5 Reasons Why Your Business Needs Automatic Carton Folder Gluer Machine？

Are you considering the purchase of packaging equipment to help you improve your folder-gluer&#;s productivity?

Contact us to discuss your requirements of Automatic Carton Folder Gluer Machine. Our experienced sales team can help you identify the options that best suit your needs.

Feeling unsure whether it&#;s the right decision for your company?

You are not alone. 

Every box manufacturer has been in the same position as you once upon a time. And being in that position can be challenging and frustrating.

As the Director of Sales and Marketing at IMPACK, I have managed over 50 project analysis in more than 20 countries around the world.

During this time, I have seen how small changes can substantially help box manufacturers reach top packing speeds and dramatically improve their folder-gluer&#;s productivity.

I&#;ve also seen how poor forward-thinking caused box manufacturers to realize significant losses and sometimes go out of business.

The goal of this VIDEO + ARTICLE is not to convince you to purchase packaging equipment. In fact, most box manufacturers interested in packaging equipment are not yet ready to invest in packaging equipment. 

This article will cover:

What Are Folder-Gluer Packaging Equipment?

Folder-gluer packaging equipment are packing systems and peripheral devices that can be added on, and around, a folder-gluer.

These packing systems and peripheral devices are divided into 4 families &#;: 

The image below shows you the organization of the 4 families of packaging equipment around a folder-gluer. 

A graphical depiction of the flow of packaging equipment around a folder-gluer.

Each of those 4 families includes distinct solutions with varying features, capabilities, and levels of automation. We classify those levels of automation into 4 categories:

1. Manual packing.

2. Semi-Automated packing.

3. Automated packing.

4. Fully-Automated packing.

If you&#;re considering packaging equipment, you&#;d want to learn about the 4 different levels of automation and how to choose the best machine for your production.

Also, you&#;ve probably noticed that some of your competitors have packers while others have stackers. 

If you&#;re confused about the difference between packers and stackers, check out the article "Folder-Gluer Packers VS. Stackers: What Packaging Solution is Best For You?" It breaks down those 2 types of packaging equipment and guides you through which one is right for your company.

Where Are Folder-Gluer Packaging Equipment Installed?

Packaging machines are installed on, or around, a folder-gluer depending on what packaging machine you purchase. 

Let&#;s take a look at the 4 families of packaging equipment and where they&#;re installed:

A pre-feeder is a unit installed in front of a folder-gluer, and before the feeder, that continuously feeds the folder-gluer&#;s feeder. 

More specifically, a pre-feeder is installed at the beginning of the flow of the packaging equipment.

IMPACK&#;s Prefio: One of the only pre-feeders on the market for corrugated board.

A pre-packer is a unit installed right after the folder-gluer, and before the packer. 

Very often, several pre-packer units are installed after the folder-gluer. Those pre-packers include box turners, batch inverters, and counting and separating devices. 

IMPACK's MFA Batch Inverter and the IN3 Box Turner installed after the folder-gluer and before the packer (Both units are pre-packers).

A packer is a unit installed behind a folder-gluer and after the pre-packer(s). 

That is, a packer is installed at the end of the flow of the packaging equipment. 

IMPACK&#;s Ergosa C: A high-performance and versatile semi-automatic packer with the performance of an automatic packer that offers 3 packing modes.

Just like a packer, a stacker is installed behind a folder-gluer and after the pre-packer(s). 

More specifically, a stacker is installed at the end of the flow of packaging equipment.

IMPACK&#;s Everio: A fully automatic stacker to stack and band your boxes coming from folder-gluer(s) or rotary die cutters.

Depending on your production processes, you either pack your boxes into cases (i.e. case packing) using a packer or stack your boxes to be banded/strapped together (i.e. box bundling) using a stacker.

In other words, you would either have a packer or a stacker after the pre-packer(s) but some clients do both processes on the same folder-gluer.

&#; Related: Folder-Gluer Packers Vs. Stackers: Which Packaging Solution is Right For Your Company?

Who Needs Packaging Equipment (& Why)?

