Application of Data Analysis Technology in Carton Production Process

Data analysis is an important part of the ISO9001:2000 quality management system. In the operation process of production process and quality control, through a series of data analysis, it is possible to accurately determine the problems in the production process and quality, and then take some necessary process improvement measures to achieve the purpose of improving product quality. The inevitable result of implementing the ISO9001:2000 quality management system is also the basic requirement of modern enterprise management.

The author has a deep understanding of the above situation in the quality of daily business. Here, how to use data analysis technology to innovate and improve the production process, so that the quality of corrugated boxes can be improved, for example, analysis and discussion for peer reference.

Analyze and identify problems based on customer feedback quality issues, and develop quality control measures

We have had such quality problems: the customers found the beer cartons we produced during the use. During the rainy season, the cartons are often prone to warping and deformation, and the compressive strength of the carton is obviously reduced. So we complained to us about this quality. problem. We conduct inspection analysis and research by in-depth observation and extraction of physical objects to find out the causes and problems. First of all, we check the laboratory's raw paper into the warehouse inspection data, the results show that the technical indicators of corrugated paper and cardboard paper entering the warehouse are higher than the standard value, especially the lateral ring pressure index which has a certain relationship with the strength of the carton. no problem. Then, where is the problem? After the detection and comparative analysis of the carton, we found the following problem: after the surface of the paper layer in the carton has dripped, the water droplets will quickly appear in the carton, and the carton feels a bit soft when touched. The value of the compressive strength of the test is also low; on the contrary, the water tank is not prone to the carton of the seepage phenomenon, the touch feeling of the carton is also hard, and the compressive strength value is also high. In addition, the carton is easy to absorb moisture, and its moisture content is also relatively high. The analysis of the test data shows that the sizing degree of the base paper is poor, so that the carton is easy to absorb moisture, the moisture content is increased and becomes soft, and the carton is prone to deformation, so that the compressive strength is lowered. According to our detection and analysis, we have developed corresponding raw material quality control standards, using a simple “drip method” to detect the water absorption and sizing degree of the base paper. The detection standard requires ≥60S, that is, water droplets to paper After the surface, there should be no seepage in the standard time. On the other hand, we also control the technical indicators such as lateral stiffness, printing surface roughness and water absorption of pre-printed whiteboard paper, and emphasize the control requirements of these technical indicators when signing the purchase contract. At the same time, high-brightness glazing oil is used for glazing, so that the carton is not easy to absorb moisture. Through data analysis, we adopted corresponding process control measures to better control the quality of the base paper, and the strength and quality of the carton was significantly improved.

Develop scientific and reasonable inspection methods through inspection and comparison analysis to ensure the quality of raw materials

Raw materials are the source of product quality, and it is very important to carry out inspection control. To this end, our factory purchased ISD-3 electronic compression strength tester, YQ-ZB-8 paper and cardboard folding resistance instrument, ZUS-20 thickness gauge and other testing instruments, which can detect adhesive strength and edge strength. Various technical indicators such as ring pressure strength, folding resistance and tightness. However, having a test instrument does not mean that the quality of the product is accurately controlled, and only by improving the accuracy of the test can the quality of control be achieved. Then, how can we improve the accuracy of the test? According to the requirements of the relevant national standards, the sample must be subjected to constant temperature and humidity treatment under certain environmental conditions for a certain period of time, so that the performance of the base paper is relatively stable and at a constant temperature. The conditions of constant humidity are tested to obtain a relatively accurate detection result. In fact, it is very difficult to do this in the inspection of raw materials. It is often only possible to use the method of sampling, ie testing, on the base paper. Such detection results and the detection results under constant temperature and humidity conditions may have certain errors in the performance of the side pressure strength and the ring pressure strength, and the value of the self-test is usually It will be lower than the value of the specification test. In response to this phenomenon, we have developed a scientific and reasonable detection method through detection and comparison analysis. The main method is to divide the same piece of paper into two parts and arrange for inspection under two conditions, one is in the laboratory of our factory. The self-test is carried out under natural conditions, and the other is to send the paper sample to the laboratory of the professional institution under the standard conditions, and then perform the constant temperature and humidity treatment on the paper sample, and then test the data, and then analyze and compare the two test results. Find the difference between the two, we call it the detection coefficient. For example, in the case of testing the lateral ring pressure index of a certain kind of paper, the result of the professional laboratory test is 6.84 N•m/g. The result of sampling by the factory is 5.7 N•m/g, and the detection coefficient is It is 1.2, and the calculation formula is: the value of the professional laboratory test value ÷ self-test of the factory. After many such comparison tests, the average of the detection coefficients is obtained as our standard detection coefficient. In this way, the value of the ring pressure index detected by our laboratory under normal conditions is multiplied by the standard detection coefficient, which is our more accurate test result. Through the above comparison test and data analysis to develop the standard detection coefficient, our test has a certain accuracy and fairness, the test results have also been recognized by the supplier, and better played a role in controlling the quality of the original paper.

