People often mention "time is money", this sentence becomes very meaningful when it comes to the problem of wasting time in production. There is a simple solution to the problem of wasting time, which is to determine the cause of the downtime and use effective measures to correct them.
My approach is to determine what are the most common mistakes made in production and how to avoid them. If you use my simple solution, your bottom line and staff morale will improve. Once you start implementing these measures, you must ensure that your employees comply with these regulations, and after a period of implementation, you will not fall back to the "original model." If these measures can be smoothly implemented in all areas of production, it will inevitably have a positive impact on your company's other functional departments such as sales, customer service and marketing.
1. Production sequence
All production begins with the documents formulated by the production sequence department. If after the factory receives the document, or after the printing has been started and the production sequence file is found to be wrong or the data is missing, then the production must be stopped, and the time spent on production preparation is wasted and leads to downtime.
The way to avoid the above errors is to set up an internal list after the production sequence file enters the production process. Doing so will prompt employees to review every job detail to ensure the correct production sequence.
Information about products that must be obtained from customers in advance must be obtained from customers in time, and do not wait until they have been printed. I suggest paying attention to customer orders while production is in progress, and communicating with customers at any time. If the formulation of the production sequence document is complete and accurate, then the entire production process will proceed very smoothly.
2. Wire mesh
Without high-quality screens, workers cannot print qualified products. No screen printing can be done with inferior screens. The screen shop must use the appropriate screen mesh and stretch tension for the photoresist and ink to be used in the printed matter. In general, the pinhole cannot be repaired in the wire mesh workshop, and the repair must be completed in printing.
Before the wire mesh is used in production, its quality must be checked. If the printing has been started but the screen needs to be repaired or needs to be replaced, it will lead to the interruption of production and lead to downtime. Workers in the wire mesh workshop should receive periodic training so that they can understand in detail the limitations of each printing and the conditions necessary for printing.
3. Ink, glue and fixing
Most printing workers are engaged in printing on many different types of substrates, so they need to use different types of inks and additives. In order to ensure that the workers are using the right ink, trained ink technicians should be placed in the ink mixing room.
At the same time, we should also ensure that the stock of various inks is sufficient to prevent any ink shortage at any time. The job of the ink mixing room is to mix common and unused inks together. Many ink preparation rooms also store printing fixtures and squeegees, and their inventory should also be maintained at an appropriate level.
The technicians in this department should inspect the printed fixtures when they are recycled and reused, and replace or repair the printed fixtures when necessary. If the squeegee needs to be sharpened due to wear or notches, the same procedure can be used.
Once the screen is handed over to the printing supervisor, you can go to the ink preparation room to get the printing fixtures, ink, and glue scrapers. One of the best ways to increase the speed of process execution is to plan all processes so that the same color ink is used in the same printing process. Screen, ink and fixtures should be stored as close as possible to the area of ​​use. These tasks should be done before the printing process starts, so the worker can continue to the next process without any delay.
4. Image Department
The imaging department plays a very important role in preventing delays in the production process. Many orders come from the work of converting customer needs into perfect artworks. However, customers often only consider from the perspective of art, they do not understand the limitations of screen printing, so the job of the image department is to transform art into graphics that can be printed.
In addition, graphic artists must undergo certain training in the production process, so that they can provide suitable artistic design for the printing workshop. I call this to make up for the shortcomings, make the most of the advantages of screen printing, use a more suitable size and style, such as leaving a small area to place the printed image at the position of the logo, this process is suitable for screen processing .
Screen printing is equivalent to the replication process on the film layer. This process is completed by the imaging department and the production process. If the print quality does not meet the standards you set due to inappropriate art design, it will cause huge losses due to production downtime. If the imaging department can do their job well, this situation can be avoided. [next]
5. product
The lack of understanding of the substrate will also lead to a decrease in the speed of completing the process in production. At this time, I think production managers should understand the details of the printed products. If the item is plastic, then it must be identified which plastic is made. Such understanding should also be made for other substrates.
Different substrates require different inks and additives, and they have different requirements for the drying process. In order for the ink to adhere to the substrate, some substrates need to be heated before printing. In some cases, the printing product must remove the covering and chemicals on the surface before using the ink.
Printing managers should have a full understanding of all this information before printing, rather than discovering these problems during the printing process. This information can be easily obtained from where the printed product is purchased. Before printing, all this information should be submitted to the production department. If it is a printing product provided by your customer, you also need to obtain information about the printing material from them.
6. Printer
Many printers do not realize that in addition to production downtime, there is another factor in the printing process that I call "inefficient time". The key to avoiding inefficient time lies with printers. It is very important to fully train new operators before they are engaged in printing.
