Corrugated cardboard waste
Corrugated board wastes are generated by: 1) defective cardboard produced in the corrugated board machine section; 2 waste generated during the handling of raw materials; 3) cardboards produced when the machine is adjusted; 4 caused by warpage, electricity or mechanical reasons Paper jams; 5 paperboards that are glued together for a stable load; 6 loaded protective paperboard (top and bottom); 7 excess to customers.
An effective solution to avoid waste must be a comprehensive plan from the bottom up, including the entire plant owner. The value of waste should be emphasized to the whole plant, and the origin and reasons of the waste should be clarified. The implementation plan should be studied through factory research and try to reduce and eliminate controllable waste. Through these measures, if the waste is reduced by 2%, it will save $40,300 per year.
â— Establish an accurate measurement system. Label the baskets and carts containing various wastes, and indicate the source and weight of the lost papers, including the types of broke, solutions, and corrective measures.
â— To truly reduce waste effectively, all levels of the plant must be aware of the need to reduce waste.
â— Set and post derogation targets for each work session, and post these targets on board reports for all departments, work stations, and companies.
â— Announce the progress of each department and factory on a weekly basis.
â— Full discussion of progress in the weekly team meeting.
â— After reaching the goal, all employees' efforts are expressed in different forms.
Where to start on roll storage (storage, handling and storage)
â— Receive any damaged paper roll and report the relevant person in charge before depositing it in the warehouse. Any obvious damage caused by transportation should be reported to the railway and automobile transportation company and claim for compensation. Remind railways, automakers and water transport companies of their responsibilities. Defective paper rolls in transit are marked after being damaged (spray color) and stored. Damaged paper rolls without any marks and other damaged paper rolls found in the factory are considered to be damaged in the factory. It is recommended that the paper roll received should have a maximum of 5 layers to 6 layers of outer wrapper, and together with the paper roll supplier, try to reduce the loss of arrival.
â— The correct roll handling procedure requires training. The code distribution equipment must be in the best condition. Check whether the fork lifting equipment is too sharp every day. The production manager should always pay attention to the working status of the forklift. When driving a driver, pay attention to safety, do not damage the goods, and do not damage the equipment.
â— Contact the regional sales manager to arrange training for forklift drivers.
â— Use the following points to establish a lay-out plan for the paper roll in the warehouse.
(1) Use a hanging sign to indicate the width of each storage area and the type of goods. Marks may also be made on the ground.
(2) Install appropriate lighting in the roll storage area to see the stored goods.
(3) The paper roll is a set of squares arranged neatly and placed smoothly one by one.
(4) Brush different colors on columns, doorways, and any obstructions to distinguish them. This can prevent loss during handling.
(5) Do not let the paper roll out of the storage area into the aisle, this will certainly be met by the car. Another area of ​​special interest is the inside of the aisle turn. Consider using a corner guard plate 1/4"*3`*6`, bent 90° so that it is 3'long on all sides of the corner. This board can be painted with yellow and black diagonal stripes, leaving holes for hand-carrying holes on both sides of the board to facilitate movement.
(6) Check the roof regularly for cracks after heavy rain and fix it before the next heavy rain.
(7) Place all corrugating medium and recycled boxboard paper on a 4"*4" wooden plank to isolate the moisture on the ground.
(8) Conduct a daily tour inspection in the warehouse to check if there are any unsmooth, unsmooth or falling paper rolls in each storage area and re-locate them. Check if there are areas where the paper roll was misplaced, proper storage conditions, and the number of small rolls left.
(9) Before the roll is put into storage, the glue-opening part must be re-glued.
(10) The remaining small rolls must be used gradually. The warehouse driver should handle the remaining small rolls before using the full rolls, and ensure that the remaining small rolls are stored in appropriate Location so easy to find and use regularly.
(11) To inspect the various pipes above the corrugated paper storage area, if any leaks, repair it in time.
(12) To make warehouse drivers aware of how to prepare and collect labels, they should ensure that labels are not lost.
(13) Review these points regularly with the warehouse driver and make sure that they understand clearly and follow the requirements.
(14) Contact with the regional sales manager to review the warehouse arrangement and management procedures.
If the loss of paper roll storage is reduced by 0.5%, it is equivalent to saving $8,400 per month and saving $100,800 per year.
Corrugated board machine broke paper
　　 In fact, corrugated board machines are the main places where each manufacturer produces broke. The standards and procedures to be implemented include at least the following:
â— Determine the maximum width of the cutting edge, and use this as the standard for the production planning by the relevant personnel. When the width exceeds the standard, it should be reported to the plant manager for approval.
â— Edge misalignment between corrugating medium and linerboard will produce trimming waste, equivalent to 0.5% scrap.
â— Each year's project review can prevent downtime, misalignment, and quality problems, keep equipment in good operating condition, and increase production efficiency.
â— The maintenance, adjustment and maintenance of the equipment must be prioritized.
â— Contact a regional sales manager to get a service plan for a technical service representative.
â— Ensure that the preventive maintenance inspections are completed well every week and that they are properly handled.
â— Contact a technical service representative to obtain a management form.
â— Strengthen the connection between the dry and wet areas through headphones or walkie-talkies.
â— Develop an in-plant training plan and conduct practical skills training. Operators and production supervisors have a thorough understanding of corrugated board machines and know how to solve the problem of waste generation.
Stripping management of paper roll in wet operation of corrugated board machine
　　 ◠The operator is not allowed to use the razor blade to remove the damaged packaging layer of the paper roll.
â— Use a plastic stripping tool (two to three layers at a time).
• Put all the peeled paper in a separate paper waste car so that it is easy to weigh, and the production supervisors check the conditions of each shift.
• Place all unprocessed shafts in a separate paper car.
• By rewinding the paper from the core, the operator immediately knows how much work to remove from the core. Although this work is simple, it can effectively use all the paper on the shaft.
If you reduce scrap by 0.5%, you will save $8,400 a month and save $100,800 annually.
Corrugated Board Dryer Board (Maximum Loss Area)
When the paper is compounded in the wet work section, it is the first part that easily produces a large amount of waste products - the dry work board. The equipment must be in a good state of operation, and personnel of the team and maintenance personnel must be allowed to inspect, clean, and repair the machine. Warpage, uneven edges, too much starch, excessive temperature, and loosely bound edges can all be reduced and eliminated through good maintenance and operator training. Find out which parts of the paper broke up, determine how these defects occurred, and take steps to correct them.
â— Reduce the production of low-quality cardboard by preventive maintenance by each team.
â— The temperature difference (edge-aligned/horizontal) temperature of the applicator, single-side machine, roll surface temperature, and surface is checked every week using various recording tables.
â— Ask technical service representatives for forms and requests for training.
â— Improve the coordination between wet and dry workers.
If you reduce the total waste by 0.5% to 1.5%, you save $8,400 to $25,200 a month, saving $100,800 to $302,400 annually.