Control carton manufacturing costs from two aspects of cardboard
1. Over-design cartons
The first department we should focus on is the design department.
In fact, in many cases, carton packaging is overdesigned.The salesperson usually obtains the order through the following steps:
1. Visit potential customers, obtain carton samples, and bring them back to the office;
2. Copy the design and set the cost;
3. If the selling price is competitive and the delivery is positive, there may be an advantage;
Then they snatch new orders from their competitors.
In this process, the practical application of cartons is sometimes overlooked.
Because the design and application of cartons were not properly reviewed internally or with the customer, much of the tissue and core paper was excessive.
Historically, workers in the latter stages of the processing process extruded the board excessively in the feed portion, well above the 0.003 "(0.08mm) maximum board thickness loss standard.As a result, heavy tissue and core paper were used to maintain the process and provide shipping packaging to meet customer requirements, but this increased costs and unnecessary loss of profits.
The process is completely different for new designs or new products from existing customers.By providing product samples, our design team has a real opportunity to adopt appropriate structural Suggestions, instill a concept of protecting the product, such as partition or foam support, and then provide RSC, winding design and/or die-cutting design.
All of these ideas are based on historical data and known production characteristics in the process of plant use.This is based on various corrugated rolls, paper combinations and the most recent successful examples of the flute design.
In order to stay up to date, the design and quality department should regularly update and review the factory's historical data and, above all, ensure that you are providing the customer with the cartons he needs, not the over-designed (or under-designed) carton.
If you are a secondary plant and you purchase paper from a different paper mill, it is recommended that you conduct a design review meeting with your paper supplier to ensure that the paper you purchase is correct or possibly consistent in all areas.
Each tile line has its own corrugated roll design in each of its single-sided machines, which may be purchased from a different supplier.When the factory transforms the corrugated board production line and buys new paper, the paper changes should be identified and passed on to the design department.
2. Collect accurate data
Any new mechanical properties of the paper, the temperature of the corrugated roll (due to improvements in the steam system), the type of spray on the core paper (moisture content) will affect the thickness of the paper.We also need to set new parameters for the machine to accommodate these changes and/or improvements.
In today's production process, the thickness of the cardboard determines the compressive strength of the carton under different corrugated combinations.This type of information will enable the design department to provide better and more accurate design products to ensure that customer requirements are met.
The method of recording the thickness of the board from the tile line also varies.The crew or team of each tile line shall develop a plan to report the cardboard thickness from the cadre.Remember, the wet end of the paper change is a dynamic target.Different factories provide tissue and core paper specific to their own factories.Again, if you are a secondary plant, the cardboard thickness will always be different, and these figures need to be managed and understood by the processor.
Similarly, during flexo printing and die-cutting, there will be a loss in the thickness of the cardboard, processing, the thickness of the non-printing area should not exceed 0.003 inches (0.08 mm).
If the paper itself changes 0.005 inches (0.125 mm) from the tile line, flexo and die cutting personnel need to be aware of this for proper setup and better management.The pressure of the tile line should also be reviewed and recorded.
The changes in the paper we are discussing have a direct impact on the amount of force required to press the line in the folding process.Standards should be established and monitored using the appropriate line bending tester, and the sales staff and their customers should check the figures together.
The tile operator should report an accurate figure that truly represents the thickness of the paper in the order.They need to check the accuracy and consistency of the figures with the customer's post-press department.Post-press departments should also give corresponding support.
It is well known that if the printing and color are correct, customers will be more willing to accept the order without further inspection.If the color is not correct due to the change in cardboard thickness, the order may be overinspected or even returned.
Tolerances and variations are part of our business, so the thickness of the board should be accurately recorded.
The industry is becoming more competitive, and we need up-to-date and accurate information throughout the process.
Manufacturing costs are also a key part of the market.Cost accounting is based on historical data, which is the only basis on which accounting can be used for accurate cost analysis.
Based on this fact, our manufacturing processes should be periodically reviewed against the tissues, cores and production rates of the processing department, the board production department and the accounting department.To keep our cost figures up to date.
In today's market, "current and accurate" is always a great tool for success.
Another very positive aspect is communicating with the sales team and ultimately with the customer.
It will enable salespeople to better discuss active manufacturing and design controls with customers.As a carton manufacturer, we need to focus on this area and position ourselves so that these customers have confidence in our process control system.
We need to be stronger and be proud of what we are doing internally and in the marketplace.Because we always know what we're doing.