Data analysis is an important part of the ISO9001: 2000 quality management system. In the process of production process and quality control, through a series of data analysis, you can more accurately determine the problems of production process and quality, and then take some necessary process improvement measures to achieve the purpose of improving product quality. This is The inevitable result of implementing ISO9001: 2000 quality management system is also the basic requirement of modern enterprise management.
The author has a deep understanding of the above situation in daily enterprise quality. Here is how to use data analysis technology to innovate and improve the production process, so as to improve the quality of corrugated boxes, for example, analysis and discussion, for peer reference.
Analyze and identify problems based on the quality problems reported by customers, and formulate quality control measures
There have been such quality problems: customers found that the beer cartons we produced during use were often prone to warpage and deformation during the rainy season, and the compressive strength of the cartons dropped significantly, so we complained to us about this quality problem . We go through on-site observation and extract the actual objects to carry out detection analysis and research to find out the causes and problems. First of all, we checked the raw paper storage inspection data of the laboratory, and the results showed that the technical indicators of corrugated paper and cardboard paper in the storage are higher than the standard value, especially the lateral ring pressure index that has a certain relationship with the carton strength. no problem. So, what's the problem? After testing and comparative analysis of the carton, we found the following problems: After dripping water on the surface of the paper layer in the carton, the water droplets soon appeared to be bleeding. The carton felt a little soft when touched. The compressive strength value of the test is also low; on the contrary, the carton of water drops is not prone to bleeding, the touch feel of the carton is also hard, and the compressive strength value is also high. In addition, the carton that is easy to absorb moisture has a relatively high water content. The analysis of the test data shows that the poor sizing degree of the base paper can make the carton easily absorb moisture, increase the water content and become soft, and the carton will also be easily deformed, which will reduce its compressive strength. According to the situation of our testing and analysis, we have formulated corresponding raw material quality control standards, and adopted a simple "drip method" to detect the water absorption and sizing degree of the base paper. The detection standard requirement is ≥60S, that is, to drop water onto the paper After the face, there should be no bleeding within the standard time. On the other hand, we also control the technical indicators such as horizontal stiffness, printed surface roughness and water absorption of preprinted whiteboard paper. When signing the purchase contract, we emphasize the control requirements of these technical indicators. At the same time, high brightness glazing oil is used for glazing, so that the carton is not easy to absorb moisture. Through data analysis, we adopted corresponding process control measures to better control the quality of the base paper and significantly improve the strength and quality of the carton.
Formulate scientific and reasonable inspection methods through inspection and comparison analysis to ensure the storage quality of raw materials
Raw materials are the source of product quality, and it is important to do inspection and control. To this end, our factory purchased ISD-3 electronic compressive strength tester, YQ-ZB-8 paper and cardboard folding endurance tester, ZUS-20 thickness gauge and other testing instruments, which can detect adhesive strength and edge pressure strength , Ring compression strength, folding resistance, tightness and other technical indicators. However, having a testing instrument does not mean that product quality is accurately controlled, and only by improving the accuracy of testing can the purpose of quality control be better achieved. So, how can the accuracy of the test be improved? According to the requirements of relevant national standards, the sample must undergo constant temperature and humidity treatment for a certain period of time under specific environmental conditions to make the performance of the base paper relatively stable and at a constant temperature. Only when the conditions of constant humidity are tested can a relatively accurate test result be obtained. In fact, it is difficult to do this for the inspection of raw materials. Often, only the method of sampling and checking the original paper can be used. Such test results and test results under constant temperature and humidity conditions will have certain errors in the performance of edge pressure strength and ring pressure strength. The value of self-test is usually The value will be a little lower than the standard inspection. In response to this phenomenon, we have developed a scientific and reasonable detection method through comparison and analysis of detection. The main method is to divide the same paper sample into two and arrange for inspection under two conditions, one is by the laboratory of our factory. Self-inspection is carried out under natural conditions, and the other is to send the paper samples to a laboratory of a professional institution under standard conditions, and then perform constant temperature and humidity treatment on the paper samples before testing, and then perform data analysis and comparison of the two test results. Find the difference between the two, we call it the detection coefficient. For example, taking the horizontal ring pressure index item of a certain type of paper as an example, the result of the professional laboratory test is 6.84Nm / g, the result of the factory sampling and inspection is 5.7Nm / g, and the detection coefficient is 1.2. The formula is: professional laboratory test value ÷ factory self-test value. After many such comparative detection experiments, the average value of the detection coefficient is then used as our standard detection coefficient. In this way, the ring pressure index value tested by our laboratory under normal conditions and multiplied by the standard detection coefficient is our relatively accurate test result. The standard test coefficients developed through the above comparative test experiments and data analysis make our test have a certain accuracy and fairness, and the test results have also been approved by the supplier, which has played a role in controlling the quality of the base paper.
