Procedures or Work Instructions on Roll Flagging for a flexible packaging company

[Compact]

We are a flexible packaging company. We print laminate and slit.
Does anybody have any procedures or work instructions on Roll Flagging? in my company we are facing a problem, the procedure isn't being followed correctly. I want to check if there's fault in our procedure or in the operators.
Many times we are sending to our customers rolls that are not cleaned correctly. Flags are skipped sometimes.
How can we solve this problem? any ideas?

[Claes Gefvenberg]

In Reply to Parent Post by Compact

How can we solve this problem? any ideas?

Perhaps by making it impossible to get a shipping order before the flag has been printed?

What does your current procedure say, btw?

/Claes

[Compact]

Claes i think you misunderstood me. To make myself clear, When we are printing an order, let's say there's a roll change, or a defect, the roll is flagged so that the next process knows there is a couple hundred feet of defects. They're supposed to remove these defects and continue. Thats what i mean by roll flagging.
our procedure now explains it like i just did above. if you see defect, stop fix, put red flag and continue printing (or laminating). the finishing section should provide a clean finished good to the customer. This is not always happening, sometimes the operators are not cleaning the flagged areas properly, or they are ignoring them. I'm not sure. I am looking for a solution. perhaps a dumb-proof way to ensure that every defected area is flagged and every flagged area is cleaned.

[Claes Gefvenberg]

In Reply to Parent Post by Compact

Claes i think you misunderstood me.

Yes, I definitely did. Thank's for explaining

In Reply to Parent Post by Compact

I am looking for a solution. perhaps a dumb-proof way to ensure that every defected area is flagged and every flagged area is cleaned.

Yep, you seem to be on the right track, but no idea on how to solve it comes to mind right now. Let's see what the rest of the Cove can come up with. We have a lot of very creative people here (That should get people going ).

/Claes

[CarolX]

Hi Compact and welcome to the Cove,

I would start with your procedure and perform a process audit. Find what works and what doesn't work. Talk in depth with the operators and find out what is preventing them from doing their job. Look for new solutions from the people performing the operations.

Hope this helps a bit.

[blue moon]

My dear you have many problems in

1- Quality Control System
2- Corrective / preventative Action
3- Internal Audit

sure also you have a problem with customers and their satisfaction is not high, start using the easy and simple way in quality ( Seven Quality Control Tools )

like check sheet , fish bone and control chart

and solve your problem using 8D or 5W , and you must ask operators and workers to participate with you

i have a previouse experience in Egypt with a courrogated box factory we was printing with flexo printers

now i am near you in saudi arabia , i am happy to support you