How to improve the printing quality of woven bags from management and technology

Hubei Chemical Fertilizer Factory Changjiang Plastic Products Factory is an auxiliary production unit of Hubei Chemical Fertilizer Plant. It mainly produces urea woven bags for chemical fertilizer plants to meet chemical fertilizer packaging requirements. It is a question worthy of discussion that such a unit based on simple labor, with large numbers of employees, low overall quality of employees, and low technological content of products, should do a good job in production management, produce qualified products, and meet market requirements. As a grass-roots management unit of the grass-roots production unit, I have worked for more than a decade at the grass-roots level, and I have a little understanding of the grass-roots production management. Here, I represent a printing job and talk about the management of grassroots management.

Basic information

The Changjiang Plastic Products Factory existed at the Hubei Chemical Fertilizer Plant and it has a history of 30 years. Initially, a heavy bag for urea packaging was produced for the fertilizer plant. At that time, there was a printing process. After 1984, it was changed to produce woven bags. The printing process still exists. The quality of the printing directly affects the appearance quality of the woven bag, and affects the urea packaging and sales of the fertilizer plant accordingly. At present, this process is an important quality control point for chemical fertilizer plants.

It should be said that as a link in the production of chemical fertilizer plants, printing production inherits the fine management traditions of petrochemical companies in addition to its 30-year production history. Therefore, it has established a series of rules and regulations in management. At present, there are more than ten production management systems in this area, such as operation management, equipment management, quality management, and performance evaluation. However, management, as an eternal theme, cannot be changed and can only be continuously innovated. Especially under the new situation, the printing technology is continuously updated, and the market demands higher and higher quality of printed products. At the same time, due to the downsizing of petrochemical companies. Efficiency gains, a loss of skilled workers. How to strengthen enterprise management and improve product quality in this case is a difficult problem for grassroots managers.

In the period after 1998, due to the shift from a planned economy to a market economy in Hubei Fertilizer Plant, coupled with the low prices of agricultural products and the reduced demand for urea, the market and sales departments put forward higher requirements for woven bags for urea packaging, and Insufficient understanding of this, the printed product pass rate is low, there have been missed printing, word drop, adhesive bags, printing is not clear, printing distortion, printing ink uneven and so on, seriously affecting the appearance of urea; and urea sales are not The problems of smoothness, long shelf life and preservation issues have exacerbated the quality of woven bags.

Analysis of the Reasons Affecting the Quality of Woven Bags in the Printing Process

Based on the obvious problems in the production and the opinions of the customers responded to by the sales department, our branch set up a technical research group for the quality of woven bag printing. We found reasons from the aspects of people, equipment, raw materials, operation methods and environment, and analyzed the reasons. The main reason is mainly reflected in the following aspects:

(-) Personnel factors are mainly people's lack of responsibility, poor quality awareness and technical inexperience.

(b) The main factors of equipment are as follows: 1. Equipment aging. The aging of the equipment causes the printing roller to press tightly or press too tightly, which may cause the printing not to be printed on or change the shape of the printing. In addition, due to the malfunction of the equipment, it also causes missing printing.
2, equipment, no bag, drying device. Equipment without a bag, drying device can easily cause ink volatilization is not enough, easy to stick woven bags.

(C) The raw material factors mainly include:

1, ink quality problems. It is easy to cause the woven bag to fade and the printing is not bright.
2, ink mixing is not uniform. Easy to print color is not bright.
3, bag problem. There are oil stains on the woven bag, resulting in inaccurate printing, or in itself a bag that does not meet the requirements.
4, offset problem. The offset plate is susceptible to ink corrosion and the font itself has been deformed.

(4) Operation methods Transferring workers and new workers are not properly handled.

(5) Environmental factors mainly include noise in the working environment and heavy smell of ink. In addition, due to air drying in the autumn and winter seasons, the static electricity on the surface of the woven bag caused the woven bag to easily invert the bag and print on the back side.
Through the above analysis, the first three items were established as the main reasons and solutions were formulated.

Strengthen management and technological innovation to solve problems in printing

In response to the problem of outstanding personnel, equipment and raw materials, our branch mainly focuses on strengthening management and technological innovation to solve the problem of printed product quality. The personnel problem is mainly to strengthen management, especially the use of the original management system and management system, to make appropriate changes in the new situation; the equipment and materials issues, mainly to update new equipment and new materials and small reforms and small innovations.

(-) Implement the existing management system, strengthen employee professional moral education, quality education and technical training, and increase the assessment of economic responsibility system.

