How to use fixtures to improve production

Foreword: The printing of color boxes and children's books is an industry that requires a lot of workers. Due to the domestic reform and opening up, a large amount of cheap labor and land are provided to attract investment from Hong Kong companies. They use domestic advantages to accelerate the move of Hong Kong's printing industry to the international market, and have also become one of the world's four largest printing centers. However, the production costs in South China such as wages, land rent, miscellaneous fees, taxes, etc. have continued to increase, and the domestic printing industry has developed to the level of Hong Kong in recent years. In order to maintain its competitiveness, the printing industry in Hong Kong is nothing more than using methods such as “opening up income and reducing expenditure”. "Open source" means the development of new customers, new technologies, and value-added services (Value-Added Service), while "throttling" is how to reduce costs, such as relocating factories to more northern places or reducing manpower.

However, investing in domestic printing companies now has hundreds to thousands of employees, and the Ministry of Labor accounts for more than half of them. The so-called cost-cutting is to use some methods to increase production, or use machines to replace labor. This article aims to introduce some simple fixtures to achieve the goal of saving manpower, reducing waste, and increasing production.

Fixture introduction:

The definition of the fixture is very wide, simple as the positioning of the "backing" - idling clips, rubber rings, and even complex such as pneumatic devices, robots, automatic feeding system, fiber optic eyes, etc. can be said to be fixtures. The use of fixtures for printing is mainly to assist production, increase production, reduce waste, and does not completely replace manpower.

1. CNC XY table:

Many companies will contact the children's books in the following books for children's books or color boxes to put film on toy box orders. The method of production is nothing more than wiping the edges with glue, and then sticking the object or film. The advantages are flexible and low cost, but they produce slowly and have a low defective rate. They must even rely on skilled workers.

Some factories use screen printing glue to process toy box. The advantage is that it saves time and rejects, but they also need to make films and screens, and the screens are sometimes blocked or broken, so the production cost is very high. It also takes place to save the grid.

See http://

See http://

See http://china.alibaba.com/athena/homepage?id=qilingtoys

In fact, the electronics industry has used “NC XY Tables” to help their glue on circuit boards for many years. The method is to use computer to deposit data (such as Auto Cad). “CNC XY” will operate according to the instructions. The files can be produced immediately after they have been extracted. For example, ATTA Technology Ltd (http://), this product appeared long ago. However, these machines have a very small coating area and are not suitable for color box production.

See http://

In fact, as long as the two pneumatic reeling devices are connected together with the pneumatic glue pen device, the above effects can be achieved. SMC (http://) "CY1H Series" and FESTO (http://ftp.festo .com/) have these equipment.

See http://ftp.festo.com/

In simple terms, the principle is to modify the plotter's drawing pen into a glue pen.

See http://

In recent years, SMC's technology has lowered the price of pneumatic coils, and it only costs 50,000-60,000 yuan to be a "CNC XY Stage" automatic coating glue device. For example, a person applies the glue for 30 seconds, and these "digitally controlled XY tables" automatically apply the glue to the device only in less than 2 seconds. If you work 10 hours a day, these "CNC XY" automatic glue dispensers can produce 18,000. Instead, we have to spend 15 workers to reach this number. If this machine were to be operated by two people, the production volume increased by a total of 15 times but 13 workers were saved. If each worker pays $600 a month, it will be almost 8 months (60,000/(13 workers x 600) = 7.69 months). Although the first-time cost is higher than that of manpower and screen printing glue, the low scrap rate, flexibility, and shortened production time will not hinder the place. It will be cost-effective to eliminate the cost of screen printing each time.

2. Press book tool:

When a child's seal or color box is glued, it is covered with small objects or film, and then pressed with a heavy object such as a book press. The disadvantage is that the entire platform is semi-manufactured. Workers do not deactivate tools to press on them. As a result, they are very tired but unstable. Some factories use a book press to press the product, but the workers do not have to press it for the sake of production. As a result, the product is unstable.

Http://

The cylinder device of SMC and FESTO can compact each product independently. If several cylinders are connected in a rotary bowl, one will generate stable power, and the table will be sorted, and products can be produced regularly.

See http://ftp.festo.com/

In the case of color boxes with film, if we combine the “NC XY table”, press tools, and transport belts, it will become a labor-saving, labor-saving, and provincial-level assembly line.

The method is to use a worker to control the “NC XY table” and then send the “press book tool 1” worker to post the film. The “press book tool 1” worker takes out the pressed box and places it on the flowing water line, and then presses it. One had just put a film on the color box, and the other had applied the online streamlined box to the edge of the box with glue; he then delivered the “press book tool 2” box and compacted the box with a book press tool. The entire process uses only 4 workers and 4 to 6 seconds to complete a box. If the traditional method of production, it may take 8 to 10 workers to complete a box takes 40 to 60 seconds. The table is full of color boxes, and its pass rate is not more than 90%. This streamline is most effective in making a seal with attached objects.

Of course, the best effect is to press the cylinder device, but the cost is also high. In fact, the "quick clip" can replace most of the cylinder devices, and its cost is only 60 yuan per one.

If 8 to 10 "quick clips" are assembled into a rotating pot, the cost will not exceed 2,000 yuan. In contrast, the rotation of the cylinder device may be as much as 10,000 yuan.

3. Other tools:

The Keyence (http://) PZ-V/M series photoelectric sensors are very useful for our inspection of products. For products such as prints and gadgets, this sensor can detect whether it has been missed.

See http://

In addition, this sensor can detect whether there is a problem with the book plywood, such as missing more hands or turning over. If the designated position of each spine is printed in black, the trapezoidal color scale is formed after the entire book is plywood. In this case, if the sensor fails to measure the specified color scale, it can be believed that the book is in error.

In addition, I have used Keyence's FS-V20 series of dual-value display digital fiber sensors to solve the problem of digital gaming. Take the example of a "Monopoly" game. The game inside must be accurate. However, there is often a big error in the assembly of the manpower. Even if the manpower is used for re-examination, there will be an eye-popping situation. The digital optical fiber sensor can accurately count the accuracy of the game, and the price is only 2,000 yuan.

However, the disadvantage of the digital fiber sensor is that it can detect only 210 grams or more of paper, otherwise it is easy to make mistakes. Although the price of Keyence's CV-700 image system is as high as 50,000 to 70,000 yuan, it can detect printing paper as thin as 128 grams, and can average 4,000 sheets in 5 minutes. This system took only 10 months to return to the original ($600 a month x 10 workers) than some companies today use more than 10 people. Actually, this imaging system is very versatile. It can detect alignment, missing prints, dirty, and some simple colors. At the exhibition, the author once saw that someone converted it into a "zinc plate to cross system" for sale.

The difficulties faced and solutions:

The printing industry has spent a lot of time on issues such as paper, ink, and machine operations, and it cannot be spent on fixtures. In fact, these fixtures spend a lot of time developing, researching, and tuning. They do not buy components to install them. If we spend time on these issues, the opportunity cost will be very high.