Ergosa C and MFA combination at IMPACK's manufacturing plant. IMPACK's experts discussing a client's test.

&#;To improve your folder-gluer productivity, you need to invest in packaging equipment.&#;

&#;The only way you can reach higher speeds is by investing in packaging equipment.&#;

&#;You need packaging equipment to reduce your packing staff.&#;

Every packaging equipment manufacturer that you approach will repeat those statements in one form or another.

Every packaging equipment manufacturer will tell you that you must invest in packaging equipment to improve your folder-gluer&#;s productivity, reach higher packing speeds, or reduce your packing staff.

That&#;s just the reality of this industry. 

But &#; the truth is, investing in packaging equipment is not the right solution for every box manufacturer.

Yes, investing in packaging equipment could be a bad decision if you&#;ve not mastered your folding-gluing process.

&#;What does that mean?&#;

Put simply, if you want to get the greatest return on investment from your packaging equipment, then you should not invest in packaging equipment until your company has pushed your folder-gluer to its maximum possible potential. 

If you&#;re not sure how to push your gluer to its maximum potential, learn about the Top 5 Ways to Maximize Your Folder-Gluer&#;s Productivity With Zero Investment.

&#; Related: Top 5 Ways to Improve Folder-Gluer Productivity with Zero Investment

You should know though that there will come a point where you&#;ve become good at tuning your folder-gluer and you&#;ve ramped up your speed through the implementation of those top 5 tips but your packing staff can no longer keep up. 

Thus, you will now deliberately have to slow down your folder-gluer and purposefully reduce your productivity.

After all, every process has its limitations and those limitations will eventually happen. 

It is inevitable. Your folder-gluer will hit its maximum potential and there is nothing you can do to make the gluer produce more (or at a faster rate) without investing in additional solutions.

Here's where folder-gluer packaging equipment comes into play.

But &#;packaging equipment&#; is an overarching term for a wide range of solutions that can be added on, and around, a folder-gluer. 

And we saw how each of those solutions varies in scope, degree, and levels of automation.

Hence, knowing that you need to invest in packaging equipment is not &#;the&#; ultimate answer to boost your folder-gluer&#;s productivity. 

It is a great first step, but there&#;s a whole world to folder-gluer packaging equipment.

If you&#;ve implemented those top 5 zero-investment tips and feel ready to take the next step, read the 7 Most Effective Ways to Maximize Your Folder-Gluer's Productivity (With Investing) that our team of engineers and packaging specialists put together from their observations of over companies around the world.

&#; Related: Top 7 Ways to Improve Folder-Gluer Productivity With Investing

So, Should You Invest in Packaging Equipment?

It all comes down to your needs, goals, and budget.

&#;&#; If you&#;re one of those people that skip straight to the end, here&#;s the quick answer:

The real tipping point between deciding whether you should invest in packaging equipment or not is the setup time.

If your folder-gluer could run faster and your packing staff can follow, then this is where tuning your gluer would be a better first option than adding packaging equipment to your folder-gluer.

To learn how to tune your folder-gluer: Follow the Top 5 Ways to Maximize Your Folder-Gluer&#;s Productivity With Zero Investment.

If you can no longer increase the capacity of your folder-gluer because you have pushed your gluer to its maximum potential, then ask yourself: Where exactly is the bottleneck taking place?

&#; 1. If your bottleneck is at the gluing and you have 1 packing person:

If your bottleneck is at the gluing and you have 1 packing person, then adding another packing person won&#;t help you as your folder-gluer has reached its maximum possible speed. 

Neither will a Manual Packing help/aid like the popular Collecting Tables on the market.

For example: Let's say you are producing 50,000 boxes per hour with 1 packing person and you've reached the maximum speed of your gluer. This means that you cannot run faster with the gluer no matter what you do. Adding another packing person does not affect your speed because the gluer has already reached its maximum speed.

Therefore, you probably do not "need" a packer for small production volumes. That said, a packer could help for ergonomic reasons and you have to evaluate what ergonomics is worth for your company.