Determine the production process of single-sided machine by testing data analysis and improve the quality of single-faced corrugated board

The strength of corrugated board is an important factor in determining the quality of the carton. The high height of the corrugated board, the number of turns in the unit of 30cm length and the waveform characteristics of the corrugated board are important conditions that affect the strength of the corrugated board. Due to the structural characteristics of the corrugated board, the corrugated paper rate of the length unit is determined. The competition in the carton industry requires the production of quality-compliant cartons on the most economical basis. So, how can we do this? We started the improvement of the production process by starting with the corrugating roller that determines the amount of paper. Based on the fact that we have two single-faced corrugated units, one of which (1# machine) has a bad tooth that needs to be replaced with a new one. So when we make a new corrugating roller, we directly customize the corrugating roller as: 48 teeth / 30cm (number of corrugated teeth per unit length); the height of the roller of the roller is 2.9mm (that is, the distance from the concave surface to the convex surface), which is 4 teeth more than the original number of teeth, and the height of the molars is slightly reduced. But still controlled within the standard range. Our other unit (2# machine) is: 44 teeth / 30cm; the height of the roller roll is 3.12mm. In this way, in the case of two single-faced corrugated units of the same type, the production process, environment and paper quality are the same. We have carried out several production tests, test comparison analysis, and obtained the following production process conclusions: 1# machine The tooth has 4 teeth more than the 2# machine, but the height of the molar is 0.22mm lower than that of the 2# machine. Thus, the 2m corrugated paper can form 1.405m corrugated cardboard. The 2# machine 2m corrugated paper can only form 1.385m corrugated board, and the edge strength, bond strength and plane compressive strength of the corrugated board produced by the machine are lower than those of the 1# machine. It can be seen that the 1# machine not only uses paper than the 2# machine, but also produces high quality corrugated cardboard. Therefore, we plan to replace the corrugated roller of the 2# machine with the same specifications as the 1# machine at the appropriate time. Improve the quality of single-faced corrugated board products.

Test and analysis of the plane compressive strength of single-faced corrugated board, can judge the rationality of the single-face machine operation process

In the quality management practice, the author found that under the same temperature and humidity conditions, sometimes the quality of the corrugated board produced by the single-sided machine is unstable. For example, the quality of the raw paper into the warehouse is high, and sometimes the hardness of the corrugated board produced by the machine is better than the quality. Corrugated cardboard with a low index of base paper is still poor. It can be seen that the single-sided machine production operation process, such as the speed, temperature, and adhesive control during the production of the machine, largely determines the molding quality of the corrugated board. Since the single-sided corrugated cardboard can not detect the edge pressure strength value, the quality of the production process is often judged by the touch of the hand, but it is difficult to accurately judge whether the production operation and the process control of the single-sided machine are appropriate. In this regard, the author through the detection of the plane strength of corrugated board, obtained scientific test data for analysis, in order to grasp and understand the production process effect of single-sided machine. The method is: firstly make a circular cast iron base with a diameter of 11.7cm, the thickness of which is 2cm, and then use the electronic compression strength tester for testing. Before the test, take a single tile (two layers) of corrugated cardboard, and punch a number of standard specimens (area 100 cm2) with a YQ-Z-7 quantitative sampling knife. When testing, first place the circular bottom plate on the lower pressure plate of the tester. After the instrument is zero-corrected, the circular sample can be placed on the circular bottom for testing. When the sample is crushed, the screen is pressed. The data shown is the value of the plane compressive strength of the sample. In general, under normal conditions, the basis weight and the ring pressure index of the base paper are high, and the value of the plane compressive strength of the processed corrugated cardboard is relatively high. If the basis weight and the ring pressure index of the base paper are high, and the flat compressive strength value of the corrugated board produced is low, it indicates that the temperature, speed or adhesive of the single-sided machine is not properly controlled, and corresponding measures should be taken to adjust and control. In order to produce good quality corrugated cardboard with good paper, the quality of the carton is fundamentally improved.

Through the sampling test comparison to determine the quality of the cardboard stickers of different machines, in order to scientifically and rationally arrange production operations

After the production of single-faced corrugated paperboard, the pre-printed whiteboard paper should be affixed with an automatic laminating machine or a manual laminating machine to complete the processing of the cardboard. Due to the different machine structure and different adhesives, the quality effect of the cardboard plaque is also very different. Through the comparison and analysis, we found that the automatic laminating machine and the hand-applied machine affixed the paperboard, and their processing quality is very different. The structure and performance of the automatic laminating machine is much better than that of the manual laminating machine, and the adhesive strength and edge strength value of the laminating paper are lower than that of the manual laminating machine, from which we can judge the operation of the machine, There are certain problems with the suitability and viscosity of the adhesive, and corresponding measures need to be taken to control it. In addition, the pre-printed whiteboard paper that has been calendered by the automatic laminating machine and the manual laminating machine respectively, the semi-finished paperboard produced by the two processes, when detecting, we found that the cardboard of the manual laminating machine blistered. The probability of degumming is high, but this is rarely the case with automatic laminating machines. Therefore, based on the analysis of the usual test data, we arrange the calendered pre-printed whiteboard paper into the automatic laminating machine for the production of the plaque, which improves the processing quality of the product.

In summary, the use of data analysis technology to detect the production process of semi-finished products, finished product quality or new processes, and obtain scientific data for analysis and comparison, can more accurately determine the problems and causes of production process and product quality, and then pass Scientifically and rationally formulating production process measures can not only achieve the purpose of saving raw materials, but also improve product quality. This is the good result of implementing SO9001:2000 quality management system, and it is also the goal of modern enterprise quality management.