Determine the production process of single-sided machine through the analysis of inspection data, improve the quality of single-sided corrugated board
The strength of the corrugated cardboard is an important factor that determines the quality of the carton. The corrugated cardboard's corrugated height, the number of corrugations in the unit of 30 cm length and the corrugated wave characteristics are the important conditions that affect the strength of the corrugated cardboard. Due to the structural characteristics of corrugated cardboard, the corrugated paper usage rate in length units is determined. The competition in the carton industry is to produce cartons of quality consistent with the standards on the basis of the most economical use of materials. So, how can we do it? We started with corrugated rolls that determined the amount of paper used and improved the production process. Based on the fact that we have two single-sided corrugating units, one of which has a corrugated roller (1 # machine) whose corrugated teeth are badly damaged and a new roller needs to be replaced, so when we make a new corrugated roller, we directly customize the corrugated roller as: 48 teeth / 30cm (the number of corrugated teeth per unit length); the height of the corrugated teeth of the roller roller is 2.9mm (that is, the distance from the concave surface to the convex surface), which is 4 teeth more than the original number of fluted teeth, and the height of the fluted teeth is slightly reduced. But it is still controlled within the standard. Our other unit (2 # machine) is: 44 teeth / 30cm; the height of the corrugated tooth of the roller is 3.12mm. In this way, under the condition that the production process, environment and paper quality of the two single-sided corrugated units of the same model are the same, we have conducted multiple production tests and comparative analysis of the tests, and obtained the following production process conclusion: The tooth has 4 more teeth than the 2 # machine, but the height of the corrugated tooth is 0.22mm lower than that of the 2 # machine. In this way, the machine can form 1.405m corrugated cardboard with 2m corrugated paper. The 2m machine 2m corrugated paper can only form 1.385m corrugated board, and the edge pressure strength, adhesive strength and plane compressive strength of the corrugated board produced by this machine are lower than the 1 # machine. It can be seen that the 1 # machine not only saves paper than the 2 # machine, but also produces higher quality corrugated cardboard. Therefore, we plan to replace the corrugating rollers of the 2 # machine with the same specifications as the 1 # machine when appropriate. Improve the quality of single-sided corrugated board products.
Test and analyze the plane compressive strength of single-sided corrugated cardboard to determine the rationality of the operation process of single-sided machine
In the quality management practice, the author found that under the same temperature and humidity conditions, sometimes the quality of corrugated cardboard produced by single-sided machines is unstable, such as the quality index of the base paper in the warehouse is high, and sometimes the hardness of the corrugated cardboard produced is higher than the quality. Corrugated cardboard formed from base paper with a low index is still poor. It can be seen that the production process of the single-sided machine, such as the speed, temperature and adhesive control during the production of the machine, largely determines the forming quality of the corrugated cardboard. Because the single-sided corrugated cardboard cannot detect the edge pressure strength value, it is often only by touch to determine the quality of the production process. However, it is difficult to accurately determine whether the production operation and process control of the single-sided machine are appropriate. In this regard, the author obtained the scientific test data for analysis by testing the plane strength of the corrugated cardboard, so as to grasp and understand the production process effect of the single-sided machine. The method is to first make a round cast iron base with a diameter of 11.7cm and a thickness specification of 2cm, and then use an electronic compressive strength tester for testing. Before testing, first take a single tile (two-layer) corrugated cardboard, and use YQ-Z-7 type quantitative sampling knife to punch out several standard samples (area of ​​100cm2). When testing, first place the round bottom bracket on the lower plate of the tester. After zero-adjusting the instrument, you can place the round sample on the round bottom bracket for testing. When the sample is crushed, the screen The displayed data is the plane compressive strength value of the sample. In general, under normal circumstances, the base paper has a high basis weight and a high ring compression index, and the flat compressive strength value of the processed corrugated cardboard is relatively high. If the basis weight and ring pressure index of the base paper are high and the flat compressive strength of the corrugated cardboard produced is low, it means that the temperature, speed or adhesive of the single-sided machine is not properly controlled, and corresponding measures should be taken to adjust and control In order to produce corrugated cardboard of good quality with good paper, fundamentally improve the quality of carton products.
Determine the quality of cardboard lamination of different machines through sample inspection and comparison, so as to arrange production operations scientifically and reasonably
After the production of single-sided corrugated paperboard, the automatic printing machine or manual laminating machine must be used to mount the preprinted whiteboard paper in order to complete the cardboard processing process. Due to the different structure of the mounting machine and different adhesives, the quality effect of the cardboard mounting is also completely different. Through inspection and comparative analysis, we found that the processing quality of the cardboard mounted by the automatic laminating machine and the manual laminating machine is very different. The structure and performance of the automatic laminating machine is much better than that of the manual laminating machine, but the adhesive strength and edge pressure strength of the cardboard it is mounted on are lower than that of the manual laminating machine, from which we can judge the operation of the machine, There are certain problems in the suitability and viscosity of the adhesive, and corresponding measures need to be taken to control. In addition, using the automatic laminating machine and the manual laminating machine to mount the calendered pre-printed whiteboard paper respectively, the semi-finished paperboard produced by these two processes produced bubbles during the inspection. 1. The probability of degumming is high, but the automatic laminating machine rarely has this bad situation. Therefore, according to the analysis of the usual detection data, we try to arrange the calendered preprinted whiteboard paper to the automatic laminating machine for laminating production, which improves the processing quality of the product.
In summary, the use of data analysis technology to detect the production process of semi-finished products, finished product quality or new processes, and obtain scientific data for analysis and comparison can more accurately determine the problems and causes of production processes and product quality, and then pass Scientific and reasonable formulation of production process measures can not only achieve the goal of saving raw materials for production, but also improve product quality. This is the good result of the implementation of the SO9001: 2000 quality management system and the goal of modern enterprise quality management.
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