Improve the productivity of bookbinding machines
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There are three main reasons for the waste of time on the binding line: equipment failure, pre-boot preparation and machine adjustment, and material is not normal. To improve the productivity of the gutter, you need to start from the following aspects.
Maintenance
Maintenance is a cultural literacy. The practice of evaluating the quality of the operator based solely on the amount of production will result in a habit of not paying attention to maintenance. If you have a strong sense of quality, turn the machine off when you have a problem and adjust the machine. Although it is very tiring to remove the old knife from the machine, this time is worth spending.
In order to extend the tool change cycle, some bookbinding factories use low temperature tempering method to cool the knife to below 300 degrees Fahrenheit with liquid nitrogen. According to reports, if handled well, low temperature tempering can change the microstructure of the knife and increase the strength of the knife. The cost of the secondary low temperature tempering process is based on the weight of the knife and the number of knives to be processed.
Reduce the preparation time before booting
In order to reduce the preparation time before starting, some people advocate using a one-minute mold change method. This method was originally developed from the automotive industry, which divides all tasks into internal and external categories. Internal tasks can only be performed during downtime, and external tasks can be performed while the machine is running. Preparing for work is a way to reduce internal tasks. For example, are all the tools and materials required to prepare for the start-up work correct and applicable? If so, are they layered and easy to get? Are all tools and materials working in a normal state? Recording the adjustment and operation of the equipment helps to identify areas that need improvement.
The adjustment of the new generation of binding machines is much simpler. Most of them use programmable logic controllers (PLCs) to control the preparation before starting, display the production status and perform fault diagnosis.
Miller Martini's Prima saddle stitcher has an automatic, computer-controlled pre-boot preparation system that allows direct adjustment and timing adjustments, automatically adjusted by a PC controller. Repeatable settings allow work data to be stored on disk for later recall. While the current job is still in progress, the next job can be programmed. According to statistics, the preparation work before the start-up, including data input, can be completed in 10 to 15 minutes.
Smooth paper
Some experts believe that folding and transporting folded paper to the matching table takes up 80% of the saddle stitching process. Some problems that may occur during the loading of the book, such as: paper skew, curling, tearing, the signature is not compacted when folding, not crisp, the notes are not uniform, etc., these problems will make paper It becomes very difficult, and the speed of the stapler is greatly slowed down.
The signature recognition device facilitates smooth paper feeding. The device has a sensor mounted in the paper feeder to optically scan the signature. It measures the specified portion of the signature and compares the measured value with a pre-set value that was automatically stored in the device at the beginning of production. Deviated signatures are detected and Removed from the production line.
Best Graphics' mid-production staple BestOsako System 368 features a central console for monitoring speed, counters, fault displays and jam alarms.
Rosback has launched the Lynx Line 724 saddle stitcher with a design capacity of 500 to 32,000 per day. It is characterized by a 4-plot vertical paper feeding device, which can hold 9in (22.86cm) paper stock and can be used to boot fashion paper.
Heidelberg's Stitchmaster 270 medium-volume saddle stitcher, signature book can be established or horizontal. The vertical structure can hold more signatures, thus reducing the number of paper loading. This feature also reduces the fatigue of the operator, who can determine whether it is established or horizontal depending on the specific conditions of each batch.
Full service Mailers installed a Fenimore-Vijuk 920 Sidewinder with nine signatures, which can be used for bookbinding of short-volume booklets. Sidewinder uses a vertical rotary paper-feeding device. Its signature system allows users to change the signature stations according to the size of the live batch. It can adjust the signatures to accommodate various thicknesses of paper. Material or signature. The Sidewinder is rated at 5,000 copies per hour and is still good if it is opened to 25,000 copies per hour.
Add supporting equipment
The efficiency of the printing shop will inevitably put pressure on the binding. In order to speed up business turnover, configure a suitable, new and efficient binding machine or add equipment such as inkjet devices or mailing stations behind the binding machine to better meet the various needs of customers.
Time-saving auxiliary equipment
People are now equipped with automatic counting stackers behind the binding machine. Many people have installed continuous paper feeding devices and signature paper feeders, but the binding of book blocks should be carried out in the printing shop. On the side of the waste paper next to the three-sided cutting machine, an automatic system can be designed to suck them into the pile of waste paper through continuous airflow and then pack them away. The binding shop often has a large number of calendars to be bound. If you can complete saddle stitching and punching on one line, you will save a lot of time. Auxiliary equipment that saves time is like strapping machines, shrink wrappers and various counting and weighing equipment.
Willing to spend time training
Training workers must be planned in a planned manner, especially when installing new machines, and it is important to arrange as much time as possible for training. Maintenance personnel should also be invited to participate in the training, because only the machine is familiar with the operation of the machine.
Finally, remember that "fast" is not necessarily good. Only when the neat and clean products are handed over, can we recover the purchase price, and the customer does not care how fast your machine turns.