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Printed carton quality

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  • #52876

    Angela Godwin
    Participant

    I am the sourcing mgr for an electric heat mfg.Β  We use lots of retail packaging and we need to know what is the proper way to measure quality on a printed carton supplier.Β  Should we measure strictly by PPM?Β  I cannot get our supplier to run at an acceptable PPM level for our QA dept.Β  Our target is a PPM of 1200.Β  We recvd apprx 290k cartons in Q3 and we had apprx 4800 rejects.Β  So they had a PPM of 16,551.Β  Cartons are printed very quickly, they do inspections at the start, mid way thru a skid of 500, and at the end.Β  When we reject the cartons we reject a whole skid instead of the cartons within the skid.Β  Please advise if there is an industry standard in measuring quality on printed cartons and what is acceptable?

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    #186609

    Severino
    Participant

    I doubt very much that you will find a standard that tells you what PPM level will be acceptable for you.Β  Only you can decide that.Β  If you need measurement techniques, I would look at ASTM, TAPPI, and similar organizations.Β  In the end, if you are having problems with a supplier you need to either get them to grow or go.Β  This may mean your quality organization needs to make a more active role in dealing with these issues by actually going to the supplier and identifying what the underlying root causes are.Β 
    … on the other hand, if the supplier was worth their salt they’d have fixed it by now.

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    #186620

    Richard Skiff
    Member

    What is the nature of your non-comformance?Β 
    Is it cosmetic (i.e. print quality) or functional (the carton will not perform)?
    Is the problem well defined and acceptable/unacceptable performance is understood by both you and your supplier?Β  Do they clearly understand your expectations?
    I agree with JSEV607 that there is no real standard for supplier quality.Β  In the paper industry, unfortunately, it is difficult to relate test criteria (i.e. TAPPI Standard physical tests) to actual product performance.Β 
    Let me know if I can be of any help.Β 
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    #186623

    Angela Godwin
    Participant

    The supplier has been and continues to be a VERY good supplier.Β  They have a 4 hr lead time to us, they stock, they schedule their holidays around ours……..Their service is unsurpassed, and we have benchmarked their prices to make sure they are competitive.Β  We have 4 color artwork that is printed directly on our cartons that contains transitions in shading…….Our suppliers issues have always been printing.Β  I know that when they are printing their cartons the cartons move very quickly and it is difficult to catch all of the defects.Β  I want to make sure that we are not being unreasonable in what we expect, but at the same time not too forgiving.Β  That why I was hoping for an industry standard in PPM expectations for cartons.

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    #186646

    Lee
    Participant

    Just a couple of thoughts –
    Β 

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    #186647

    Lee
    Participant

    and the remainer of the message is …
    1Β  Take a step beyond doing atttribute checks (go/no-go) and look at the reject cartons.Β  You indicate your have a very good supplier, so why not partner with them to solve your specific quality issues?Β  Help them be better, they may not have training at their facility to know how to make the next step.
    2Β  You said their turnaround is quite rapid.Β  Is the printing issue related to cartons being stacked so quickly that the ink is not dry?Β Different inks dry at different rates depending on the thickness applied and the paper stock.
    3Β  Remember that you are the customer here, andΒ “The customer is always …” but balance that with demand that are realistic for your supplier.Β Β  Have you had a sit-down with them yet?

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    #186656

    Severino
    Participant

    Sounds like your supplier needs an inline vision system with an air jet to kick off bad cartons.Β  Assuming its not terribly cost prohibitive, they can then use the reject data off the machine to determine things like ink refill times, pad replacement times (assuming they are pad printing), etc.Β  Additionally, if the machine is not solely dedicated to your product it can benefit their other customers as well.
    What’s the dollar value of your rejections each year (you’ll see the cost as a little higher than they will, but at least it provides an estimate)?

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