"No-stencil printing" increases production efficiency

For a long time, due to the impact of the economic crisis, the company's orders have been very light, and the workshop has also been less busy. Because the company implements piece-rate wages, the income of shop floor operators also goes down. Therefore, the turnover rate of employees has rapidly increased. In response, the human resources department was under pressure and turned to the president: Because the wages were too low, many workers left. For this reason, the sales manager received training in front of the president. So he vowed to the president that he would definitely increase the amount of orders.

The sales department has made orders more than doubled in just four days through various methods such as price adjustment, but it has also created a problem that is all production obstruction. The customer's prompt phone calls one by one. So, the president again called up a project team to urgently solve the problem that orders cannot be produced.

In fact, the problem of rigid production has always existed in enterprises. With a small number of orders, there will soon be a problem of idle production capacity and a sharp drop in workers' income. With a slight increase in the number of orders, orders will not be produced. The conference on too many orders and too few orders is held many times each year, but almost every time it is a "fire-fighting club," but this time, the president delivered this to the project department at key points in the production management reform.

Through observation and investigation, project personnel found that the company's capacity utilization rate was extremely low. Capacity utilization is different from equipment utilization. Equipment utilization refers to the ratio of the time the equipment is operating to the total time, but many times, although the equipment is running and there is no production product, it does not create value. Therefore, here, the ratio of the amount of equipment used for production to the theoretical total amount of equipment that is operated at the normal speed of three shifts is used as the assessment basis. In general, there are three factors that affect the utilization of capacity: First, the equipment has no activity and can be turned off; Second, the equipment is adjusted to prepare the production process; Third, the equipment is short-lived in production because of fault or quality problems. Stop and adjust. Through the observations obtained, the author finds that the current equipment spends most of its time in preparation for production. The following observations can better illustrate these conclusions.

As can be seen from Table 1, the current capacity utilization is less than 10%, which means that at least ten times the production capacity can be tapped. From the analysis of Table 2, the school printing process (including the paste and trial printing) is the most time-consuming process. If this process is shortened, it can significantly increase the capacity utilization. There are many methods for shortening, such as strengthening training, adding staff, using hang-ups, etc., but the program proposed by the author to cancel the printing process eventually passed.

How to cancel the school printing process? The author believes that this can be achieved through the standardization of hanging plates.

First, the plate substrate is standardized. The use of a small substrate for large-format small-printing plates for large plates used for the purpose of fabricating a substrate (PVC) is no longer used. All the substrates are exactly the same, and the plate is unified at the starting position. This ensures that the press operator does not need to adjust the starting position of the feed mechanism for different plates.

Second, in addition to the hang bar, the hanging plate adds calibration marks along the edge of the hanging plate (these points are also marked on the embossing roller). In the process of registering the printing press operator, as long as the marking points of the whole block are overlapped with the markings of the embossing roller, it is possible to ensure that the hanging plate is reasonable.

Third, for the change of the font, the blank is processed along with the printing plate, and the initial position is marked. As long as the position markers match, you can ensure that the change of characters is acceptable.

After this small improvement, the printing efficiency of corporate packaging has been greatly improved. At present, there is basically no problem of production congestion, and quality problems caused by printing errors and position errors are greatly reduced.

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