1. Analysis and understanding of the bottleneck problems restricting the production cost of cartons
Due to the rapid development of the carton industry, now the unfair industry competition is more and more fierce, resulting in the price of product printing continues to pressure, production profits are getting lower and lower, the risk of operation is getting greater and greater, in this case, when the market changes slightly or the production control is slightly careless, it is very likely to appear losses. We know that the current carton industry post-press production process is generally labor-intensive production characteristics, low production efficiency, unstable product quality, high production consumption, is its most basic characteristics. In particular, die-cutting, laminating, paste box, paste box and other post-printing processing production processes, the labor intensity is relatively large. Despite rising wages in recent years, skilled operators are still hard to find. According to the author's understanding and understanding, whether it is flexo printing process of carton production, or offset printing, gravure process of pre-printed carton production, printing production due to the high degree of automation of the machine, the production efficiency is also high. Therefore, although the salary of the printing operator is relatively higher than that of other processes, the labor cost of the printing process is still lower than the labor cost of the post-press process from the point of view of the printing price and printing cost of the market order. Then, from the overall situation of the carton production enterprise, the main reason for restricting the production cost of the carton is still in the post-press production link, because the post-press production process of the carton is mostly manual work, and the low production efficiency is the basic characteristics of manual work, which is also the main reason why the production cost is difficult to get better control. The existence of this problem, to a large extent, also affects the production plan of enterprises to receive orders. The author once had a deep appreciation for the production situation of such an enterprise. The original backward production of a carton factory in a certain place has restricted the progress of production and the confidence of receiving orders. Now the enterprise not only after the laminating process are all fully automatic coating machine production, and laminating, die cutting, paste box, paste box are also all automatic machines, not only greatly improve the production efficiency, but also better reduce the production cost, the advantages of enterprise production highlight, It is in sharp contrast to the production situation of backward and inefficient manual work in the last process a few years ago. According to a manager of the factory, the post-production labor intensity, low production efficiency, unstable quality, large production consumption, labor costs are rising, and it is difficult to find the right operator, so in the past, there is a single dare not pick up, for fear that the post-manual operation process production is slow, affecting delivery time, destroying the credibility of the enterprise. Since the latter are automated production, workers not only reduced production intensity, but also can steadily earn wages, so now the latter production process does not worry about no workers, the latter production no longer restricts the entire production schedule. It seems that the development of automated machines suitable for factory production characteristics is a way to reduce the cost of carton production, and it is also a strategy and direction for the survival and development of a large-scale enterprise.
2. Comparative analysis of die cutting production status and different performance die cutting machine production costs
Die cutting production status. Die-cutting is an essential process of carton production post-press processing, and now a considerable part of the factory is still mainly produced by vertical artificial paper-feeding die-cutting machine, which is called "tiger mouth" die-cutting machine in some places. I estimate that at least 60% of die-cutting products are still produced by this machine, because this type of machine has a simple structure and low production investment. However, its operation strength is large, the production efficiency is low, the product quality is unstable, the consumption is relatively high, and it often faces the confusion of the lack of die cutting workers. Between April and May this year, a factory die-cutting process production is particularly busy, and a die-cutting worker asked for a long holiday, die-cutting products backlog a lot, the factory finally temporarily asked a die-cutting worker to come and barely help for a few days, the hourly wage is 20 yuan, almost every thousand pieces of 20 yuan, and the factory some die-cutting products receive orders of wages, only 20 yuan per thousand pieces, If the power consumption and machine depreciation costs are taken into account, the company is operating at a loss when the die cutter is temporarily asked for emergency production. In my opinion, die-cutting production efficiency and die-cutting workers are difficult to find, which has always been a bottleneck restricting the production of carton factories, and has become a headache for enterprise production management, and almost every factory manager has the same feeling.