1. Strengthen the professional moral education of employees Combining with the theme education activities of our factory, and linking the actual conditions of the factory, we held a discussion on “How to survive in Changzhou Plastics Factory”, emphasizing the sense of crisis and enhancing the sense of responsibility of employees.
2. Strengthen quality education We invited the quality engineer of the plant to give the staff two quality courses to improve the quality of the staff and to solve the quality problems. In addition, the employees were also led to visit the packaging workshop and sales department to learn the dangers of poor quality of the woven bags.
3. Strengthen the technical training for employees The factory arranges technicians to perform technical training for employees on the job for one week, mainly explaining the basic operation methods and common problems, as well as the simple maintenance knowledge of the equipment. In addition, we have used our long-term job training and one-for-one questions to strengthen the actual operation level of employees.
4. Implement rules and regulations, intensify economic evaluation, and improve relevant systems. The branch has revised its economic responsibility system, and has set scrap rates and assessment indicators, and rewards and punishments. Also pay attention to the management of upstream and downstream processes, pay attention to the cooperation of the auxiliary department. Some provisions have also been made on clearing and other aspects.

(b) Pay attention to the renewal of equipment and materials, and implement technical reforms.
Due to the poor corporate efficiency, our factory owes too much on equipment and so on, and the application of new equipment, new technologies, and new processes is insufficient. In order to solve the problem of printing quality, our factory has made great efforts to update the equipment and applied some new materials and new technologies.

1, update the printing machine for equipment aging and other issues, after inspection, one after another to replace four three-color printing presses and a whole roll printing press.

2, replace the ink for ink adhesion is poor, not bright, poor weather resistance and other issues, after inspection, replaced the ink.

3. Replace the offset printing plate Through the analysis of the semi-offset used originally in our factory, it is believed that the corrosion of the plate is the cause of unclear printing deformation. By comparison, the full offset version was used.

4. The series of equipment was modified to solve the problem of over-thickness caused by sticky bags. We installed a bag-feeding device behind the printing machine, and we also designed the ink-mixer to use it, and we also installed an air-drawing device on the post. A series of measures have effectively improved product quality.

5. Strengthen the cooperation of electromechanical devices, strengthen the maintenance of equipment, and reduce the waste caused by equipment failure.

Results and benefits

Through nearly one year's efforts of branch employees, especially after updating equipment and applying new materials, the statistics show that the quality of woven bags has been greatly improved, the defective rate of scrap has been reduced to a certain extent, and certain economic benefits have been achieved. Mainly in two aspects:

1. After adopting the full-size offset plate, the offset plate has less corrosion and the use time is longer, which accordingly reduces the material cost. After calculation, one year can save nearly 60,000 yuan in material costs for offset printing.
2. After the scrap defective rate is reduced, it will produce certain benefits accordingly. Through the calculation, the rate of waste defective products is reduced by 1%, which can save a cost of 100,000 yuan a year.
From the analysis above, we can see that by strengthening the management and technological transformation of the technology, not only improve the quality of the product, but also create a certain economic benefits for the enterprise.
Of course, after equipment upgrades and technical innovations, the quality of the woven bags in my branch is not perfect, there are still certain problems, there are still many problems that need to be solved, and the corresponding systems need to be persisted and improved. We need to further work on this. .

in conclusion

Starting from the two aspects of equipment and technical reforms, it solved the practical problems in the printing of woven bags, effectively improved the printing quality, reduced the scrap defective rate, and achieved certain economic benefits. From the above situation, we can draw the following conclusions:

1, increase equipment updates, strengthen equipment maintenance.

Equipment is the basis of material production for enterprises and is a prerequisite for enterprise production. The quality of the equipment and its capabilities directly determine the production and operation of the company. Therefore, it is necessary to increase equipment upgrades and strengthen equipment maintenance. After all, the equipment is updated faster than the production process. In the production process, the development of the technology can be reflected at the earliest stage. After the investment, the efficiency is also the greatest, although the initial investment cost is high.

2. Pay attention to the application of new technologies and new materials, and strengthen the technical reforms.

Production management personnel should pay attention to the update of technology and materials, pay attention to the application of new technology and new materials in production, and must also strengthen the technical reforms in combination with the actual situation.

3. Strengthen the production and equipment management, strengthen the implementation methods and implementation of the management system, and pay attention to further refinement and updating in combination with the actual situation.

Author: Friends of the San Min from: the Yangtze River in Hubei fertilizer plants plastic products factory