Corrugating — Plant-3-Chengdu
Workshop monthly trend, line benchmark & line detail · Jun 2026
This week on Line-1, Shift-A leads by +0.8pp1 over Shift-B (Zhang) — driven by register variance (±1.2mm vs ±1mm). Worst asset is Corrugator-2 at 93.0%2 (PM OVERDUE, 37d vs 30-day cycle).
- Shift spread at +0.8pp between Shift-A and Shift-B
- Corrugator-2 PM overdue 7d past cycle
- P1Roll out Shift-A tight-control protocol to all shifts on Line-1OpenOwner:Due:Impact:Why:Shift yield spread+0.8ppTemp variance±1.2 vs ±1mm
- P1Emergency PM + moisture probe replacement on Corrugator-2OpenOwner:Due:Impact:Why:Corrugator-2 yield93.0%PM status37d / 30d cycle
- P2Coach Zhang's crew on register-control SOPOpenOwner:Due:Impact:Why:Shift-B temp variance±1mm
- P3Add SPC alarms for register excursionsOpenOwner:Due:Impact:Why:Detection gapno SPC alarms
Week-over-Week Movement
1 improved2 worsened· Jun 2026 vs May 2026Biggest Drivers
- Corrugator-2 lowest at 93.0%
- Shift-A leads Shift-B by +0.8pp
Corrugating — yield trend
Monthly · year to Jun 2026
Workshop Manager review — Corrugating
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
Corrugating — 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 |
|---|---|---|---|
| Liner moisture (Supplier-2 recycled grade) | -1.09pp | RMB 2400K | Incoming QA — L. Zhao |
| Corrugator wrap-arm drift (Corrugator-2) | -0.73pp | RMB 1600K | Line Engineer — W. Chen |
| Overdue PM / moisture probe | -0.42pp | RMB 914K | Maint. Tech — J. Guo |
| Shift-A pre-run calibration gap | -0.23pp | RMB 514K | Shift-A Lead — H. Lin |
| Setup & make-ready loss | -0.13pp | RMB 286K | Ops — F. Wu |
Change & switch log — Corrugating
Every material switch, changeover, PM and protocol change · who performed it & its yield impact
| Date | Type | Activity / switch | Reason | Performed by | Yield Δ |
|---|---|---|---|---|---|
| Jun 04 | Material | Incoming liner grade switched to Supplier-2 recycled | Supplier-1 allocation shortfall; procurement cost-down | L. Zhao · Incoming QA Engineer | -1.6pp |
| Jun 07 | Maintenance | Corrugator-2 moisture probe recalibrated (not replaced) | ±1.5mm drift flagged on run B-3841 | J. Guo · Maintenance Technician | +0.4pp |
| Jun 11 | Changeover | Board-grade changeover B-flute → BC-flute double wall | Ecom-KA3 qualification run | W. Chen · Line Engineer | -0.5pp |
| Jun 15 | Protocol | Corrugator hot-plate setpoint lowered 2°C | Adopt Shift-B tighter-control protocol | H. Lin · Shift-A Lead | +0.7pp |
| Jun 19 | Maintenance | Corrugator-2 PM deferred (over 30-day cycle) | Order backlog; no scheduled slot | J. Guo · Maintenance Technician | -0.9pp |
| Jun 23 | Quality | Lot B-3846 quarantined (warp out-of-spec) | Warp 4.8mm vs <4.0 spec — reprocess | F. Wu · QA Inspector | -0.6pp |
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 | 94.3 | 8.7 | +1.0 | PASS | |
| B-3849 | Jun 25 | 92.9 | 8.5 | +0.8 | PASS | |
| B-3848 | Jun 24 | 94.6 | 8.8 | +1.1 | PASS | |
| B-3847 | Jun 23 | 91.0 | 9.3 | +1.6 | REVIEW | temp excursion |
| B-3846 | Jun 22 | 94.1 | 8.6 | +0.8 | PASS | |
| B-3845 | Jun 21 | 89.8 | 9.6 | +2.0 | FAIL | reprocess |
| B-3844 | Jun 20 | 92.8 | 8.5 | +0.8 | PASS | |
| B-3843 | Jun 19 | 93.1 | 8.4 | +0.7 | PASS | |
| B-3842 | Jun 18 | 91.1 | 9.3 | +1.7 | REVIEW | temp excursion |
| B-3841 | Jun 17 | 94.2 | 8.6 | +0.9 | 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 04 | PO-7425 | Heavy-duty pallet box | Appliance-KA1 | 21.8 | Corrugator-2 | – | Normal | Awaiting QC |
| Jul 08 | PO-7423 | Litho-laminated display | Appliance-KA1 | 30.8 | Corrugator-1 | Yes | Normal | Material at risk |
| Jul 10 | PO-7421 | B-flute single wall | FMCG-KA1 | 33.7 | Corrugator-1 | – | Normal | Scheduled |
| Jul 21 | PO-7424 | Litho-laminated display | Appliance-KA1 | 16.9 | Corrugator-1 | Yes | Normal | Material at risk |
| Jul 23 | PO-7420 | BC-flute double wall | Export-KA2 | 12.4 | Corrugator-2 | – | Normal | Scheduled |
| Jul 27 | PO-7422 | B-flute single wall | Ecom-KA1 | 23.7 | Corrugator-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 Line-1 Corrugator-2 moisture probe + emergency PM | J. Guo · Maintenance Technician | 48 hrs | +2.0pp yield on Corrugator-2 |
| 2 | Re-test incoming moisture on all Supplier-2 liner lots; quarantine >4.0mm warp | L. Zhao · Incoming QA Engineer | 24 hrs | Stop contaminated feed |
| 3 | Roll the Shift-B register-control protocol to Shift-A & Shift-C on Line-1 | H. Lin · Shift-A Lead | 3 days | +1.5pp yield across shifts |
| 4 | Add pre-run moisture probe calibration to SOP checklist | W. Chen · Line Engineer | 1 week | Prevent drift recurrence |
| 5 | Log & reprocess quarantined run B-3846; RCA to shift board | F. Wu · QA Inspector | 2 days | Recover 0.6pp, close finding |
| 6 | Confirm Supplier-1 stock for the next double-wall changeover order | Y. Tan · Planner | 1 week | De-risk the Ecom-KA3 qualification run |
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 |
|---|---|---|---|---|---|---|
| Corrugator-2 | OVERDUE | 93.0% | – | 14.5 | 1.1 | 37/30 |
| Corrugator-1 | On Schedule | 94.5% | – | 18.0 | 1.0 | 4/30 |
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.