On the other hand, if you have large production volumes (run sizes) of 150,000 boxes or more, a Fully Automatic packer, such as IMPACK's Virtuo + ACF, could be a lucrative solution as it could remove that 1 packing person and place them into higher-value activities (if the production volumes are fitting).

&#; 2. If your bottleneck is at the gluing and you have 2 packing persons:

If your bottleneck is at the gluing, and you have 2 people packing, then adding more packing personnel won&#;t help you as your folder-gluer has reached its maximum possible speed. 

For example: If your gluer is running at a speed of 50,000 boxes per hour with 2 people working hard to pack at that speed, and you already know that your folder-gluer has hit its maximum speed, then you might want to consider adding a packer.

A packer would help you reduce 1 or 2 packing person(s) and continue producing at the same speed. 

This means that you either need no packing persons remaining or that the remaining person is packing twice as fast as before.

&#; 3. If your bottleneck is at the packing:

If your bottleneck is at the packing, then whatever you do with a packer it would be worth the investment.

If your folder-gluer is running at a speed X with 1 packing person, and you know that your gluer can run faster, then the next step would be to add a second packing person to push your gluer to a higher speed.

One step further, you can reduce 1 of the 2 packing persons with the help of a Semi-Automatic or an Automatic packer, such as IMPACK&#;s Semi-Automatic Ergosa packer or Automatic Virtuo packer.

Alternatively, you can move both packing persons to higher value-added activities with a Fully-Automatic packer, such as IMPACK&#;s Virtuo + ACF.

For simplicity, let&#;s take the same example: Your gluer is running at a speed of 50,000 boxes per hour with 2 people working hard to pack at that speed. This time though, you know that your folder-gluer can run at a speed of 80,000 boxes per hour. 

In this specific situation, you would want to find a packer that helps you achieve your folder-gluer&#;s maximum possible speed of 80,000 boxes per hour either fully automatically or with 1 packing person only.

On the other hand, if you&#;re always in the small-volume ranges of 20,000-40,000 boxes per setup, then you typically won&#;t reach your folder-gluer&#;s maximum speed and this is where IMPACK&#;s &#;Packing Help Stations,&#; or the other Collecting Tables on the market, would be a better choice than a packer. 

And this would be for ergonomic reasons or organizational efforts.

&#; Related: Manual Vs. Semi-Auto Vs. Auto Vs. Fully-Auto Folder-Gluer Packers: Which Is Right For Your Company?

Who Should You Buy Your Packaging Equipment From?

If you&#;ve decided that investing in packaging equipment is the right choice for your company, your next step would be choosing a packaging equipment manufacturer. Here are your options:

Your Current Partner

If you already have a partner from which you purchase your packaging equipment, then they would be your best bet as you already have a relationship with them and they are the &#;person of trust.&#;

Folder-Gluer Manufacturers

Your second option would be a folder-gluer manufacturer/supplier.

Most folder-gluer manufacturers also offer some types of packaging equipment. Typically, they either have the most basic Collecting Tables or Automatic packers. It is rare to find folder-gluer manufacturers that offer Semi-Automatic packers.

If their proposed solutions fit your budget and production requirements, then they might be a good fit for you. Furthermore, if you're buying a folder-gluer, they might even throw in a special discount on the packaging equipment!

Just remember that even if they offer you a packer at a discount, if it doesn't fit your production needs, then it&#;s not worth the investment. 

Packaging Equipment Manufacturers

Your third option would be a packaging equipment manufacturer/supplier. manufacturers have experts with deep technical knowledge of the equipment they make and sell. 

Most of the time, these experts are sales reps that have personally tested, installed, and administered the operator training on dozens of machines around the world. In some cases, those sales reps have, themselves, wired and started those machines.

Some examples of manufacturers exclusively selling packaging equipment for folder-gluers include: Graphic West Packaging and WSI Global.

We, at IMPACK, are a packaging equipment manufacturer that designs, builds, delivers, and installs Manual, Semi-Automatic, Automatic, and Fully-Automatic packaging equipment and peripheral devices. 

