Carton soft proofing process and relation presetting technology

The complexity of a carton business almost amassed all the complexities of other companies involved. These complexities are usually concentrated in the stage of customer demand determination. Therefore, there is obvious industry commonness in design, plate making, and proofing. For a specific carton manufacturer, this process of almost every new one has its own special place. If it is a little careless, it will bring a lot of economic losses.

The focus of our attention is usually hard technology, such as what kind of plate-making equipment? What kind of design technology? What kind of proofer? How to use ink? How to make a suitable structure and so on. These are all very important. In the actual work, the author found that the "soft proofing" link is very easy to ignore. Even if the technology is harder, the ultimate company will not make any money. In many cases, the list that seems to make money will eventually lose money. This is the result of the incomprehensive combination of technology and business. Under normal circumstances, everything from design to proofing and trial production is a process led by technicians. What they care about is how to do right, not how to do economic right, how to make such products harmonize with other products, and how to make rear production A good order. Even if it is considered, it cannot be responsible for the final profit.

In this process, it is necessary to design the two lines of technology and economic production at the same time. Economic production is how to carry out large-scale production from a commercial perspective. How to make a harmonious production with orders for other products. The author refers to the economic production process as the process of "soft proofing" (hard proofing relative to a purely technical perspective).

"Soft Proofing" Must Consider Many Aspects

Product Suite: Is the product composition determined to be a variety of "subproducts";

Product Maturity: Is the product composition an old product that has already been done (the product database has a number inside it). Does the new product involve a new process? new material? This customer did not have such needs before? Or carton companies have not appeared? How difficult is the technical difficulty:

Available inventory: Fully in line with the effective inventory of the products required by this order, and processing can meet the required effective inventory through minor changes;

Special materials: Whether it involves basic papers or inks that have less use or use frequency or have not been seen before:

Cardboard technology: whether there are special pressure lines, special corrugation direction, secondary twisting, etc.;

Preparation for printing: existing storage locations for printing plates, films, PS plates, etc., available time, and the time available for new production facilities;

Printing process: Offset, watermark color, color accuracy requirements:

Forming process: punching board or slotting process, whether the mold has storage location, available time, the time that the new production facility can place;

Combined process: Technical requirements for nail packaging:

Packing process product packaging bundle, end, single package quantity and other requirements:

Document service: The time and requirement for the supplier to check and check the report:

Contract review: review elements, review results, execution monitoring points and monitoring time requirements, such as the delivery of certain processes.

The above 12 items belong to product management, process conditions, service, and process monitoring. These factors will consume a large amount of resources after the products are mass-produced. If they are all personalized, then the total investment will certainly be less than the company's income. This product is losing money. This is where "soft proofing" is concerned.

Understand the knowledge in "soft proofing"

Management issues and planning issues

Trial production (proofing) and mass production, the most prone to problems is the process of grasping, in fact, the fundamental, is the proportion of knowledge in the carton order fulfillment process is far greater than the material properties of the reasons, and these knowledge is usually Implicit methods exist, when the matching pattern of people, machines, and materials is inconsistent with the order requirements, the tacit knowledge will disappear partially, causing defects in the final delivery.

For example, the final delivery time of the offset printing finished product box order is determined by the operation time of each link. The difference between the delivery period and the actual performance delivery promised by our customers is due to the uncontrolled and uncertain midway links. Uncontrolled refers to itself. The quality of the product is not well controlled. The uncertainty is caused by interference with upstream or downstream products and other orders in its own process. So that we can't be sure whether we can follow the plan.

The order of the offset stamped product box has a complicated process at the order information and material preparation stage. For an order with a cycle and no revision of the process requirements, the work of uncertainty can be omitted and the semifinished product preparation process can be directly entered (temporary material shortage Except, and once the emergency purchase procedure is entered, the delivery cycle will increase exponentially. In the case of a new order, the work to be prepared before and after will be very complicated. A single evaluation will be required and a detailed plan will be made. The core is the completion time of floor plans and structural drawings. They determine the completion time of the mold until the completion of the two materials (offset panel, four-layer cardboard). These two aspects involve the planned connection of processing units. From a planning point of view, it is most appropriate that both materials are completed at the same time and arrive at the carton processing site. The completion of the two materials, the longest time for the key chain, need protection.

The order of the offset printed board finished product box is a continuous process in the pure carton processing link, and its progress is determined by the internal planning of the carton processing unit, and the fastest processing is the non-floor processing of the material (without stagnation). The provision of the die-cut version must be preceded by the preparation of the blanking process. The general control method is to treat it as the third material in the carton processing unit. In the three processes of the carton processing process, preparation time for the other processes is negligible except for the preparation time for the punching plate.

