Scrap Tracking
The Vietnam factory records scrap by production line and shift each month using the form titled 廢料統計表 / BIỂU THỐNG KÊ PHẾ LIỆU. Source files are stored in OneDrive under 越南廢料表/ (e.g., 76_廢料統計表-biểu thống kê phế liệu(11月)－231114.xlsx).
Production Lines and Shift Structure
Each monthly workbook has one worksheet per production line per shift (A shift / B shift):
| Line (Chinese) | Line (Vietnamese) | Machine Code Prefix |
|---|---|---|
| Zipper Film Blowing (夾鏈吹膜) | Thổi Zipper | ZE-01+ |
| Zipper Bag Cutting (夾鏈切袋) | Máy cắt Zipper | Z-01+ |
| Flat PE/PO Film Blowing (平口吹膜) | Máy thổi PE / Máy thổi PO | FE-01+ |
| Flat PE/PO Bag Cutting (平口切袋) | Máy cắt PE / Máy cắt PO | F-01+ |
Each line has an A-shift and B-shift worksheet (8+ worksheets total), plus a summary sheet labeled 結論 (Conclusion).
Defect Categories
Zipper Lines (Film Blowing / Bag Cutting)
| Chinese | Vietnamese | Description |
|---|---|---|
| 尺寸不正確 | Kích thước không đúng | Incorrect dimensions |
| 厚度不正確 | Độ dày không đúng | Incorrect film thickness |
| 筋鬆 | Đường zipper bung / yếu | Zipper track loose or weak |
| 筋緊 | Đường zipper cứng | Zipper track too tight |
Flat Film Lines (Film Blowing / Bag Cutting)
| Chinese | Vietnamese | Description |
|---|---|---|
| 尺寸不正確 | Kích thước không đúng | Incorrect dimensions |
| 厚度不正確 | Độ dày không đúng | Incorrect film thickness |
| 膜色異常 | Màu màng bất thường | Film color abnormal |
| 膜線易撕裂 | Màng dễ bị rách | Film tears easily |
Spreadsheet Layout
Each worksheet follows this column structure:
Header row: Machine No. (Số máy) | Defect type | Day 1 | Day 2 | … | Day 31 | Subtotal
- Machine No.: Line-specific codes (ZE-01, Z-01, FE-01, F-01, etc.)
- Defect rows: Multiple rows per machine, one per defect type
- Daily columns: Count of defective units for that day (blank = 0)
- Subtotal: Monthly cumulative count per machine per defect
Responsibilities
| Role | Responsible Person |
|---|---|
| In-shift scrap recording | Shift supervisor (班長) |
| Monthly summary compilation | Statistics staff (結論 worksheet) |
Monthly Summary (結論 Worksheet)
The 結論 sheet aggregates scrap weight across all lines. Sample values from October 2023:
| Line | Value |
|---|---|
| Zipper Blowing - Shift A | 3,330.2 |
| Zipper Blowing - Shift B | 2,480 |
| Zipper Cutting - Shift A | 3,772.8 |
| Zipper Cutting - Shift B | 2,602 |
| Flat film lines (sample) | 5,040.6 |
Filing Convention
- Monthly files named with month and preparation date: e.g.,
76_廢料統計表(11月)－231114.xlsx - A Vietnamese-language version (
THỐNG KÊ PHẾ LIỆU TH-11-YYYY.xlsx) uses the same layout with Vietnamese sheet names - All monthly files are stored in the OneDrive folder
越南廢料表/
Process Flow
- During production, the shift supervisor records scrap counts per machine per defect type in the appropriate day column
- At month end, the statistics staff totals each worksheet's subtotal column and aggregates results into the 結論 summary sheet
- The completed file is saved and uploaded to OneDrive with the month and preparation date in the filename