In order to ensure the conductivity of aluminum cans is qualified, the following will start from the five major factors of "people, machines, materials, methods, and environment" that affect product quality in the theory of total quality management and conduct item-by-item inspection and analysis.
First, the top management must attach importance to product quality.
Second, to achieve full participation and teamwork.
Third, we must keep in mind that "quality begins with education and ends with education". All operators (including inspectors) must undergo rigorous training and can only take up their posts after passing the examination.
Fourth, all positions (especially internal spraying machines, finished product stacking and inspectors) should strictly implement various standard operating procedures.
First, set the temperature of the internal spraying machine, the pressure of spraying, and the parameters of the spray gun (such as angle, distance, height, etc.).
Second, the internal spraying machine should be equipped with a non-rotating control system, and each spray gun should be equipped with a pressure-free and low-pressure monitoring device to prevent leakage.
Third, there is an ink dot marking system that can be traced back to the internal spraying machine number (if possible). Fourth, set the baking temperature and time of IBO. When the baking temperature exceeds the set temperature, the oven must automatically stop.
Fifth, there should be no retention cans on the oven entrance bridge plate, and there should be no dead corners in the oven.
Sixth, the oven temperature curve must meet the curing temperature and time requirements required by the internal coating supplier.
Seventh, the oven temperature card should be reviewed and updated monthly according to the temperature changes, and posted for comparison and inspection.
First, ensure that the supplier, model, and expiration date of the internal coating used meet the customer and process requirements.
Second, the actual viscosity of the internal coating must meet the supplier's requirements.
Third, use the filter mesh recommended by the internal coating supplier and clean the filter regularly.
Fourth, check the condition of the aluminum cans in the previous process. There are four key points for inspection: the cleaning effect of the white cans at the outlet of the can washer; the pollution of the inner wall of the can by the chain needle oil and varnish of the color printing machine; the pits on the can body; the can inversion at each station before entering the internal spraying machine.
Fifth, check the condition of the cans in the subsequent process. Focus on checking the impact of the necking and flanging machine mold and the stacking machine insert rod on the inner coating of the can wall.
"Emphasis on institutionalization and standardized management."
First, implement the quality plan for internal spraying (quality standards, inspection frequency, sample size, inspection time, inspection personnel, etc.).
Second, the operator of the internal spraying machine must master the setting requirements and spray gun cleaning requirements of the internal spraying machine.
Third, if the internal spraying machine is shut down for more than a certain period of time, before restarting, the operator must immediately check and thoroughly clean the nozzle, and must remove the first few first-opened cans that are at risk at the moment of startup.
Fourth, check the coverage and quality of the internal spraying material, including: spray shape, spray overlap and coverage effect, spray overflow, and whether there are defects such as leaks, bubbles and paint clots.
Fifth, the dry film weight and dry film distribution of the internal spraying paint.
Sixth, set the test standard for conductivity, and note that the internal control standard should be stricter than the national standard and customer standard. When the conductivity reaches the internal control standard warning, corrective action should be initiated immediately.
Seventh, in the actual test of conductivity, pay attention to check that the electrolyte level should be 2mm away from the can mouth. If the conductivity is found to be excessive, the position of the exposed metal on the inner coating should be checked for further investigation.
Eighth, the calibration of the conductivity detector is calibrated using a standard calibration resistor of 1KΩ (display current value 6.3mA).
Ninth, the furnace temperature curve meter should be calibrated regularly.
Tenth, detect the discoloration and adhesion of the inner coating after boiling.
Eleventh, the stacking machine operator visually inspects the finished aluminum cans and tests the conductivity of the cans after extraction and contact with the plug.
Twelfth, further handle the unqualified products isolated due to excessive conductivity.
Implement 5S, namely, sorting, tidying up, cleaning, cleaning, and literacy.
First, cleaning of the internal spraying machine (including spray guns, nozzles, tower wheels and guide rails, etc.).
Second, other cleaning (including exhaust pipes, pipes, machine covers, conveyor line covers, frames, etc.).
Third, cleaning at the entrance and exit of the oven.
Fourth, the internal spraying machine needs to be closed.
Fifth, the cover of the conveyor belt needs to be tightly covered to prevent pollutants from falling from the top at the entrance and exit.
The top management attaches great importance to product quality. As long as the top management of the company is willing to pay a "high" price to improve product quality, the common problem of excessive conductivity of aluminum cans can be solved.
Correct the relationship between product quality and quantity. In terms of "product quality and quantity", the company should reach a consensus among all employees, that is, "quantity without quality is meaningless, and only quantity based on quality constitutes quantity in the true sense."
Adhere to the four basic principles in production practice. That is, in production practice, adhere to "accurate measurement, sophisticated equipment, excellent talents, and standardized production", only in this way can it be invincible in the fierce market competition.
