What a simple defect ranking should change on the press
Change only the top three that make up most of the count. One defect, one cause. Next week, accept or reject by the count.
If the top three defects are most of the count, the press changes only the cause that belongs to those three. Do not change ink, paper, and pressure at the same time. Leave what ranks lower. Next week, see whether the counts of these three dropped.
Why it is judged this way
A ranking chart is for doing less. Changing ten defects at once means you cannot tell which change worked. Write the cause of the first one firmly: a doctor blade line goes to the blade, missing ink goes to the roll, register goes to tension. After the change, look only at that bar.
What to compare
| What you see | What to call it | What not to do |
|---|---|---|
| The top three have a clear cause | Change those this week | Start from the smallest one |
| One defect maps to many causes | Split the name first | Adjust them together |
| Next week’s count did not drop | The cause was wrong | Keep the same adjustment |
At job change or when a roll is opened
- Draw this week’s top three.
- Assign only one adjustment to each.
- Compare the counts next week.
