 X (1O5 - 1OO) gate 000000 = 6.76 square meters Causes: The number of papers on a single tile machine is too high, and the single tile machine is inaccurate.
Improvement measures: The use of a corrugator production tube system can solve problems such as inaccurate paper loading and inaccurate sheet-feeding on a single-tile machine.

Trimming loss

Trimming refers to the part of the trimming pressure line machine repaired when it is trimmed.
Formula definition (paper width of one trim width X cut number) X cut length X (good number of cutting knife + defective number of cutting knife)
For example: Paper width 175Omm Width cut 845mm Cut number 2 Cut length 8OOmm Good product number of cutters 1OO Knife defective Item number of cutters 1O blade Trimming loss area = (1750-845 X 2) X 800 X (100+1 O)/ 1000000 = 5.28 m2 Cause: Normal loss, but if it is too large, analyze the cause. For example, the order's trim width is 981mm, while the corrugator's minimum trim is 20mm, then 981mm+2Omm=1 001mm, which is just larger than 1O00mm, only with 1 050mm paper, then repair. The edge width is 1 050mm to 981 mm=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 trimming, use 1OOOmm paper to go paper, to the back of the printing box when rolled off, can save 50mm width paper.

Tabloss

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 through 1OOOmm paper, but due to lack of 1O00mm paper or other reasons, it needs to use 1050mm paper, and the extra 5Omm is a tab.
The formula is defined as: (the paper size of the paper after skipping the grid) X cut length X (the number of good cutters + the number of defective cutters)
For example, after skipping the web 1050mm schedule paper 1O00mm cut length 8OOmm good product number of cutters 1O0 knife bad product number of cutters 1O knife cut-out area = (1050-1000)X 800× (100+1O) gate 000000=4 .4 square meters generated reasons: raw paper is not reasonable and so on.
Improvement measures: Material should review the purchase of raw paper, prepare the warehouse to meet customer needs, 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.

Printing box loss

Increased loss

Due to the fact that the carton is in production, such as printing machine testing, accidents, etc., it will inevitably produce a certain amount of loss, so a certain amount of additive processing will be added when the order is scheduled. For example, when customers order 1,000 cartons, they should take 1O1O sheets of paper when the corrugator moves the paper. The 1O sheets of paperboard are added.
Formula definition: schedule plus quantity x carton unit area Example: schedule plus system quantity 1O cartons Unit area 1.5 square meters Addition volume square meters = 10 x 1.5 = 15 square meters Causes: There are many reasons, for example: The loss of printing presses is high, the operation level of printing press operators is not high, and the packing loss of the rear section is large.
Improvement measures: This item should be the performance loss of the printing box department, which can be used as an assessment index of the department and promote the improvement of personnel quality and operation level.

Rolling edge loss

In the production of the carton, the part of the periphery of the paperboard that is rolled off by the flat mill or the back mill is the edge loss.
Formula definition: (Paper preparation area after rolling area) X Storage quantity Example: Sheet area 1.5 square meters Area after rolling 1.4 square meters Storage quantity 1O0 Edge loss area=(1.5—1 .4) × 100 = 10 m 2 Cause: Normal loss, but the reason should be analyzed when the quantity is too large.

Full version trimming loss

Some cartons are required to have no edge leakage. To ensure quality, a certain area (such as 2Omm increase) is added around the circumference of the original cartons to ensure that the rolled cartons do not leak out, which increases by 2Omm. In part, it is full-size trimming loss.

Formula definition: (paper-preparation area-real cartons area) X storage quantity Example: Paper-prepared area 1.5 square meters Actual carton area 1.4 square meters Warehousing quantity 1OO Full-size trimming loss area: (1.5—1_4 ) × 100 = 10 m 2 Cause: Normal loss, but the number should be analyzed and the reason should be improved.

The significance of subdividing the above losses is to let managers know 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 accuracy of single-machine paddles, Excessive tabbing loss may require reviewing the rationality of base paper backup, etc., in order to achieve control and reduce losses, reduce costs, and improve product competitiveness. The benefit of subdividing the loss lies in the ability to distinguish the responsibilities of various departments, avoiding mutual adjudication among departments and problems, and knowing where the problems lie in the end, and can formulate assessment indicators for various departments based on various kinds of losses, and reward good and bad. Improve the enthusiasm of all departments to reduce losses.

Source: Global corrugated box industry