Order Mix and Roll Size Analysis, How to Capitalize on Computer Data, 1998 Corrugated Containers Conference Proceedings

Using a plant’s corrugator run data for the past three to six months, it is possible to determine a number of relevant facts pertaining to the plant’s roll matrix and the causes for excessive side trim. Specifically, in addition to traditional reports and measurements, this analytical approach indicates: side trim percentage by board combination and size, and side trim percentage by individual roll size.

Such data allows the analyst to get good indications of what specific size changes may lead to reduced side trim. Once roll sizes have been determined, it is important to the plant to know which items do not fit the matrix and which customers generate excessive trim. Other reports indicate: Side trim by Customer, and Side trim by Individual Item.

Finally, it is possible to identify with clarity the cost of upsizing. If we are stocking 60 and 57 inch paper, and we see a significant amount of lineal footage running out of 60", but trimming at 56" and below, we must ask why didn’t those runs use 57"? The cost of upsizing has been observed to be substantial in some plants, and we explain the causes.

Our discussion uses data and reports which are intended to give managers ideas and techniques which they may be applied in their plants to develop deeper insight into their roll sizes and order mix.