Comparative analysis of production cost of different die cutting machines. Out of concern for the die-cutting production, the author specially on the artificial die-cutting and automatic die-cutting production cost of a comparative analysis, with a value of 60,000 yuan vertical manual paper-transfer die-cutting machine per shift production of 12 hours per day to calculate, if the average die-cutting corrugated cardboard output of 12,000 per shift, the machine power of 5.5kw/h, Electricity consumption per hour is almost 5.5 degrees, each degree of electricity to 1 yuan, the cost of power consumption per shift is 66 yuan. In addition, the manual operation of the die cutting machine per thousand unit price according to 10 yuan, 120 yuan per shift payable wages, then the manual transfer operation of the die cutting machine per shift total production costs of 186 yuan, manual die cutting per thousand production costs is 15.5 yuan. And a corresponding specification of a horizontal automatic paper transfer die cutting machine needs to invest 700,000 yuan, the average die cutting output of corrugated cardboard 54000 pieces per shift, the machine power 16kw/h, the production power consumption cost per shift is 192 yuan, per thousand die cutting unit price calculated by 6.5 yuan (including the salary of an auxiliary staff), the average wage payable per shift 351 yuan, The total cost of automatic die cutting machine production per shift is 543 yuan, then the cost of automatic die cutting production per thousand sheets is about 10.06 yuan. It can be seen from the above data that the production capacity of a horizontal automatic die-cutting machine is 4.5 times that of a "tiger mouth" die-cutting machine, and although the price of the "tiger mouth" die-cutting machine is cheap, it is balanced according to the proportion of production capacity, and after adding 4 sets of similar equipment, the total investment of the equipment is only 300,000 yuan, which is more than 1 times cheaper than an automatic die-cutting machine. We need four more operators. Then according to the above caliber to produce 330 days a year, every day according to 24 hours of two shifts of inverted power to calculate, the annual output of an automatic die-cutting machine =54 thousand pieces ×2 shifts ×330 days=35,640 thousand pieces; Annual production cost=35,640 thousand sheets ×10.06 yuan=358,638.40 yuan. And 5 sets of "tiger mouth" die cutting machine production cost of 35640 thousand pieces =35640 thousand pieces ×15.5 yuan =552420 yuan, then, a horizontal automatic die cutting machine and 5 sets of "tiger mouth" die cutting machine one year production of the same output, its production cost difference =552420 yuan -358638.40 yuan =193781.6 yuan, It can be seen that with an automatic die-cutting machine production time of more than 3 years, and the cost difference generated by the production of the "tiger mouth" die-cutting machine, you can purchase an automatic die-cutting machine. It seems that although the purchase price of the automatic die-cutting machine is expensive, it still has great advantages and potential from the perspective of the performance of the equipment and the control of the production cost of post-press die-cutting. If the carton factory has a long line of die-cutting products, it is worthwhile to buy an automatic die-cutting machine for production, and the efficiency advantage of die-cutting production is still quite prominent.
3. Control the production cost of products through scientific and reasonable process design
In fact, according to the characteristics and uses of the product, the design of a reasonable post-press processing production process can not only reduce the consumption of equipment and raw materials, but also reduce the production cost of the post-press process. Therefore, when designing the post-press processing process of the product, we should pay attention to the design of the process from the use and applicability of the product, for example, the carton products that can be replaced by the coating process with the glazing and calender process, do not design the coating process. For hot stamping aluminum foil, UV process color box products, do not put the layout design too large to avoid waste of materials. For the small size carton products that are printed in a set of plates, when assembling, attention should be paid to the direction and position of the layout, which should be determined from various factors such as printing paper saving and convenient post-printing processing, such as using the form of "concave and convex insert" according to the box structure can achieve the purpose of saving paper; The layout of the carton is properly turned to an Angle, which can be conducive to the processing of the rear channel. For the design of product packaging matching trademarks, labels, instructions and other products, as long as it can be a "one-sifits-all" layout, the edge of the adjacent layout should not be left to repair the position, which can not only achieve the purpose of saving paper, but also improve the production efficiency and accuracy of cutting, reducing the production of unqualified products. There are also laminating processes like calendered pre-printed carton paper and corrugated cardboard, due to the hardening of the face paper material after calendering, the stiffness is correspondingly enhanced, and the flatness of the paper is decreased, if the manual operation of the coating machine pasting corrugated cardboard, it is prone to foaming and poor bonding quality defects, resulting in an increase in the rate of unqualified products, so the laminating process of calendered paper, The production process should fully take into account the characteristics of the face paper, and it is best to use an automatic surface coating machine for mounting, because this type of machine has a pressurized device, and the corrugated cardboard after mounting is not easy to produce foaming or poor bonding quality ills.
