[China Packaging Network News] In today's soft package printing market, competition is fierce. In addition to the factors that customers consider, customers also pay great attention to product quality. The pros and cons of product quality, reliability, stability, and the cost of production directly affect the competitiveness of the company in the market, affecting the efficiency and survival of the company. As a person in charge of quality management, how to ensure high-quality factory, especially how to ensure high-quality products with low-cost products, is very difficult. This article mainly shares some personal experiences and gives a good idea to friends in the soft package industry.
Challenge: Manual detection of defects - low efficiency and high customer complaints
Challenge: Manual detection of defects - low efficiency and high customer complaints
Our company is divided into production workshop and post processing workshop. The production shop does the printing, and the post-processing workshop does the rewinding and cutting.
First, analyze the situation of our production workshop. At present, our printing speed is fast, can reach about 200 meters/minute; rely on the still picture, the occasional observation of the strobe light controls the production quality.
We purchased advanced printing presses in the industry, hired experienced operators, tried to use good quality raw materials, and introduced advanced 6S management. However, no matter how advanced the printing equipment, how high the worker's operating level, how strict the control of raw materials, how standardized management, the emergence of a variety of defective products can not be avoided.
Second, analyze the situation of our post-processing workshop:
The most troublesome thing in the post-processing workshop is the factory quality inspection. We reduced the speed as much as possible, but basically we couldn't detect occasional flaws, and even some small consecutive flaws were missed. Moreover, the results of workers' inspections are good and bad, and the standards are not uniform. Workers can't always satisfy us. They also complain about tired eyes and labor intensity. However, our customers' requirements are getting higher and higher. Products that customers recognized very much two years ago now complain frequently.
Quality Control Breakthrough - Vision Inspection System
How to increase the production rate in the production process and how to improve our factory quality inspection process has become the bottleneck of our factory production. With the rapid development of technology and equipment in today's world, we have discovered that Beijing Lingyun Company has introduced a printing vision inspection system that can use machines instead of manual inspections.
For our current problems, Beijing Lingyun Company has given two solutions:
An on-line inspection system is installed on the printing press to carry out quality control on the label printing process, and sound and light alarms are performed after defects are detected.
This program focuses on controlling defects in the printing process. The defect is found immediately after the defect is found, and the root cause of the problem is rectified. Can effectively reduce the occurrence of defective products.
The visual inspection system is installed on equipment such as slitting machines and re-inspection machines. After defects are detected, they can be repaired and cut, and the quality of the products can be tested before leaving the factory. This program focuses on controlling the factory quality and guarantees that 100% of qualified products leave the factory.
Based on the principle of “customer firstâ€, we believe that ensuring the quality of our products is the most important thing and we chose the second solution. And the introduction of a Lingyun automatic detection system, installed in the rewinding machine of our company Tianjin branch trial. During the trial period of two months, we discovered that the Lingyun visual inspection system not only greatly improved the detection speed and reduced the labor cost, but also had a much higher detection accuracy than that of labor. The customer's satisfaction with our products was greatly improved. With the successful experience of the Tianjin plant, we also introduced the Lingyun visual inspection system at the Zhuhai plant.
The rewinding machine with Beijing Lingyun visual inspection system installed
Lingyun visual inspection system uses the world’s most advanced line-array high-speed imaging ultra-high-definition camera to take pictures continuously, and then uses its own research and development testing software to analyze the photos, find defects, and feed back the inspection results to the rewinding machine. Park bugs to designated locations to eliminate bugs. Compared to labor, the advantages are:
1, the standard is strictly unified, and different products can be differentiated and tested, such as the quality inspection test set values ​​are set as follows: A level --- strict; B --- general; C level --- loose;
Grade A: "Cutting Line - (70% - 90%)" "Ink Point - (70% - 90%)" "White Point - (50% - 70%)" "Color cast defect - (40% - 60% )";
Grade B: "Cutting Line - (60% - 80%)" "Ink Point - (60% - 80%)" "White Point - (40% - 60%)" "Color cast defect - (30% - 50% )";
Grade C: "Cutting Line - (50% - 70%)" "Ink Point - (50% - 70%)" "White Point - (30% - 50%)" "Color cast defect - (20% - 40% )";
2, high color resolution, 100% inspection, never fatigue;
3, Rich defect browsing and analysis functions; When the detection is completed, the defect data is saved in the detection system. The Lingyun detection software has the following functions to process data:
· Print defects according to batch
·Browsing of defects in list and view modes
·Can output report (defect list, defect distribution chart)
·Long-term detection and statistics function
· Local area network sharing browsing defect
Managers can remotely view defect data without having to know the quality of the production. The technologist can find the location where the defect occurs most intensively through the long-term defect statistics function, defect distribution, etc., thereby improving the production process and so on.
Our company has introduced Lingyun visual inspection system and installed it on a free winder. The inspection speed reaches 250 meters per minute and the machine automatically stops when it encounters defects. It is fast and efficient. Customers with high quality requirements have now replaced manual labor with visual inspection systems. The customer complaints received are almost zero.
Some wise and soft pack companies in China have already taken the lead in the industry, taking the lead in introducing all kinds of automation equipment to replace traditional labor, reducing labor costs and increasing production efficiency. Our country is a big printing country and hopes that some of my experiences will help our friends in the industry.