Six Sources of Production Costs in Iron Printing Workshops
Since we want to reduce production costs, we first need to identify where the costs will occur. Generally speaking, the manufacturing cost of the iron printing workshop mainly comes from the following six aspects.
Raw materials mainly refer to substrates such as iron and aluminum.
Accessories such as: coatings, solvents, inks; rubber rollers, plates, blankets, etc.
Water, electricity, including oven fuel, etc.
Equipment maintenance Including repairs, spare parts inventory, etc.
Equipment depreciation involves equipment utilization and productivity.
Labor is worker salary, insurance, benefits, etc.
Five aspects to reduce production costs
After clarifying the main sources of production costs in the iron printing workshop, we will analyze which links have a larger space for cost control, so that we can effectively control the right medicine. Specifically, it can be analyzed and improved from the following five aspects.
Make the best use of people That is “everyone has something to do, everything is done by someone”. The most serious waste in an enterprise is often the waste of labor. Many ordinary workers or new employees, because they are not familiar with the equipment or the technology, often only do what the foreman says. When you’re idle, you don’t know what to do. Although the salary of ordinary workers is not high, in addition to reducing work efficiency, labor waste will also cause dissatisfaction among other people and affect the enthusiasm of the entire team.
The improvement method is to train all post personnel, make corresponding job descriptions, job responsibilities, and conduct corresponding job appraisals and performance appraisals. Only in this way can employees become proactive and achieve “everyone has something to do, and everyone does everything”.
Maximize equipment utilization and work efficiency Generally speaking, if the customers of the iron printing company are relatively stable and the manuscripts are more complex, one single-color machine, one two-color machine and one multi-color machine should be equipped to maximize equipment utilization. In this way, the equipment can be fully utilized according to the process requirements, and the process of some manuscripts can be optimized, or the number of model changes can be reduced by methods such as centralized production of the same process.
In addition, in order to improve the working efficiency of the equipment, the school bus data, ink ratio, and scale of the coating film thickness should be recorded for the manuscripts that are often painted, so that the time for changing models and school buses can be reduced.
To reduce the waste of drying furnace fuel, the following three improvement measures can be taken to reduce the waste of drying furnace fuel.
First of all, when the downtime of equipment failure maintenance or manuscript change exceeds 30 minutes, the furnace fire of the oven should be turned off in time to reduce the waste of gas when the furnace is empty. Or add some automatic devices, such as using PLC, time relay and other automation equipment to determine the length of downtime and automatically turn off the fire, which can not only reduce the waste of gas, but also avoid the abnormality caused by the negligence of personnel forgetting to ignite when restarting.
Secondly, for a drying oven with a closed bottom and a flower stand preheating function, the preheating of the flower stand can be improved as much as possible without affecting the manuscript. Since the heat of the preheating function of the printing iron oven is generally derived from the excess heat in the drying furnace, it not only avoids the waste of excess heat energy in the upper drying room, but also can use the preheating function of the flower stand to increase the temperature in the drying room, that is, Save fuel costs.
Third, it is necessary to regularly check and clean up the agglomeration in the drying furnace. The drying furnace often agglomerates due to incomplete combustion and other reasons, which will not only cause dust and black spot pollution on the painted iron sheet, but also affect the drying process. Drying effect and waste of fuel.
Optimizing the inventory of equipment parts Many factories often encounter these problems: equipment failure, parts must be imported from abroad, or local suppliers temporarily have no spare parts, resulting in long-term downtime of the production line. If you buy a lot of parts in advance for spare, it will not only increase the inventory cost, but also easily cause the parts to rust and damage if they are not used for a long time. By following the following five principles, it is possible to reduce the inventory of spare parts and avoid the trouble of temporarily not having spare parts due to equipment failure, that is, to optimize the inventory of spare parts.
First, spare parts inventory can be reduced or even zero inventory for parts that have little impact on production.
Second, for spare parts that have a greater impact on production, if it is easy to purchase, inventory can be reduced or even zero inventory.
Third, parts that have a great impact on production, are not easy to buy, and have a high failure rate can be shared if there are partners in the industry nearby. For example, some spare parts for motors or reducers can be stocked according to different models, so that both It can reduce the cost of parts inventory, and can be used in an emergency when a failure occurs.
Fourth, if some spare parts can be replaced by domestic products, try not to import them. At present, the manufacturing capacity of domestic iron printing equipment has been greatly improved. Unlike more than ten years ago, many parts were imported from Japan and Germany.
Fifth, strengthen the management of spare parts inventory, establish a safety stock system, and conduct regular inventory.
Controlling the loss rate of raw materials (substrates) Plain iron (substrates) is the most important raw material in an iron printing workshop, and it is also the first cost. Controlling the amount of plain iron used is also equivalent to controlling the loss rate and quality rate. The use of plain iron can be controlled from the following points.
First, recycle the protective plates of the upper and lower layers of plain iron. Generally, there will be protective plates on the upper and lower layers of plain iron. These protective plates are generally abnormal, and there are many kinds of abnormalities. Of course it is not usable if the appearance has been distorted to the point where it cannot be painted. But if there are only slight flaws in appearance, and these flaws can be covered up by printing or coating, it can be applied to some less demanding manuscripts (such as miscellaneous cans).
Because food cans and beverage cans generally have strict requirements, some plain iron defects cannot be recognized by the naked eye, but will affect the subsequent canning or preservation effect of cans. Therefore, it is recommended that food cans and beverage cans should not be recycled to use protective plates.
Second, the iron sheets that have been printed and painted but have not been baked in the furnace are cleaned and reused. In fact, many iron printing workshops are doing this, but the cleaning methods are different – some are manually cleaned, and some are cleaned with an iron washing machine. Regardless of whether you use machines or manual recycling and cleaning, you must strive to make the cost of cleaning lower than the cost of recycling iron sheets. Therefore, if the number is not large, try to use manual labor, otherwise it is more cost-effective to use machines.
Third, regularly analyze the causes of loss and formulate relevant preventive measures. Generally, iron printing products need to go through 3~5 coating and printing processes, and each process needs to go through 6~7 equipments such as feeding table, conveying table, coating machine (printing machine), drying room, cooling area, iron collecting machine, etc. , In the process of conveying and folding, every place may have traffic jams or poor conveying, resulting in loss of iron sheets. Therefore, it is necessary to convene on-site personnel on a regular basis (if possible, try once a day) to review and analyze the processes and parts with more wear and tear, and formulate corresponding countermeasures.
To control the manufacturing cost of a factory, in short, it is nothing more than increasing revenue and reducing expenditure. If it can manage well and implement it effectively, so that people can perform their duties and make the best use of everything, then it can reduce manufacturing costs and save energy and protect the environment. Purpose.