4. Reduce post-press production costs by changing the employment mechanism
As one of the factors of factory production, people are one of the important conditions to determine the production cost. Advanced management methods, innovative management measures, are man-made; Advanced equipment, advanced production technology, but also through the correct grasp and application of human results. The production efficiency and high-quality results brought by advanced production processes are also achieved through extraordinary human efforts. For example, the same piece of equipment, by the technical quality, ideological quality and personality of the two people respectively to operate, its production efficiency and product quality effect, there will be obvious differences. This point, the author in many years of work is deeply felt. Therefore, the author believes that the carton factory has both labor-intensive characteristics, and technology-intensive characteristics, different levels, different personalities, different quality of employees have, and the correct mechanism and method of employment can make different types of people, give full play to their due role, otherwise, may bring certain losses to the factory. Therefore, changing the concept of employment and employment mechanism is a crucial link. We should pay attention to choosing excellent talents who are sensitive and good at studying technology, and arrange good employees to important production positions. If some employees are clever, studious and willing to work, the factory should consider allowing them to train once again in multiple production technical positions, so that they can master a number of production operation skills, so that those who can open the die-cutting machine, but also can open the program-controlled cutting machine; Both can open the coating machine, and can open the laminating machine production personnel, appropriate to give the corresponding favorable treatment, in order to stimulate the enthusiasm and initiative of employees to learn production technology. Training multi-functional production backbone can not only make the most effective use of the factory's human resources, improve the income of employees, effectively prevent the outflow of employees, and make the light and peak season production of each post better adjusted, but also better reduce the cost of post-press production, improve the competitive vitality of enterprises.
5. Reduce the production cost of post-press processing by using printing press embossing
Some color box products or handbag products undertaken by the carton factory often use embossing process to decorate the surface of the product and improve the printing quality of the product. The traditional embossing process is to use the embossing machine to use the surface structure of the circular arc drum steel plate, through the effect of pressurizing the roller, so that the surface of the printed matter forms a clear concave and convex trace. If the embossing machine is used for embossing production, the embossing plate needs to be made by a professional manufacturer, the plate material is very expensive, the production time is long, and the replacement of the drum type steel plate device is very time-consuming. The use of vertical flat die cutting machine with relief plate embossing, large area embossing products, in terms of quality and production efficiency are unsatisfactory. In view of these problems, the author gets inspiration from the letterpress technology, so the use of offset press to carry out the embossing process test, and obtained a better process effect. The process is as follows: first, the resin embossed plate is sun-baked with negative picture film, the exposure time is controlled to 360S, and then the layout is rinsed with tap water, and the layout is gently wiped with a soft sponge until the resin of the blank layout is washed off. When the rinsing and developing operation is completed, the embossed plate can be placed at about 10cm away from the Iodogallium lamp of the printing machine to dry for 30min, the purpose of which is to enhance the embossed hardness of the embossed plate, prevent the cracking of the raised lines during the embossed process, and improve the bonding force between the polyester support film and the photosensitive resin layer. The embossed plate can be loaded after the production of the plate, when the plate is loaded, the rubber sheet on the rubber drum is removed first, and the replacement of a waste rubber sheet is specially used for embossed, so that the good rubber sheet can be avoided into a depression, so that it can not be used in the future printing, resulting in waste of materials. After replacing the rubber blanket, turn off the water and ink system, stick the resin embossing plate to the appropriate position of the embossing cylinder with double-sided adhesive, and adjust the appropriate embossing pressure through the appropriate addition or reduction of the liner, you can carry out the formal embossing production. The author believes that the use of offset printing press embossing production, with a simple and fast operation method, low production cost, embossing production efficiency and product quality, no less than the process effect of special embossing machine, the development of this innovative process, can make the function of the existing printing production equipment has been expanded, improve the utilization of equipment resources, for the post-press processing production has created a new development prospects.
Throughout the carton factory post-press production situation, production cost control has become a more prominent problem, and post-press production methods and process measures lag, has affected the competitiveness of some enterprises, to a certain extent, also restricts the development and survival of the factory, so the author believes that the current carton enterprises should have a correct understanding and business concept, Not only should we pay attention to the optimization of the production process, not only should we properly introduce advanced post-press processing production equipment to enrich the production according to the actual production situation of the factory, but also through the innovative application of old equipment and old technology, as well as the change and innovation of the employment mechanism, so that the inherent resources of the enterprise can be fully utilized, so as to achieve better control of the production cost of post-press processing. Improve the production efficiency and benefit of enterprises.
