Maintenance, calibration and process control: key issues to optimize print production and production
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There are two basic goals for print managers: making money and saving money. How to manage to achieve these two goals? Sales are a must, but quality production is also the most common answer to this question.
How can a printing company achieve optimal production quality during operation? Many companies choose to use a quality management system, which is considered to be one of the ways to maximize the effectiveness of operations.
But there are still some questions: How does the printing company precisely control its process? How do the workers operate according to the rules?
The GATF developed the TPM (Total Production Maintenance) - comprehensive production maintenance inspection and registration process. The program consists of three basic elements: maintenance, calibration, process control activities and procedures for all production equipment including prepress, printing and postpress throughout the production process. The idea is to combine quality and production by combining all the printing processes.
The descriptions of the key issues of improved process and throughput for maintenance, calibration, and process control activities are all considered from the perspective of implementing the requirements of the GATF TPM program.
Maintenance
Maintenance refers to the protection of printing equipment and test equipment used in pre-press, printing, and post-press processes to optimize their working conditions. This step requires the following work to be done:
* Arrange a phased diagnosis
Detect device performance using the correct test tables and test samples. For example, many printing companies detect printing presses for half a year. Diagnostic results should be documented to document the quality level of equipment production.
* Restore the device to an optimized level
Don't wait for the equipment to be repaired. Whenever necessary, you should restore your device to an optimized state as soon as possible. There must be appropriate data support to allow the recovery and maintenance process to be processed and completed as quickly as possible.
* Use autonomous maintenance procedures to avoid equipment damage.
The damage process of the equipment can be effectively prevented by an effective autonomous maintenance system. Within an autonomous maintenance program, the responsibilities and actions of equipment operations and maintenance personnel should be covered.
The content involved is an essential part of an effective program. The behavior should include the following aspects:
1. Calibrate the operation of the device (correct adjustment of the device)
2. Maintaining basic working conditions (cleaning and oiling the machine) is helpful in preventing damage to the equipment.
3. Monitor equipment conditions regularly to test for damage.
All of the above aspects need to establish documentation to support the implementation of self-maintenance behavior and help to consistently establish maintenance arrangements.
* Establish a maintenance plan
The frequency of maintenance cycles, tasks, and diagnostic activities is as important as the program itself. The maintenance cycle can be divided into: daily, weekly, monthly (500 hours), quarterly (1500 hours), half a year or one year. Establish a dedicated activity cycle based on recommendations from equipment manufacturers and best industry practices, and provide clear documentation of maintenance plans.
Calibration
Calibration involves testing and adjustment of equipment (such as scanners, laser imagesetters, displays, vacuum boxes, printers, die-cutters, etc.) and feature processes that meet industry and manufacturer-specific conditions. The goal is to provide an accurate display and output of image reproduction for the device/process.
The required activities are as follows:
* Phased calibration and test equipment
* Use the correct instrument, scale (example: specified linear standard, transmission density meter, plate control standard, gray ladder, register test piece, PH / conductivity measuring instrument, and printing machine test table, etc.) to ensure equipment Produce optimized products.
* Use manufacturer-specific calibration tools based on equipment, materials, and industry acceptable targets (like SWOP, ShOPS, SNAP, GRACoL, PROP, and FIRST).
* Calibrate and test under the guidance of the manufacturer and industry guidelines defined for accuracy and cycle.
Process control
Process control activities involve the management of equipment and processes using feedback from operational and technical systems. The input and output data lists are displayed against specific standards and control limits based on specified rules and "best" industry practices. Equipment and tools are adjusted if necessary to comply with specific standards and control limits.
The required activities are as follows:
* Monitor daily prepress and printing using manufacturers and industry-recognized technologies and instruments, visual observation methods, approved measurement scales, industry-approved lighting conditions, pre-printing scales, densitometers and hygrometers, color control panels, etc. And the quality of equipment production in the field of post-production production.
* Place documents next to the device to support proper quality control process control.
* Based on quality process control standards consistent with manufacturers, industry, printing companies and user-approved features such as SWOP, ShOPS, SNAP, GRACoL, PROP and FIRST.
* Process control using quality products that control the company's quality practices or the user's specific needs.
* In the TPM checklist, list the period of monitoring quality as a file and place the checklist next to the device. For example, the pre-press checklist may indicate the pre-press staff's test camera and imagesetter operation, and the vacuum box and monthly single-step repetitive operation of the equipment; the printer's test list may record the press The impression of the printer during the specified period, the test density of each printing process, the expansion of the dot, and the daily detection of the pH and conductivity of the dampening solution, the weekly installation of the roller, the monthly printing workshop Lighting conditions, etc.
Main TPM behavior
The key to the GATF TPM quality control program is maintenance, calibration and quality control. The company's main TPM development activities should focus on eliminating the loss of the six major equipment. Combining these behaviors with devices and systems can reveal many hidden issues that can affect the loss of six major devices. Efforts to improve quality and yield are well worth the effort.
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What are maintenance, calibration and process control activities?
* Maintenance Behavior: Maintain or protect printing equipment and test equipment - pre-press, print, and post-press processing so that they remain in optimum and initial working condition.
* Calibration behavior: Test and adjust equipment and processes such as scanners, displays, laser imagesetters, vacuum frames, presses, or die-cutters based on industry and manufacturer conditions, as well as acceptance characteristics, to provide them with duplicate images Accurate display and output.
* Process Control Behavior: Provides feedback on the operational technology system to the display and management equipment and processes.