I have a lot of problems with customers when they ask me to show them any stadistical control when I print labels. Even they ask for PPM's.

Let me show how my process works, I set up the material needed, such as ink, adhesive, polyester, in the machine and I need some material to adjust the set up, this is not considered as a scrap, 'cause I need to do this.

Once this is done, machine prints hundred of labels in minutes, then I move the huge roll to make small rolls according with my customer requirements. While the operator is counting the exact labels for one roll, she is making a quality inspection to detect dot, misalligned, color differences, etc and write it down in one report.

I have convinced my customers with this report, but this tells me a little bit of how my process can be controled and improved.

Any ideas of how to do SPC.

Thanks,
Antonio

I have a lot of problems with customers when they ask me to show them any stadistical control when I print labels. Even they ask for PPM's.

Let me show how my process works, I set up the material needed, such as ink, adhesive, polyester, in the machine and I need some material to adjust the set up, this is not considered as a scrap, 'cause I need to do this.

Once this is done, machine prints hundred of labels in minutes, then I move the huge roll to make small rolls according with my customer requirements. While the operator is counting the exact labels for one roll, she is making a quality inspection to detect dot, misalligned, color differences, etc and write it down in one report.

I have convinced my customers with this report, but this tells me a little bit of how my process can be controled and improved.

Any ideas of how to do SPC.

Thanks,
Antonio

How many labels / how much square footage is rejected after mfg.?

How close do you have to be on your indexing targets?

Do you analyze for color? Hue, density, brightness?

Label stock - weight, Cobb test, tear strength?

Rub tests for print?

Peel tack tests on the adhesive?

Adhesive coating weights?

I'm not saying that all or any of these are critical to your operation or the customer's fitness for use. But they may be - and they may be a place to start.

Parts Per Million = ((Qty Parts Scrapped+Qty Parts Reworked)/Parts Manufactured)*1,000,000

This gives you the total of possible defects per million.

How many labels / how much square footage is rejected after mfg.?

I'm working on this 'cause we can produce 10,000 labes in 5 minutes, and it is difficult to see defects here. I have another machine where I can see defects and in here I'm documenting the data. I have a big roll with 50,000 labes, I can do SPC per roll but this will be a headache if the roll contains 500 labels.

How close do you have to be on your indexing targets?
The target is no more than 2%


Do you analyze for color? Hue, density, brightness?
Yes, I have a spectrophotometer.

Rub tests for print?
Yes

Peel tack tests on the adhesive?
Yes