We have currently manufactured and installed over 400 units across 4 continents and with projects in over 55 countries. Box manufacturers leverage our 20 years of experience to help them choose the best machine for their production.

Have You Made a Decision?

&#; If you&#;ve decided that investing in packaging equipment is the right choice for your company, here are your next steps:

1. Compare IMPACK&#;s 3 main packaging equipment and discover which is best for your company.

2. Find out How Much a Folder-Gluer Packer Costs and what costs you can avoid.

3. Contact an IMPACK expert for a FREE productivity analysis to learn what&#;s hindering your company from producing more output, faster.

&#; If you feel that your company is not yet in the position to invest in packaging equipment, here are your next steps:

Before Investing Optimize Your Existing Processes

Every company aspires to increase its folder-gluer productivity and maximize output potential. Before considering investments in new machinery, it's prudent to analyze your production process and unlock its full potential. Many of the most impactful ways to enhance productivity require dedicating time and effort to optimize your existing processes. 

Hello, I'm Stefan Badertscher, Director of Revenue at IMPACK. Over the last 8 years, I  visited over 400 production plants and saw, first hand, what the most and least successful packaging producers do in their day-to-day work. Here's a summary of optimization strategies I've gleaned to help you get to your highest productivity levels.

1. Production Planning & Operational Optimization

Meeting customer demands all starts with efficient production planning, accurate forecasting, and meticulous scheduling. But even the best laid plans can be affected by external factors, such as supplier issues, transportation delays, or global events like the COVID 19 pandemic, can disrupt the supply chain and hinder production. In addition to supply chain and inventory management having a disaster recovery plan is crucial to prevent shortages that could disrupt production. 

OPTIMIZATION OPPORTUNITY 1

OPTIMIZATION OPPORTUNITY 1

Continuously improve supply and demand planning. Schedule quarterly meetings to review inventory, supply chain and demand fulfillment issues. Compare corresponding quarters and identify unique external factors that influenced shortages. Have a disaster recovery plan.

Operational optimization is really the foundation for productivity, but with over 20 years of experience analyzing folder-gluer finishing lines and designing solutions to make them more efficient, our specialty at IMPACK is WORKFLOW OPTIMIZATION.

2. Optimize Your Workflow 

Poorly designed or inefficient workflows can lead to bottlenecks, delays, and wasted effort and time. As operations evolve over time, functions and machines are added, sometimes inefficiencies develop. Scheduling time for your team to review your workflow will reveal ways the layout can be improved. On the folder-gluer finishing line, seconds matter, as they can quickly add up and turn into thousands of boxes - making you more competitive and profitable. Take a close look at the layout, walk patterns and work methods to find ways to make it as efficient as possible. As you analyze your production, you will be looking at how you can shave seconds off the time it takes to do tasks at several points along the production.

Potential 4 Finishing Line Bottleneck's:

• Changeover time

• Employee fatigue and physical limitations

• Poor quality control

• Poor machine maintenance

Frequent changeovers between different product types or sizes can be time-consuming. Streamlining changeover processes and reducing setup times is crucial. 

Inefficient layout and lack of ergonomics for physical jobs can lead to unnecessary fatigue and affect employee satisfaction levels. Inefficient workflows and employee disengagement can result in safety issues, leading to workplace accidents, injuries, production stoppages and increased insurance costs. Prioritizing safety measures is essential to prevent such incidents.

Inefficient processes or a lack of quality control can result in excessive material waste or product scrap. Properly conducted quality checks and inspections are essential to prevent the production of defective products that may require rework or disposal, affecting both productivity and profitability.

Neglecting routine equipment maintenance can result in breakdowns and reduced productivity. Unexpected breakdowns can disrupt production schedules, delay client fulfillment, and reduce overall output. Proper equipment maintenance and preventive measures are essential to mitigate this issue. Implementing a robust maintenance schedule is essential. Having a supply of replacement parts and readily available tools can help mitigate downtime resulting from unplanned maintenance.