In the initial stage, the operator should determine his position in the printing operation he is to engage in. Once this position is determined, the new operator should gradually start printing under the close guidance of skilled workers. You must confirm the production level of each printing process and printing process of the product to be printed.
Every operator must complete a processing link of the product, and the production manager needs to check and statistical data on this every day. This process will identify those operating workers who do not meet the minimum standards, so that managers can try to work with them to improve production levels. If the operator still can't meet the standards of product quality and quantity after 30 days, it needs to adjust the personnel.
Some people are not suitable as printing workers, they need to be transferred to other positions or dismissed. A good operator is the key to avoid inefficient time, they can also increase the value of labor. Every day, you must confirm that all printing processes are well executed, and all your instructions can be smoothly executed in the factory.
7. Environmental protection + health + safety
In today's workplace, you must strictly abide by all levels of government regulations on protecting employees' health and safety. If your company is not large enough to establish an environmental protection + health + safety department, then senior management must assume this responsibility.
If you are found not to comply with these regulations due to occupational safety and health regulations inspections or worker complaints, then not only will you be fined, but your factory may be closed until you correct the violation.
Many companies are not aware of the importance of this issue, or they do not think it is necessary to pay attention to this issue. This is extremely wrong. You must understand in detail all the regulations concerning the health and safety of workers. You must establish written safety regulations in production and ensure that these regulations are well implemented. Industrial accidents that may cause huge losses may occur at any time and lead to production downtime.
Every part of the equipment should be regularly subjected to preventive maintenance and inspection; this will help prevent machine accidents. Workers should work under safe conditions, and you must provide them with this kind of security.
If you do not adhere to the safety regulations, then your company will encounter some serious accidents in the production process and cause work stoppages. Don't ignore this aspect of work. Expenses in this area should be included in the company's budget. If you need help in this regard, SGIA will provide you with effective help and provide you with the latest relevant regulations. [next]
8. Drying and packaging
The last step of production may also lead to delays, but good planning can eliminate this situation. For different substrates and different inks, the drying method is also different.
Whichever method you choose may cause problems. If you use a drying rack and air for drying, make sure that it is in a dust-free environment to avoid contamination of the product when the ink is not dry. If that is the case, it will have to be reprinted.
If you use hot air or uv lamps for drying in the transmission mode, make sure that the thermostat is set and the transmission speed is sufficient to ensure the drying time of the product. As long as one of the above two points is not well implemented, it will destroy the product, and you have to increase investment to reprint.
Another drying method is to use a hot oven. The main point of his use is that the product should be placed directly on the grill of the oven after printing, avoiding two handlings. You should regularly check the thermostatic device to avoid excessively high temperature causing the printed matter to burn and the temperature is too low to dry the ink. And always ensure that there is enough free space around the drying equipment used.
If the product requires special packaging, the production manager must prepare it in advance. Before the printed matter arrives, the packaging materials should have arrived at the packaging department, and the production instructions on what kind of packaging should be clearly explained. Good planning can avoid downtime due to packaging workers waiting for packaging materials.
9. QC
A good quality control department can execute your "redo" instructions in the shortest time. This is true for printing plants of any size. If your factory is not large enough to require a dedicated quality control person, then production managers and printing workers should assume responsibility for quality control.
The quality control procedure must form a written document, and you must emphasize that everyone is responsible for quality control. In this case, once a quality problem is found in the production process, it is best to interrupt the production at the beginning. This may cause some delays, but can prevent the product from being returned by the customer due to quality problems, or cause more losses.
Paper and product proofs must be provided to the printing shop together with the order in order to check the quality. The work system that stops printing when problems are found at the beginning of printing ensures the quality of the product. But quality control is not just at the beginning. Quality problems may occur at any stage, and quality should be checked throughout the production process.
In order to better complete quality control, the person responsible for quality control must have the right to stop production when it finds that the quality does not meet the requirements. To prevent the workflow from being interrupted, the quality of the printed product should be finally checked after the printed product is delivered and before they enter the production process. This process may cause a time delay at the beginning of production, but it will save even greater losses.
in conclusion
In screen printing production, these are the nine aspects that most easily lead to ineffective work. If you review the operation process of these aspects, and pay enough attention to all errors, your screen printing production will run more smoothly.
The quality of the factory's products is the most important factor to consider. For improving the company's production efficiency and the level of the production line, people are the most critical element and need the support of all employees.
Many successful screen printing companies have highly efficient equipment. If you have achieved good results in the above nine main aspects, then you have entered the second stage. Investigate other aspects of product production to optimize the production line. Once you implement changes to the factory to improve efficiency, you must persevere instead of returning to the original state.
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