The importance of the laboratory: From a management point of view, the various conditions for laboratory proofing strive to be similar to those for large-scale production in the workshop. The laboratory proofing work is to serve the workshop, not to require the workshop to follow the conditions of the laboratory. Production, but the laboratory should strive to imitate various conditions in the workshop when making samples. No matter how sophisticated the laboratory is, if it cannot effectively provide data and process support to the workshop, then the value of the laboratory will not be reflected.
1 The current printing and dyeing enterprise laboratory Current situation and shortcomings
1.1 Current situation
(1) The main work is to rely on manual proofing and duplication, and does not make good use of modern tools for computer testing The color matching instrument is inefficient and seriously restricts the delivery time of bulk goods.
At present, the laboratories/technical departments of many printing and dyeing factories are doing repeated proofing and copying of color samples. If the customer does not confirm, they will return the sample and reprint it until the color sample is confirmed. We have just started making duplicate samples to make large quantities of goods. Since the coloring cloth used by most companies is not the cloth used for workshop production (cloth for duplicate samples), we have to re-print three or four times or even more times before leaving the workshop. The color may not be correct when leaving the workshop, which seriously affects the company’s delivery time and the company’s credibility.
At the same time, due to various factors such as changes in light, weather, the mood of the color grabber on the day, the length of working hours, the ability of the color grabber, etc. will all affect the color grab quality. For example, for the same color, he may give a greatly different prescription in the morning, afternoon or even night, because a busy day of color picking causes visual fatigue. If you are in a good mood, the color may be adjusted in two or three times. If you are in a bad mood, it may be done in 5 or 6 times.
(2) There is no detailed analysis of the performance of the dyes and chemical materials used, and the formulated process conditions or processes mainly rely on experience The accumulation has not been scientifically designed, and it is uncertain whether it is reasonable or optimized, and refined production cannot be achieved.
(3) Due to the incomplete understanding of the quality of the dyes and chemicals used, the properties of the fabrics, etc., when diseases occur, the problem is solved simply and crudely.
(4) Insufficient innovation capabilities in new technologies and new materials seriously restrict the development of enterprises.
1.2 Defects or shortcomings
The Art of War says: Know yourself and the enemy, and you will never be in danger in a hundred battles. The same goes for being a printing and dyeing factory. Do you have a clear understanding of your raw materials, fabric quality, related machines and equipment involved, etc., such as the solubility of reactive dyes, salt and alkali resistance, spots of disperse dyes, and high and low temperature dispersion? Etc., the hardness and pH of the water used, whether the temperature and pressure of the equipment used are accurate, etc. Many companies do not pay attention to or even consider this aspect of testing.
There are also drip machines used in many laboratories now. Whether the drip is stable and whether the solution concentration design is reasonable is also related to the error of the drip itself.
Especially the equipment department of the enterprise. Is the focus of the equipment department’s work on maintaining equipment or repairing equipment? Generally speaking, repairs are only considered when the equipment has obvious faults and cannot operate normally. The importance of equipment maintenance is ignored, because before the equipment cannot operate normally and needs repairs, the equipment usually works for a period of time, and may have been damaged during this period. The quality of the product has had a certain impact.
These may seem like small problems, but they are actually big problems. Without these basic analysis data, if a problem occurs, you will not know how to analyze it. It is like a blind man trying to feel an elephant, and you will not know whether the problem is inevitable or accidental. In this way, there is no way to talk about how to improve the success rate.
2 The composition of the technical system and the work responsibilities of each department
Based on the above analysis, we believe that the technical system of a printing and dyeing enterprise should consist of three major laboratory systems:
The first is the color laboratory, whose main job is to make color samples and send them to customers for confirmation. , as well as the first cylinder copy work of new colors, which is basically done in every dyeing factory, but most of them still rely on manual color mixing. There are too many influencing factors, which seriously restricts the delivery time;
The second is the technology research and development center. This laboratory is the core of the entire technology system and is responsible for the company’s personnel training and future development. But on the contrary, many companies do not have this laboratory, and only a few large and high-quality companies have it.
The third is the quality inspection laboratory. This is usually found in high-quality companies that make export products. It is also a very critical auxiliary laboratory, but most companies have quality inspection laboratories. The laboratory only does QC inspection of batches of products, such as various fastnesses, strength, etc. The execution of other tasks, such as the early inspection of incoming batches of dyes and chemical materials, was neglected.
The following is a brief introduction to the work responsibilities of the three major laboratories. ：
2.1 Responsibilities of the color matching laboratory
(1) Proofing work in the laboratory
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3 Technical system construction Importance
In summary, how to establish a good technical system and how to effectively control every detail of the laboratory is directly related to the stability and efficiency of mass production in the workshop performance and the profit margin that executives are most concerned about.
A qualified technical center is actually a small printing and dyeing enterprise, involving all aspects of the entire process, and is far from a simple proofing organization , it is related to the long-term development of the enterprise.
The actual situation is just the opposite. Most enterprises believe that the laboratory is just for proofing and cannot directly bring objective profits like workshop production. We are very active in investing in equipment for workshop production, but we are rarely willing to invest in laboratories and ignore its importance. Therefore, we must also warn about the occurrence of this situation.</p