Analyze Your Production 

During a folder-gluer operation, there are certain steps and procedures that are regularly taken. Who sets up the folder-gluer? Who is responsible for bringing the pallets with the box blanks? Who prepares the case labels? Who is responsible for periodically checking the inventory of tools and machine spare parts?

I recommend taking some time to evaluate the layout, walk patterns and work methods during a production run, but don't do this alone. Hovering over your workers with a clipboard will just make the team feel intimidated or suspicious. Get your finishing line team involved. Explain that the goal is to make their job more efficient and ergonomic - making their life easier. 

With your current Standard Operating Procedures(SOP) in hand, analyze your work methods at each station and assess walking patterns during setup and production. You may be surprised to see workers repeatedly reaching for, bending toward, and walking to inconveniently placed materials. Empower your team to make changes to the line that reduce steps and movements. 

Assess Walking Patterns During Setup and Production

 

Take time to observe the walking patterns of all your personnel during repeated production runs and setups. The goal is to reduce steps, and avoid having people crossing each others&#; paths during operations, especially around the packing station. Observing walk patterns can be very revealing in terms of unnecessary movements. It could be something as straightforward as inefficient placement of tools during a folder-gluer setup. Move tool storage close to where they will be used. Another example is often-used supplies. You don't want packing personnel taking a long walk to find tape when it runs out. Think about what actions need to be frequently taken and organize a sequence so that your operator standardizes what to do, when, and with what tool.

OPTIMIZATION OPPORTUNITY 2: Improve the Layout and Workflow

Working with your finishing line crew, adjust the layout around the folder-gluer to maximize efficiency. Closely related to walk patterns are the movements and sequences required to carry out a task. Analyze each step, task and movement in the process. For each task define what to do, when to do it, where to do it and with what tool (if needed).  

3. Make Manual Tasks Ergonomic to Improve Efficiency and Staff Retention

Look at your team. Have you experienced a lot of employee turnover in the past few years? Efficient layouts that reduce worker movements and ergonomic machine configurations can go a long way to improving worker productivity.

A case of this size can weigh around 10kg or 22lbs. If he palletizes two cases per minute he could be lifting 9.5 tons per 8 hour shift. These are the type of tasks that can be automated or at least made more ergonomic.

The company is the world’s best Corrugated Cardboard Cutting Machine supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.

Remember the acronym P.E.M. 

• Proximity &#; move materials and tools close to where they will be used.

   

• Ergonomics &#; adapt the environment and tooling to be ergonomic.

• Minimize - minimize manual effort. 

  
  

Think about where the most convenient location would be for all materials and tools. Shelves, lifts, and conveyors put materials close to where they will be used, saving precious seconds at several key locations. Use lifts to bring carton blanks to the pre-feeder, integrate shelves for samples and breakers at the packing station, and install lifts and tables to make the work of erecting and palletizing cases more ergonomic.

These adjustments to your finishing line will go a long way toward increasing speed and improving worker satisfaction and retention. Minimizing movements and reducing rotations reduces injuries and allows workers to get more done without unnecessary effort. Ergonomic aides such as tables and conveyors are very inexpensive ways to improve the work experience of your workers.

But you may already be noticing that there are still some time consuming and physically demanding movements such as rotating and flipping batches of boxes that can not be eliminated with these "aides". Part 2 of this Series "Boost Productivity by Investing in Automation" will help you identify machine solutions that will eliminate these bottlenecks and double finishing line speeds.

OPTIMIZATION OPPORTUNITY 3: Ergonomics Improve Productivity and Employee Retention

Make tasks more ergonomic by installing tables, shelves, lifts and conveyors to minimize movements and reduce rotations and ultimately increase speed.

4. Develop and Implement SOPs, Recipe Books, QA Protocols and Maintenance Logs

After defining a more efficient layout and process, document your refined process in Standard Operating Procedures and Logs.

Properly documenting your workflow and process has many benefits including:

• Reduce your setup times by defining what setup is the best for each box type.

   

• Establish an instructional process for the setup of each box type.

   

• Share this know-how and best practices among your team.

   

• Facilitate structured training for your new employees.

