Aluminum plate printing cost control

Low cost and high profit are the unremitting pursuit of the company. In the aluminum plate printing industry, certain products, different enterprises, are profitable and have losses; those with more profits and less profits. In a word, the different measures taken in cost control are the main reasons for this phenomenon. Based on the personal experience of first-line production, the author analyzes the main factors that affect the cost of aluminum printing, and discusses how to control the cost of products and increase profits.

1, the impact of temperature factors on the cost and control measures

Before the aluminum plate printing, the aluminum plate must be first cleaned, the rolling oil on the surface of the aluminum plate removed, and the pre-production preparation for the subsequent process. The commonly used purification treatment method is high-temperature baking, which vaporizes and volatilizes the rolling oil adhering to the surface of the aluminum plate. The method of obtaining the baking temperature varies from one company to another: heating with electric heating tubes, heating with kerosene, heating with liquefied gas, and so on. However, regardless of the method, the consumption is directly proportional to the cost, which consumes a lot and the cost is high. Each type of aluminum plate has a different optimal baking temperature. In this temperature range, not only the rolling oil is removed, but also the cost is minimal. For example, the southwest aluminum plate has a lower baking temperature and is baked at a constant temperature of 180±10° C. for 10 minutes. Harbin aluminum baking temperature is high, the need for constant temperature 190 ± 10 °C baking 10 minutes. The baking temperature should not be too high or too low, and the optimum baking temperature for each type of aluminum plate should be found for the characteristics of different aluminum plates. Only in this way can the production cost be reduced. Because the baking temperature is high, not only increase the cost, but also because the aluminum sheet is soft and the melting point is low, deformation (even annealing and softening) occurs during the baking, resulting in flatness of the aluminum sheet does not meet the printing requirements, and even lead to defective products. The production of; baking temperature is low, can not achieve the purpose of removing rolling oil, rework will increase the cost of the product.

2. Influence of coating factors on costs and control measures

After the aluminum plate is cleaned, the coating process must be performed according to the user's requirements before printing. The color of the paint is different, and some paints and colors reach the specified film thickness (the so-called "film thickness" is the dry film weight of the varnish or paint after curing per unit area, usually expressed in g/m2). The paint color is not Any further change, if the film thickness is not controlled at the time of production, will increase the cost and cause the waste of the paint. The following measures shall be taken for this part of the coating: 1 First, the film thickness of the coating shall be controlled at the critical point where the color no longer changes, and it shall be fixed in the form of a process file. 2 The operator must perform the process when producing and record the thickness of the coating film during production to prepare the process inspection and provide the basis for the type test.

After the paint is finished, brushing the car is a key link in controlling costs. Usually, one product is produced, and the next product is followed. Because different paints have different properties, different paints cannot be mixed. Operators can deal with paints in the oil pipe of the paint. It is washed away with the coating used in the next product. It takes about 1kg each time. The price per kilogram of paint is in the range of tens or even hundreds of dollars. Accumulated for a year, the waste is staggering. The measures to reduce costs are as follows: after the paint is finished, the paint oil pipe is flushed with the matching thinner, and the washed paint has no change in viscosity except for the viscosity. The paint with high viscosity can be mixed after the next production.

3, ink factors on the cost and control measures

The waste of ink in aluminum printing can not be ignored. After the boxed ink is turned on, there is a layer of moisturizing plastic on the inside, and the ink attached to it occupies about one-twentieth of the total amount. Some printing workers directly tear open and discard and directly increase the amount of ink used.

When the spot color ink is formulated, if there is no strict operation specification, it will also cause a lot of waste of ink. Printing workers usually use the same ink blade to take ink in different colors of ink, resulting in passive contamination of the main ink. When printing with a single color ink, in order to prevent the contaminated ink from affecting the overall color of the printed product, the contaminated ink will Being cleared, this indirectly increases the amount of material used.

If a printing company has the above two phenomena, the actual use of a box of ink accounts for only 70% or 80% of the total amount, and the amount of waste throughout the year is also considerable.

Therefore, the cost control measures taken by the company against ink waste: documented ink access operation procedures, regulate the production operations of the printing workers. After the new ink is turned on, the moisturizing plastic should be as small as possible with ink, and the company should specify the allowable range in the operating procedures. For the spot color ink deployment process, any ink is used to use a single ink blade to prevent the box from being formed. The phenomenon of mutual ink mixing, to save ink as much as possible, so as to achieve the purpose of reducing costs.

4, the impact of aluminum plate on the cost and control measures

A total of 3,600 tons of standard aluminum sheets, the current average price per ton of aluminum plate is about 26,000 yuan, the price of a single sheet of aluminum 7-8 yuan, a printing line normal loss of 4-5 per day, but the company usually the amount of losses in the Up to 10 sheets may sometimes be lost in dozens of sheets due to equipment, etc., and the total price is a few hundred dollars. Many companies do not mobilize the enthusiasm of operators to control costs. They only pay attention to direct labor costs and ignore direct material costs. Wages of employees are clearly visible and easy to calculate, but the loss of aluminum plates is unclear and uncertain, but it can be more or less. If a company loses more than a dozen sheets or more than two sheets of aluminum, it is tens or even hundreds of dollars. , higher than the normal loss of several times or even ten times, and the daily wage of a worker responsible for the accumulation of aluminum plate is also around 30 yuan, if the wages of the workers responsible for the accumulation of aluminum plate with the loss of the number of aluminum plate, do a good job Wage is rewarded on the basis that the lack of responsibility causes additional losses to be punished. This not only motivates the production enthusiasm of the workers, but also greatly reduces the production costs.

5, the effect of spot color ink color test time on the cost and control measures

Because spot inks are formulated with several inks, the color change after baking is unpredictable. Therefore, experiments should be conducted before formal production. At this time, the technology of the printing workers is very important. After a skilled worker in an experiment, According to the color change of the ink, the proportion of the ink is adjusted, and the second time can be basically tested. If the quality of the printing worker is not high and the number of experiments is too much, not only the aluminum plate is wasted (the aluminum plate after printing is not reusable. Substance), but also will increase the fuel consumption, and accordingly increase product costs.

Therefore, measures to reduce costs are: the use of skilled workers, and on-the-job staff regularly on-the-job training, and constantly improve the quality of employees. Short-term training expenditures are exchanged for long-term low-cost operation of the company.

6, waste defective directly increase the cost of the product

In the production process, unqualified products caused by unpredictable factors or operator's mistakes cannot generally be reinstated, so the product cost will be directly increased. Therefore, the number of defective scraps is closely related to the cost. Unqualified products are unavoidable, but measures can be taken to reduce their quantity. More effective measures are: formulating corresponding rewards and penalties, rewarding advanced personnel, establishing typical and punishing employees with weak sense of responsibility, and improving the overall quality of employees. Reduce the number of defective scraps.

The cost control of aluminum printing also includes management fees, financial expenses, etc., but the direct impact on direct material costs, direct labor costs, and the direct cost control are the key to determine product price competition.