Actual planning. In fact, there are 3 lines in the front road (information and materials section) and 1 line in the back road. The combination of the longest and the trailing of the 3 lines is the total process time. We use the product as the main classification basis to structure the time laws of the relevant operating units in the lines through which they pass, and then assemble these times according to the route of technological activities until they are finally delivered to the customer's storage location.

If a factory happens to have all the equipment needed for the production of the offset-finished box, there is no other production task. There is ample inventory of the materials required for order fulfillment. The sum of the total working time of this order is safe at the time of final delivery. Within the area. Then it can calmly accomplish this task, even perfect. However, there are such simple things in the world? Usually, the situation we need is much more complicated than the situation of this single order, and even the number of geometric poles! We can think that an order is a project. The order of hundreds of large and small orders a day is actually hundreds of items. How complicated is the shuttle between dozens of devices and dozens of individuals, although each of their operating details may have standard operating instructions.

The complexity of the system is determined by the entropy of the elements. The more elements interlace and flow, the more chaotic the order, the higher the entropy, and the complexity of the system. It is even more elusive. In essence, we see that the order between elements is still the order of the elements, which is the order of the key chains. Knowledge is only attached to a chaotic order, and it has a distinctly hidden nature; otherwise, most of it must exist in an explicit manner. How to make implicit knowledge explicit? The first thing to do is to order elements, and then there are several issues of knowledge itself. How to order the elements? Our approach is to consolidate products into similar items, leaving key chains spatially independent and unique in resource space in a single space-time. It is like a seat on a bus. In the running time between two stations, the space of less than half a cubic meter is exclusive to you, and changing a time and space is not yours. Therefore, the so-called order of elements is essentially the order of capabilities. The order of capabilities is colluded through the key chain of homogenization and is in the tunnel of time and space.

Relationship presets are the core of "soft proofing"

The relationship preset is the core of "soft proofing", that is, according to the requirements of the product realization process for the capability unit, prior link planning, which is a resilient link. On the one hand, through business activities, certain conditions of the capability unit are locked, and rules for occupying its time and corresponding activities are obtained. On the other hand, the rules for the interaction of adjacent capacity units on this link are determined, similar to the meaning of interfaces. . In this way, after a preset relationship is established, customers' orders can be responded to at any time and the product realization process can be immediately driven.

At the same time, we also very clearly see that modern personalized products are not always available as fixed programs. Then, on the processing of relationship presets, it will be more resilient, that is, more ability to connect the design (essentially the design of the process activities on the mold) capabilities and production capabilities. This is a service model of a secondary supply chain to a main supply chain. In terms of design and production, it is virtually impossible to clearly describe which one belongs to the second and which one belongs to the main body. This is a bit soft and gentle.

Ability unit is the main object of relationship preset

Relational presetting is a very specific job, just like the construction of a species's genes, so that our products will have vitality and become the customer's dependence.

The importance of relational presuppositions is to allow organizations (combinations of larger capacity units) to have a relatively stable production order and to meet customer needs on this basis. In other words, the customer's demand is not to enter the production system all of a sudden. This preset has a business process based on the business basis. This process is obtained through the intervention and compromise of customer requirements, so as to obtain the business unit continuity between the capability unit and the customer. For most enterprises, besides facing the final consumption, In addition to the activities of the participants, most of the work is focused on the business synergy of multiple sets of capability units.

While considering the output of one's own ability, the capability unit must also consider the frequency relationship of the output types, which directly determines the level of benefits of the unit after paying the labor. For example, a large capacity unit consisting of 3 ink-jet printers (3 capacity units) meets the needs of 120 customers with more than 1000 products. There are more than 30 kinds of these products in the printing color combination for ink printing machines. In fact, more than 30 color combinations are the basis for their type change. Ink replacement requires the cleaning of the ink cartridge (a completely non-value added activity). This job must be performed with the printer stopped. Therefore, the control of changeover is a natural requirement for the ability unit to maintain its enthusiasm. However, the production unit often passively performs the order task that the sales department undertakes, and the complete production according to the single order is likely to result in frequent type change. This not only causes material waste, but also discounts the delivery time guarantee.

In this case, relationship presetting is very important. First analyze the situation based on the combinations of more than 30 colors, understand the demand and demand cycles of orders for them, comb out the basic frequency distribution map, and take time to separate the three frequency units, like the processing of flight schedules. Like the method, the hotline can have several classes every day. For example, a pure black color can make a capacity unit maintain the frequency of 1234567, and it is a double shift. This ability unit also bears the black and red and black and blue groups.