For some small and medium-sized printers, a giant Heidelberg offset press with a value of 10 million can occupy a large part of the company’s fixed assets.
In today's low-profit era of the printing and packaging industry, printing companies can only recover their costs as quickly as possible by increasing the operating rate of their printing presses.
How to increase the printing machine's operating rate?
Reducing printer turn-around time is one of the most effective ways we can increase the efficiency of printing presses. If we make 20 orders per day for each press and we change the time for each order to 20 minutes, then each printer will need to switch orders for up to 400 minutes a day. If it can take only 10 minutes to change orders, it will directly save 200 minutes and increase efficiency by 50%.
To do this, we need to rationally arrange a series of work from preparation before printing to on-site commissioning and personnel division. Only by increasing the operating rate of the equipment to achieve the goal of 50% efficiency!
How to do it?
First, do a good job in prepress preparation and do more with less
Let's talk about the details that need to be taken into account in prepress preparation. What do we need to prepare for prepress? How to ensure that preparations are in place?
1. Prepare the ink needed for the printing machine
Pick up the ink and check the ink's pH, viscosity, and hue for compliance with the standard. Due to the PH value control of the printing of the paper on the adsorptive force, especially to do the most prominent network dot overprint. If you adjust the PH value of the previous red PH value is set to 9 and the back stack color blue PH value is set to 8, so that the effect of overprinting is the blue can not cover the red, superimposition will be poor. The same viscosity is one of the most critical factors for controlling the printing quality. If the viscosity is too high, the printing may be unclear, deinking, etc., so it must be tested. Do not check the hue, ink is not found after washing the ink, it will lose 2 kilograms of ink and spend at least 15 minutes to stop the change of ink. After viewing the print production schedule, arrange the staff to pick up the ink that needs to be used on the day and place it in the on-site workshop. Stir the ink before putting it on the machine and then ink iteratively to produce it.
2. Prepare the printing plate required by the printing machine
In our printing process, the printing plate often appears on the machine and it is found that the printing plate is not correct or that the printing plate is worn out, resulting in the inability to print, resulting in a stand down. Each time it will cause 30 minutes of shutdown waste and the waste of each cleaning ink is at least 2-4 kg of ink. How to overcome this kind of situation?
(1) The printing room personnel take the printed version according to the production schedule and send it to the printer.
(2) The version picker first tests the printing plate, if the text is correct.
(3) Check whether the layout is stained or worn, etc., and then send it to the machine and check whether the printing plate number is correct.
3, cardboard preparation
During the printing process, the printing plate and the ink were all on the machine. It was found that the cardboard did not come out, which caused the machine to change the order and wash the ink. This type of event occurred from time to time. The following suggestions are for your reference and can be used to prevent similar problems.
1) First check whether the cardboard has been produced, avoid hanging the printing plate, etc., but no cardboard printing.
2) According to the production schedule, sort out the order of the production of cardboard.
Summary: If the above three aspects can be achieved, our on-site downtime will be reduced by 20%. Only by controlling the details can we gradually increase the efficiency of the press.
Second, synchronous management of internal and external tasks to improve press efficiency
Enterprises want to improve the printing efficiency, Huayin experts believe that the best way to improve is to record our current work situation: record all the tuneup actions and divide them into internal and external tasks, and convert internal tasks into external tasks as much as possible. And reduce the time required for external tasks.
Internal task
The internal task is the activity that must be performed in the locked state of the device: if the printing plate is changed, the position of the pressure roller is adjusted, and the machine must stop. How can we complete internal tasks in advance? Usually four people a device, No. 1, captain 2, 3, 4 deputy.
(1) We often find that after the last list is over, employees do not know what to do, that is, wait there or wait for the command of the captain. Therefore, we need to reduce the connection time before opening the machine after a single stoppage, so as to shorten the preparation time.
(2) After the order is over, the equipment stops. Our staff often finds tools repeatedly to take tools and do repeated actions. We must reduce the number of times employees 1 and 2 and 3 repeatedly access the machine to get tools after the machine is turned on. When the number of repetitions is reduced, the time is reduced.
(3) In the normal operation, after the previous one is printed, the previous single-printer ink is cleaned and then the printing plate is removed. This process will waste 1-2 minutes. The correct approach is to prepare plates, liners, and inks to be replaced in advance and place them in the printing unit that needs to be replaced. This saves 2 minutes.
(4) It is very important to adjust the process parameters of the next work order. It is necessary to make adjustments according to the data records on the process card to prevent adjustment after the machine is put on. This specific operating standard can be viewed on a test machine related WeChat.
(5) The printing press is a team cooperation team. When a certain position does not finish internal matters, other personnel should actively produce in production, and concentrate the manpower to complete internal events.
Summary: According to the above operations, it can save 4-5 minutes, which means that 20 orders a day will save 100 minutes and increase the efficiency by 20%.
2. External tasks
External tasks are activities that can be performed during the production of cartons in the equipment: quasi-printing, ink, or inking. How can we reduce external time?
1. After the order is over, we should promptly clean the paper feeding section and start to adjust, take away the printed materials, and adjust the stacker to prepare the tray.
2. We need to use employee No. 4 to complete external events. Only by rationalizing the work flow of employees can the waiting time be reduced.
From this it can be seen that with the on-site operation and verification, it is entirely possible to achieve the actual need to increase the printing efficiency by 50%.
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