Professional Documents
Culture Documents
Dryer
Press
Rewinding
Unwinding
Figure 1 gravure printing process
The methodology used in this study composed of five steps: quality problem definition, root causes identification, problem-solving
generation, selection of alternative application, and evaluation. Along with these steps, the employed quality tools shown in table 1.
Tools/Techniques
Process flowchart
Graph
Brainstorming
Cause-and-effect diagram
Questionnaire
Pareto diagram
Brainstorming
Brainstorming
Tree diagram
Affinity diagram
Design of Experiment
Phase IV: Selection of alternative application
Phase V: Evaluation
Brainstorming
Brainstorming
Use
To provide a diagrammatic picture of the focused process
To show the quantitative data
To summarize the focused problem
To determine and break down the potential causes of the
problem: material, machine, method, people, etc.
To relate the important priorities of problem causes by
individual importance ranking
To focus efforts on the root causes of problem from
importance ranking
To summarize the root causes of the problem
To find the ranking of possibility causes of the focused
problem from members in the team
To generate the problem-solving alternatives
To allow the team to summarize groupings among
problem-solving alternatives
To estimate the main effects and interactions of factors
which affect the focused problem
To develop the action plan and implement
To evaluate and summarize the results
Supplier
Material
inspection
Blowing
Slitting
Gravure
Printing
Conversion
Quality
Inspection
Packing
Customer
Causes
Solutions
Design of experiment
Factor
Temperature of printing unit no.7
Temperature of printing unit no.8
Web tension
Level
Low (-1)
50
50
15
Unit
High (+1)
70
70
20
C
C
N/mm.
Response:
The parameter observed in this experiment was the number of overlapping printing defect. It was not the percentage of the defect because
the defect inspection of the case study would finish after packing process. Therefore it was not detected in a real time, but it could be
detected the number of defect in every roll after finished print instead by using the specific inspection machine which works by using the
image processing principle.
Experiment Plan:
The experiment was done under the randomization by using MINITAB program to generate the random sequence such as table shown in
table 3. The sample size was three replicated due to the limited plastic film roll of the case study, therefore the total runs of this
experiment was equal to 3x23 = 24. The sequence and output of each run shown in the figure 3.
A
(Temp1)
-1
-1
-1
1
-1
-1
-1
1
1
-1
-1
-1
1
1
1
-1
1
1
-1
1
1
-1
1
1
B
(Temp2)
1
-1
-1
1
-1
1
-1
-1
1
1
1
1
-1
1
-1
1
-1
1
-1
1
1
-1
-1
-1
C
(Tension)
-1
1
1
-1
-1
1
-1
-1
1
-1
1
1
-1
1
1
-1
1
-1
-1
-1
1
1
1
-1
Number of defect
11
8
10
13
9
15
7
11
18
13
16
12
13
17
12
13
15
12
5
10
14
9
13
9
Data analysis:
The data in table 3 was analyzed by using the ANOVA in MINITAB processing shown in the table 4. From the result of ANOVA could
interpret as shown in the figure 11 that the main effects included the temperature level on the heater of printing unit no.7, the temperature
level on the heater of printing unit no.8 and the web tension, and the interaction between the temperature level on the heater of printing
unit no.7 and 8 affected to the number of defect.
Table 4 Analysis of variance for overlapping printing defect in coded units
Source
Main Effects
2-Way Interactions
3-Way Interactions
Residual Error
Pure Error
Total
DF
3
3
1
16
16
23
Seq SS
157.458
23.792
2.042
47.333
47.333
230.625
Adj SS
157.458
23.792
2.042
47.333
47.333
Adj MS
52.486
7.931
2.042
2.958
2.958
F
17.74
2.68
0.69
P
0.000
0.082
0.418
Figure 12 Main effects plot and interaction plot for overlapping printing defect
5.2 Work instructions development
Work instructions were developed from the standard steps of printing process shown in figure 6 include the web inspection process, the
gravure cylinder setting process, the ink formulation process, impression roll setting process, machine and equipment checking process,
web loading process, machine preparation process, printing operation process, problem solving between operation process, and quality
inspection process. Figure 13 provides an approach to establish the work instruction step.
No.
1.
2.
3.
4.
Task description
Printing
step
training
Reconsider the overall steps of each operator
Perform along with the established work instruction
Performance
Responsible person
Printing leader
Printing machine leader
Printing machine leader
Team members
evaluation
7. EVALUATION PHASE
The results from the problem solving application include the parameter setting of the temperature level and web tension, and the work
instructions performance will be described in this phase.
7.1 Result
After finished due date of the problem solving implementation, the outcome was revealed that the average number, the average
percentage of the overlapping printing defect, and the average processing time of printing operation were reduced 27.12 points per roll
per month, 14.94 percent per month, and 8.87 minutes per roll respectively (see table 6).
Table 6 Result from problem solving implementation
Outcome
1) Average number of overlapping printing defect (points/roll/month)
2) Average percentage of overlapping printing defect (%/month)
3) Average processing time of printing (minutes/roll)
Before
35.14
27.60
37.26
After
8.02
12.66
28.39
Difference
27.12
14.94
8.87
Ease of use
Suitability
Easy
Easy
Easy
Not easy
Easy
Not easy
Easy
Easy
Difficult
Suitable
Suitable
Suitable
Suitable
Suitable
Suitable
Suitable
Probably suitable
Suitable
Implementation probability
after study
Probable
Probable
Probable
Probable
Probable
Probable
Probable
Probable
Not probable due to
statistical analysis requirment
8. CONCLUSION
In this study the problem solving alternatives of overlapping printing defect in gravure printing process of plastic packaging were
generated including the design of experiment and the work instruction development. From the design of experiment found that the
temperature level on the heater of printing unit no.7, temperature level on the heater of printing unit no.8, web tension level, and
interaction between the temperature level of printing unit no.7 and 8 affect to the number of overlapping printing defect, and the suitable
level of those factors were all in low level. After the work instruction development and implementation revealed the average number of
defect and the average percentage of defect were decreased. The unexpected outcome was the reduction of the average processing time.
However, there are some limitations due to this research scope of the focused process (gravure printing) and the focused machine (only
one gravure printing machine was observed).
9. REFERENCE
Bergman, B. and Klefsj, B. (1994), Quality from customer needs to customer satisfaction, McGraw-Hill, Sweden.
Chandra, M. (1993), Total quality management in management development, Journal of Management Vol.12, No.7, pp.19-31.
Gravure Education Foundation and Gravure Association of America. (2003), Gravure process and technology, Quebecor World Inc., KY.
Hagemeyer, C. H. and Gershenson, J. K. (2006), Classification and application of problem solving quality tools, The TQM Magazine
Vol.8, No.5, pp. 455-483.
Montgomery, D. C. (2005), Introduction to statistical quality control, 5th edition, John Wiley & Sons, New Jersey.
Park, K, and Ahn, J. H. (2004), Design of experiment considering two-way interactions and its application to injection molding
processes with numerical analysis, Journal of Materials Processing Technology 146, pp. 221-227.
Siam City Bank Public. (2550), Thailand Packaging Bag and SagGrowth in importDecline in export, Bangkokbiznews, [Online]
Available at: http://www.bangkokbiznews.com/2007/03/30/WW02_0209_news.php?newsid=62016
Spring, M., McQuater, R., Swift, K., Dale, B. and Booker, J. (1998), The use of quality tools and techniques in product introduction: an
assessment methodology, The TQM Magazine Vol.10, No.1, pp. 45-50.
Wikipedia. (2008), Rotogravure, Available at: http://en.wikipedia.org/wiki/Rotogravure