Converting — Plant-3-Chengdu
Workshop monthly trend, line benchmark & line detail · Jun 2026
This week on Line-1, Shift-A leads by +0.9pp1 over Shift-B (Wang) — driven by register variance (±1mm vs ±1.2mm). Worst asset is Diecutter-2 at 92.5%2 (PM On Schedule, 31d vs 45-day cycle).
- Shift spread at +0.9pp between Shift-A and Shift-B
- Diecutter-2 PM overdue 0d past cycle
- P1Roll out Shift-A tight-control protocol to all shifts on Line-1OpenOwner:Due:Impact:Why:Shift yield spread+0.9ppTemp variance±1 vs ±1.2mm
- P1Emergency PM + moisture probe replacement on Diecutter-2OpenOwner:Due:Impact:Why:Diecutter-2 yield92.5%PM status31d / 45d cycle
- P2Coach Wang's crew on register-control SOPOpenOwner:Due:Impact:Why:Shift-B temp variance±1.2mm
- P3Add SPC alarms for register excursionsOpenOwner:Due:Impact:Why:Detection gapno SPC alarms
Week-over-Week Movement
0 improved3 worsened· Jun 2026 vs May 2026Biggest Drivers
- Diecutter-2 lowest at 92.5%
- Shift-A leads Shift-B by +0.9pp
Converting — yield trend
Monthly · year to Jun 2026
Workshop Manager review — Converting
Decisions to make now: close the 2.6pp yield gap (actual 93.4% vs target 96%), verify who changed what, and de-risk the next scheduled orders.
Yield-loss decomposition
Converting — target 96% down to actual 93.4% by cause
Loss causes & accountability
Each loss cause mapped to its accountable frontline owner
| Loss cause | Yield Δ | Cost | Accountable |
|---|---|---|---|
| Changeover & make-ready waste | -0.99pp | RMB 2172K | Line Engineer — Y. Tan |
| Glue & scoring control | -0.70pp | RMB 1543K | Process Eng. — M. Sun |
| Diecutter blade wear | -0.52pp | RMB 1143K | Maint. Tech — J. Guo |
| Manual handling / palletising | -0.39pp | RMB 857K | Shift Lead — K. Xu |
Change & switch log — Converting
Every material switch, changeover, PM and protocol change · who performed it & its yield impact
| Date | Type | Activity / switch | Reason | Performed by | Yield Δ |
|---|---|---|---|---|---|
| Jun 05 | Changeover | Product changeover — coating grade A→B | Scheduled order sequence | Y. Tan · Line Engineer | -0.4pp |
| Jun 12 | Protocol | Drying tunnel temperature profile adjusted | Moisture trending toward spec limit | M. Sun · Process Engineer | +0.5pp |
| Jun 18 | Maintenance | Filter media replaced on Line-2 | Differential pressure alarm | J. Guo · Maintenance Technician | +0.3pp |
| Jun 24 | Quality | Re-inspection re-grade of held lot | Edge scratches on slit rolls | K. Xu · Shift Lead | -0.3pp |
Line benchmark — last 14 days
Daily yield % by line · toggle lines in the legend
Line detail — Line-1
Daily trend, run log, planned orders and frontline actions below are all scoped to Line-1.
Last 14 days — daily · Line-1
Daily yield & register variance
Run-by-run log — Line-1
Last 10 runs · register excursions flagged
| Run | Day | Yield% | Cycle hrs | Register dev mm | Result | Note |
|---|---|---|---|---|---|---|
| B-3850 | Jun 26 | 93.0 | 7.2 | +0.7 | PASS | |
| B-3849 | Jun 25 | 92.9 | 7.2 | +0.7 | PASS | |
| B-3848 | Jun 24 | 92.5 | 7.4 | +0.9 | PASS | |
| B-3847 | Jun 23 | 92.4 | 7.4 | +1.0 | PASS | |
| B-3846 | Jun 22 | 92.4 | 7.4 | +1.0 | PASS | |
| B-3845 | Jun 21 | 94.5 | 7.4 | +1.0 | PASS | |
| B-3844 | Jun 20 | 92.3 | 7.5 | +1.1 | PASS | |
| B-3843 | Jun 19 | 92.0 | 8.4 | +2.1 | FAIL | reprocess |
| B-3842 | Jun 18 | 93.4 | 7.0 | +0.5 | PASS | |
| B-3841 | Jun 17 | 93.4 | 7.0 | +0.5 | PASS |
Next planned orders — Line-1
Forward order book for this line · changeover & material risk flagged for scheduling decisions
| Start | Order | Product / grade | Customer | Vol (KSqM) | Machine | Changeover | Priority | Status |
|---|---|---|---|---|---|---|---|---|
| Jul 02 | PO-7425 | UV-coated folding carton | Appliance-KA1 | 15.4 | Diecutter-2 | Yes | Normal | Scheduled |
| Jul 04 | PO-7421 | Heavy-duty pallet box | Export-KA2 | 31.1 | Diecutter-2 | – | High | Awaiting QC |
| Jul 12 | PO-7423 | Heavy-duty pallet box | Ecom-KA3 | 15.3 | Diecutter-2 | Yes | Normal | Scheduled |
| Jul 15 | PO-7420 | Litho-laminated display | Export-KA2 | 20.6 | Diecutter-2 | – | High | Material at risk |
| Jul 15 | PO-7422 | Heavy-duty pallet box | Ecom-KA3 | 27.8 | Diecutter-1 | – | Normal | Scheduled |
| Jul 25 | PO-7424 | Litho-laminated display | Appliance-KA1 | 26.5 | Diecutter-2 | – | Normal | Awaiting QC |
Frontline actions — Line-1
Cascaded to the responsible engineer / team leader with due date & expected impact
| # | Action | Owner | Due | Expected impact |
|---|---|---|---|---|
| 1 | Replace filter media on Line-1 at DP alarm threshold | J. Guo · Maintenance Technician | 3 days | +0.4pp A-rate |
| 2 | Lock drying tunnel temperature profile in recipe | M. Sun · Process Engineer | 1 week | Hold moisture < spec |
| 3 | Reduce changeover flush loss — dry-flush trial | Y. Tan · Line Engineer | 2 weeks | Recover changeover yield |
| 4 | Re-grade held lot & feed back edge-scratch RCA | K. Xu · Shift Lead | 3 days | Reduce re-inspection loss |
Machine detail — Line-1
Worst-first · PM status and register control per machine on this line
| Machine | PM | Yield% | A-Rate% | Cycle hrs | Register ±mm | Days since PM |
|---|---|---|---|---|---|---|
| Diecutter-2 | On Schedule | 92.5% | – | 14.1 | 0.9 | 31/45 |
| Diecutter-1 | On Schedule | 94.8% | – | 14.5 | 1.1 | 3/45 |
Root-Cause Convergence
Supplier-2 recycled-liner moisture: Incoming liner moisture 9.8% vs 8.5% spec → warp carried into every Plant-3-Chengdu corrugator line.
Corrugator-2 overdue PM: Moisture probe drift → poor wrap-arm control → ±1.5mm register variance → trim waste rises.
Shift-A practice gap: No pre-run moisture probe calibration → amplifies the Corrugator-2 problem.