   

• Define and distinguish the roles of your packing person(s) and folder-gluer operator(s).

   

SOPs and logbooks are similar in many ways. The main difference between an SOP and a logbook is that an SOP is used to break down a large or complex process into a step-by-step procedure and with the purpose of standardizing your process to achieve consistent performance levels. On the other hand, a logbook provides instructions in a defined order that you must follow to achieve a desired outcome.

Make those instructions concise, as easy to follow as possible and in the style/format/language that will be best understood by your team.  

To develop and implement a successful SOP, follow the &#;Plan-Do-Check-Act&#; (PDCA) quality management model: 

1. Research the steps in a process (plan):

   During your folder-gluer operation, observe the actions your personnel take and write down the most obvious actions you see in their day-to-day routines.

    

2. Create a procedure (do):

   Once you have those actions written down, create a step-by-step procedure that outlines those actions in order and then put this procedure into action with your team.

    

3. Verify the procedure (check):

   After you&#;ve tried the procedure, audit your procedure&#;s execution and get feedback from your team. Ask your team:

    

4. Were there any problems that hindered you during this step-by-step procedure or slowed down your progress?

    

5. Do you see any opportunities for improvement in any step(s)?

    

6. If you were to implement this step-by-step procedure as part of your daily work routine, what pros and cons do you see?

    

7. Revise and standardize your procedure (act):

   Previously, you researched the actions taken in your process, created a step-by-step procedure & tried it, and then you verified your procedure with your team&#;s feedback. Now, it is time to revise and fine-tune your procedure based on your team&#;s feedback.

    

8. Repeat the PDCA cycle to standardize your SOP.

    

Developing and implementing SOPs will allow you to define &#;best practices&#;. SOPs give you the power to measure your performance and detect any deviations in results. This will ultimately allow you to take corrective actions, when needed, to ensure consistency in your performance and achieve continuous improvement. 

OPTIMIZATION OPPORTUNITY 4

OPTIMIZATION OPPORTUNITY 4

Create Standard Operating Procedures (SOPs), Recipe Books, Quality Assurance (QA) Protocols, and Maintenance Logs to eliminate unnecessary inefficiencies in your process.

Additional tips for creating great SOPs and Log Books later in this article.

5. Nurture The Human Factor 

Insufficient training or inadequate skills among operators and technicians can result in errors, slow production, and the need for constant supervision. Errors made by employees during various stages of production can result in defects or rework, affecting productivity and product quality. Although some companies may be hesitant to pause production for training, investing time in training and skill development is critical, with any perceived loss quickly regained through increased productivity. 

Poor communication between different departments or shifts can lead to misunderstandings, delays, and errors. Effective communication channels and practices are crucial. Low morale among workers can result in reduced effort, absenteeism, and higher turnover rates, all of which negatively impact productivity. Low morale can also lead to disengagement, which affects product quality. The solution lies in a strong upper management commitment to creating a positive workplace culture. If you suspect morale issues in your company, engaging an outside firm to help effect change can improve everyone's quality of life and positively impact your bottom line in a short amount of time. 

OPTIMIZATION OPPORTUNITY 5

OPTIMIZATION OPPORTUNITY 5

Take care of your team. Engage an outside firm if you sense that employee morale is at an all-time low. Investing time in employee training will result in increased productivity. 

Regular assessment, continuous improvement efforts, and a commitment to operational excellence are key to overcoming production bottlenecks and productivity challenges. Let&#;s review the 5 ways you can boost productivity to reach your maximum folder-gluer output before investing in new equipment.

Top 5 Ways to Boost Productivity Before Investing

1. Improve supply and demand planning, have a disaster recovery plan

2. Analyze the workflow and make processes and walk patterns as efficient as possible

3. Make manual tasks ergonomic to improve efficiency and staff retention

4. Develop and Implement SOPs, Recipe Books, QA Protocols and Maintenance Logs

5. Take care of your team through regular training and fostering a positive company culture

   
   

But what if you&#;ve already implemented these success strategies and you&#;re ready to take the next step by investing. Part two of this series: 7 Ways to Boost Folder-Gluer Productivity & Speed by Investing in Peripherals will review ways that investing in machine technology, specifically automation, can help you become more competitive even in challenging economic times. 

