Quality Control Operations


Managing Film production l-2

Job description and allocation of duties for each unit, intra organizational networks and influential factors in every unit are as follows (in terms of point of limitations or intervening planning factors):

-Orders are registered with regard to scheduled delivery and production time that are according to the production capability declared by the production planning unit, thus, avoiding impossible delivery scheduling.

-Production plan of all the available machines is submitted to sales unit by planning unit on a weekly basis, and reporting the capacity of the machinery to be considered for further order registers.

– Every customers’ unique needs along with general requirements of the ordered product are reported to the quality assurance unit by sales unit to be considered and fulfilled in production processing.

– The customer is contacted in case of any required changes for obtaining (written) permission in order to apply new planning or group technology method which offers benefits to manufacturing in many ways.

– Proceeding with lateral services related to product manufacturing including solution design; and submitting them to the plant or considering follow-up financial affairs, so that production proceeds without interruption.

Logistics and Sales Unit:

-Supplier of raw material and required production services according to production control unit.

-Supplier of required peripheral items especially solutions, or other requirements made by production control unit.

-Supplier of maintenance and repair unit requirements to prevent delays caused by lack of defected part or required repair service.

Maintenance and Repair Unit:

-Quickly repairs equipments which are broken down due to technical problems; requests and tracks spare parts needed for replacement or stock charging.

-Basic maintenance for defined periods of time, regular service of machines and lateral installation.

Film Production Station:

1. Thickness Parameter:

-For the ease of adjusting optimal product’s thickness in film production process, the best approach is to program from thicker to less thicker products, as the same applies in reverse, in order to minimize the waste.

-In addition to what is mentioned above it needs to be clarified that while the machine is off and needs to be started for production process, it should be programmed from high to low thickness because starting the production with low thickness increases the waste due to burnt materials and sensitivity of lesser thick products.

-Moreover, when the machine is off, never start it with a program of less than 50-micron thickness production; especially when a transparent color is chosen.

2. Color Parameter:

– Since transparent and light yellow colors are the major products’ colors, the following notes should be considered.

– The machine should start with light yellow color to have easier regulation and lesser waste.

– Shifting production from transparent into light yellow color will have lesser waste compared with light yellow to transparent shift.

– In case of stoppage of machines, it should be noted that the last production phase is with transparent color, if the machine stops with light yellow color, the operator ought to discharge the whole light yellow color material by adding transparent color material, hence the production has high waste.

–  Products with light blue color should be produced after the production of transparent color products or at the time of machine’ start, because those materials have low customer order and used mainly in industrial covering following sealing.

3. Width Parameter:

-Generally, it is easier and with less waste if the production is programmed from low width into high width shift, in this case a stoppage or non-stoppage of machine process does not matter. But note that when the thickness of both shifted products are the same; in that case it is more beneficial and generates less waste when the shift is from high width into low width products.

4. The Type of the Product Parameter:

Priority of the type and material of the product in terms of waste reduction and easy production:

a. Bottom sealed and side sealed mega-sacks and custom printed bags.

b. General purpose 3- layer polyethylene films.

c. Shrink films utilized in packaging of food industry and others.

d. Laminated polyethylene films.

e. Thermal films.

f. 3-layered self-adhesive polyethylene films.

g. Black/white 3-layered polyethylene films.

h. FFS industrial sacks for petrochemical packaging.

5. Material Parameter:

This parameter is somewhat present in number 4 and is included in the priorities mentioned above. Apart from the limitations mentioned above, it generates no more limitations in production programming unless there are some problems in material supplies.

Cutting Station:

-There are no parameters to be considered in programming of this station, therefore just general guidelines are considered.

Printing Station:

-Programming printing is not dependent on the width and thickness of the product.

-The most important thing to consider is that the films and rolls required should be produced primarily and in sufficient number and tonnage; then printing process should begin. Therefore, the printing process is not deferred due to film production disruption which results in waste duplication that is a coefficient of printing times for the order. For example, normal printing waste for 5000 ton items is 20 kilograms, while the same tonnage being printed in three intervals generates 60 kilograms of printing waste.

– Regarding the number of colors used in printing, it is best to start printing program with the products having wider range of colors to programming of products with narrower range of colors. Since shifting from 8 colors to 6 colors increases the chance of colors sameness, the need for  cleaning the drum, etc, and resetting the machine decreases. However, starting printing program from 2 color to 5 color products decreases the chance of repeated colors. Generally, the decision should be made according to customer’s approved sample or a printed version of sample on the paper submitted to production line by sales unit or the customer. Thus, the process should be arranged in a way that any shift in production follows the least change of colors in ink tanks which contributes to less waste generation, less items used such as drum washer, etc.

-Generally, the printing program should start with matte or dark color products which results in easier machine adjustments and less waste and then continue to the products with transparent background with respect to the shades (the amount of darkness and clearance). Note that printing BOPP rolls should be placed at the end of printing program.

Sealing Station:

-The selection of products according to their thickness, width or materials to be sealed makes no difference in programming, because stopping the machine to be restarted for sealing the next product generates no waste.

-However, to reduce production time and increase personnel efficiency, the products should be sealed in an order which considers the kinds of sealing they need and the type of product’s handle. In other words, those products which are similar in these respects should be produced respectively in the program. Therefore, the time needed for resetting the sealing machine for a new program decreases.

Storage Station:

-Required measures taken to provide vehicles for distribution.

-Required measures taken for preparing, packaging and weighing the product and issuing good distribution receipt.

-Proceeding with financial unit for pricing and issuing distribution permit.

-Ordering and receiving raw materials and other necessary items at an arranged time and delivering the supplies to production unit.

-Ordering and proceeding with any necessities and charging the stock in case of shortage of stored items of repair items and other.

Quality Assurance Unit:

-Always present at the production lines to make sure the products conform to custom requirements and prevent unwanted repetition, waste generation or non-compliant items.

-Counseling the planning unit to improve the plans for better efficiency and greater exploitation.

-Counseling logistics and sales unit to select and buy proper raw materials, because the low quality of the materials may cause mismatch, and to avoid storing unusable raw materials.

-Documenting production process in all lines; so that it could be repeated and in optimal way it will increase the efficiency of the process in following orders of the same product.