Element 1: person
The most fluctuating human factors play a decisive role in the influence of product quality. How to improve product quality through people?
One is to train the skill level of machine operators to meet the production requirements. Enterprises can encourage machine operators through some encouraging measures, such as printing technical grade certificate, printing title and so on. In this way, Shenzhen Nine Planetary Printing Group has improved the skills of operators, ensured the stability of product quality and achieved good results in the actual production process.
The second is to cultivate people who follow the process system and are trustworthy. Watada is a well-known printing and production supplier in Japan, providing packaging products supporting services for Sony, Nintendo and other well-known large electronic enterprises in Japan. My deepest contact with them is that they can tolerate the defects of product quality, but they can never tolerate the non-implementation of the process. They believe that the product quality can be continuously improved and the technology can be improved, but it is absolutely not allowed to violate the production process, operation guide and management system. This is their red line. Once the enterprise violates it, it will immediately face the great risk of canceling the order.
Thirdly, on-site operators should have the ability to evaluate product quality, identify product quality risks and take measures to prevent product quality in advance. Yachang Printing Group, in order to meet the special requirements of customers (artists), also devoted time to training the captain of the machine to let him know the art of art painting and collectibles, so as to better understand the requirements of customers and meet the quality characteristics standards of products.
Element 2: Machine
Stable working equipment is the basic requirement to ensure product quality. In order to ensure the stable operation of equipment and product quality, the following points should be achieved:
First, repair the equipment on time in strict accordance with the maintenance plan, and do not use the busy delivery date and tight time as an excuse not to repair the equipment or operate the equipment with illness;
Second, in normal work, we should operate the equipment in strict accordance with the requirements, manage the spare parts at ordinary times, and immediately repair the equipment once it fails to ensure its smooth operation;
Third, through the performance evaluation of equipment, identify, evaluate and prevent the quality risks brought by equipment to product quality in advance, plan ahead, and take preventive measures against product quality risks according to the characteristics of equipment before production.
Element 3: Materials
Some enterprises blindly pursue the low cost of materials in order to save costs. The quality manager can only ask the managers of all departments to jointly review and sign, and eventually the customer complains, returns and claims, which seriously affects the quality and reputation of the enterprise.
First, the quality department is responsible for customers and fully understands their quality requirements, so the quality manager has the right to decide all quality decisions, including material procurement suggestions, seven elements of quality management and seven elements of quality management. At present, 95% of enterprises generally have quality differences, either the general manager has the final say or the marketing business has the final say. At this point, the quality manager has completely lost the power to make the final quality decision.
Secondly, in order to ensure the stable supply of product quality, Watada printing mentioned above generally designates material suppliers. These suppliers have excellent material quality. Although the price is relatively expensive, the product quality is very stable, and printing manufacturers are afraid to change material suppliers easily, otherwise they will immediately face the danger of canceling orders.
Third, the method should be resolutely implemented, and the human relationship between the buyer, the factory director and the general manager should not bring great risks to the product quality. Incoming inspection is the first level. Can not meet the production requirements, we must resolutely return.
Element 4: Law
The process of general business printing products is relatively simple, and the quality requirements are not harsh. In contrast, in the field of high-end packaging and printing, the requirements for product quality are much higher. For example, the quality requirements of luxury wine box packaging products are very demanding and difficult. Because there are many processes, it is not a workshop or a link that can complete the manufacturing of products, so higher requirements are put forward for every workshop, every process and every link.
In fact, the profit source of printed matter is the sum of the output value created by each process. Therefore, in manufacturing, the standardization and meticulous management of each process, link and step and the strict implementation of SOP work instructions are the key factors to ensure product quality and profit. Any mistake in the next process will lead to all the efforts of the previous process being wasted. The company will face the bad situation of delayed delivery, declining reputation, brand damage and re-filling orders.
Therefore, in the early stage of manufacturing, it is particularly critical to fully decompose the design structure and various technological processes, identify and propose product quality risks, prevent and propose effective preventive countermeasures, and record and track the technical parameters of each step of the production process.
Element 5: Ring
Everyone knows that the printing workshop mainly uses paper as raw material, and paper is sensitive to the environment. When the weather is wet, it is easy to flounce; When the weather is dry, it is easy to have tight edges. In the production operation, it is easy to cause overprinter and die cutting problems. When I was in Hucai, Qinghai, the weather in the north was cold at that time, and it was MINUS 20 degrees at night. There was no constant temperature and humidity system installed in the workshop. There is often water mist on the surface of composite and transfer gold cards, and the ink often falls off when printing begins, so the whole batch of products faces great risk of scrapping. Later, by installing a constant temperature and humidity system in the workshop and preheating the products in the workshop five days in advance, the problems of ink dropping and poor adhesion were finally solved.
In addition, the printing workshop also has requirements for color environment, and the light and shade of the workshop and the light source for observing color are all particular. Only by doing it properly can we effectively prevent the quality problems caused by the environment. In Guangdong coastal provinces, there are more rainy days from March to May, so the protection of materials and semi-finished products is also very important. After the semi-finished products are completed, they must be wrapped with plastic wrap to make the production process as compact as possible, so as to avoid serious deformation of materials in half a month, and reproduction will bring many quality problems.
Element 6: Measurement
At present, many printing enterprises that make cigarette packets have established their own laboratories or quality inspection centers, which effectively prevent the occurrence of product quality accidents. Under necessary conditions, the establishment of its own testing center is of great benefit to the quality assurance of enterprises.
Incoming inspection is the first pass. When the first pass is stopped, the quality is half finished.
The production inspection in the process should be done anyway. Doing well can effectively avoid a large number of fatal product quality defects; If you don't do it well, you will face a huge risk of scrapping the whole batch. In the general production process, bar code detection is the most common and critical; In terms of color, Essex spectrometers, 528 and 530 are generally used. Under special circumstances, use Glinda or G7 certification and GMI certification for quality management.
For products with very high product quality requirements and complex processes, quality verification before and after the production process is particularly critical. At present, middle-level management cadres in many enterprises, including managers and supervisors, lack overall awareness, only care about the quality of their own processes, and do not fully consider the quality risks and impacts brought by post-processes, which eventually cause great losses to enterprises.
Element 7: Letter
Although the transmission of information cannot control the quality of products, many people ignore it, which brings a lot of trouble to the next process. Therefore, we should pay attention to the following three points:
First, the upper and lower processes must block the circulation of defective products. In principle, the next process is the customer of the previous process, and no defective products are manufactured or delivered.
Second, if there are multimode products on the printed sheet, some can be taken and some can't be taken, so be sure to mark them clearly. Watada's requirements are: draw a "schematic diagram of multimode products", where to check good products and where to draw lines for bad products, so that all fools can understand where there are quality problems;
Third, large goods and products with abnormal quality must be isolated and cannot be placed on a card board. For bulk products, black printed product process tracking record cards can be used, and for problematic products, yellow printed identification cards can be used; For scrapped products, you can divide an area separately, print the identification card in red, and clean up the scrapped area in time every day to avoid confusion.
Fourth, the quantity of products must be accurate, the records should be clear, and the technological process should be clear, and it should not be altered. When the upper and lower procedures are handed over, the safest way is to communicate face to face with special handover personnel and sign for confirmation.