Additional tips to help carton packaging producers create great SOPs for their folder-gluer finishing lines:

 

Understand the Process: Begin by thoroughly understanding the folder-gluer finishing line or machine process. This includes identifying all the steps involved, potential hazards, and quality control checkpoints. Collaborate with experienced operators and technicians who have in-depth knowledge of the machine. Their input is invaluable for creating comprehensive and effective SOPs. 

• Clear & Concise Language: Use plain and simple language that is easy for all team members to understand. Avoid ambiguous terminology.

   

• Consistent Formatting & Structure: Organize the SOPs in a clear and consistent format. Use headings, subheadings, and bullet points to make the content easily scannable.

   

• Step-by-Step Instructions: Break down the process into step-by-step instructions. Each step should be specific, concise, and sequential. 

   

• Safety First: Prioritize safety procedures and precautions. Ensure that operators are aware of potential risks and the proper safety measures to take.

   

• Include Visuals: Incorporate diagrams, images, or videos to enhance comprehension. Visual aids can clarify complex procedures.

   

• Checklists: Include checklists at key points in the SOP to help operators verify that they've completed each step correctly.

   

• Parts and Tools: List and describe all equipment and tools needed for the process. Determine and define convenient tool and part storage.

   

• Quality Control: Define quality standards and inspection points throughout the process. Explain how to recognize defects and what actions to take when they occur.

   

   

• Troubleshooting: Include a troubleshooting section with common issues and solutions. This helps operators address problems swiftly.

   

• Legal Compliance: Ensure that the SOPs comply with all relevant industry regulations and safety standards.

   

• Revisions and Version Control: Foster a culture of continuous improvement. Encourage team members to suggest changes to enhance efficiency, safety, and quality. Establish a clear process for updating and revising SOPs. Regularly review and improve them based on feedback and changes in technology or processes. Maintain a record of different versions of the SOPs. Clearly label and date revisions to avoid confusion.

   

• Documentation Storage: Establish a centralized location for storing and accessing SOPs. Ensure they are easily retrievable for all team members.

   

• Accountability: Clearly define responsibilities and accountability for following the SOPs. Reward compliance with SOPs. Schedule periodic audits to verify that SOPs are being followed correctly and to identify areas for improvement.

   

 -------- 

Logbook Tips: 

Tips to help packing producers develop an effective logbook for machine set-ups especially those that do not have the support of an automated interface: 

• Clearly Define Each Recipe: Start with a clear and concise title or name for each recipe, indicating the intended product.

   

• Document Essential Parameters: List all critical machine settings as well as peripheral integration measurements, settings, etc.;

   

• Step-by-Step Setup Instructions: Provide detailed logical step-by-step instructions for setting up the machine & peripherals.

   

• Materials and Resources: Specify the materials, tools, and resources needed for the setup, such as types of carton-board, adhesive, etc.

   

• Quality Control Guidelines: Define quality standards and checkpoints for each recipe.

   

• Include Visual References: Incorporate images, diagrams, or sketches to illustrate setup steps, machine configurations, and quality checkpoints.

   

• Testing and Calibration: Describe any testing or calibration procedures necessary to ensure the machine is set up accurately. 

   

• Cross-Referencing: Cross-reference related recipes or instructions that may have dependencies. This helps maintain consistency when multiple recipes are used together. (For example, when using an in-line window patcher on your folder-gluer, you need one recipe for the window patcher and one for the folder-gluer.

   

• Storage and Accessibility: Store the logbook in a secure and easily accessible location. Consider having digital formats available for easy searching and sharing. Create backup copies of the logbook to prevent data loss. Store copies offsite in case of emergencies.

   

• Regular Updates: Schedule periodic reviews and updates of the logbook to reflect changes in machinery, materials, or best practices.

   

See how investing in updated technology can help you address labor shortages, machine obsolescence and rising energy costs in part 2 of this series.

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