The Quality Improvement of Die Cut Machine: A Case Study of Sticker Roll Manufacturing Industry

  • ธนวรรณ อัศวไพบูลย์ Rangsit University

Abstract

The aim of this research is to improve the quality of die cutting process in the digital label print production. At the beginning of the process improvement, the data collection of the defects and problem analysis with QC 7 tools was conducted. Check sheet, graph, and cause-and-effect diagram are the three of QC 7 tools that are implemented to analyze the correlation between the die cutting speed, the die cutting force, the types of die cut, and the defects. The maximum number of defects in the cutting process was 60373.35 meters or 45 percent of the total defects in the digital print production line. The conveyor speed and die cutting force observed from the process were 33 m/min and 30 Psi respectively for all die cuts used in the production. In general, the die cuts can be separated into three groups which are fancy, round, circle. The amounts of defects based on the fancy, round and circle die cuts were 27040.13, 15418.45, 17914.77 meters or 44.79%, 25.54%, and 29.67% of the total defects in the digital print production line respectively. The further investigation on cause-and-effect of the defect shows that the conveyor speed and die cutting force are not suitable for each type of die cut. Hence, the parametric study of die cutting process based on the conveyor speed in the range of 31-34 m/min and die cutting force in the range of 29-32 Psi is conducted. The experimental results show that the number of the defects has strong correlation with the conveyor speed and die cutting force. The minimum number of defects from the fancy-typed die cut was found at the conveyor speed of 32 m/min and die cutting force of 31 Psi, the round-typed die cut was found at the conveyor speed of 31 m/min and die cutting force of 32 Psi, and the circle-typed die cut was found at the conveyor speed of 32 m/min and die cutting force of 30 Psi. The minimum number of defects for the fancy-typed, round-typed, and circle-typed die cuts were 453.74 meters or 10.05% of 4,512.85 meters of production associated with fancy type, 827.91 meters or 10.88% of 7,606.89 meters of production associated with round type, and 703.32 meters or 11.37% of 6,187.52 meters of production associated with circle type.

Published
2022-09-05