The key problem of optimizing printing production

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The key problem of optimizing printing production and output

printing managers always have two basic goals: making money and saving money. How can management achieve these two goals? Sales is necessary, but high-quality production is also the most common answer to this question

nbsp; How can the printing company make the operation process achieve the best production quality? Many companies choose to use quality management systems, which is considered to be one of the ways to maximize the effectiveness of operations

nbsp; But there are still some questions: how does the printing company accurately control its process? How do the workers operate the procedure

GATF developed TPM (total production maintenance) - a comprehensive production maintenance inspection and registration procedure. The procedure includes three basic elements: maintenance, calibration, process control activities and procedures, which are used for all production equipment in the whole production process, including pre press, printing and post press. This idea is to maximize quality and output by combining all printing production processes

the following descriptions of maintenance, calibration and process control activities, which are key issues to improve the process and output, are all considered from the perspective of implementing the requirements of GATF TPM procedures


maintenance refers to the protection of printing equipment and testing instruments used in the pre press, printing and post press processes to make them in the most ideal working state. In this step, the following tasks need to be completed:

* arrange periodic diagnosis

use the correct and commonly used test tables and test samples to test the performance of the equipment. For example, many printing companies test their printing machines every six months. The diagnosis results should be documented to record the quality level of equipment production

* restore the equipment to the optimization level

don't wait for the equipment to be repaired. As long as necessary, the equipment should be restored to the optimized state as shown in Table 9 as soon as possible. There must be corresponding data support to enable the recovery and maintenance process to be processed and completed as soon as possible

* use independent maintenance procedures to avoid equipment damage

the damage process of the equipment can be effectively prevented by using an effective independent maintenance system. In an independent maintenance program, the and behavior of equipment operation and maintenance personnel should be involved

nbsp; These contents are necessary for an effective program. The behavior should include the following aspects:

1. Calibrate the operation of the equipment (correct adjustment of the equipment)

2. Maintain basic working conditions (clean and oil the machine), which are helpful to prevent damage to the equipment

3. regularly monitor the equipment conditions to test the damage

the above aspects need to be documented to support the implementation of independent maintenance behavior. As long as the spring is put into the test disk, it will help to stably adhere to the establishment of 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, every week of electric vehicle development, monthly (500 hours), quarterly (1500 hours), half a year or one year. According to the suggestions of equipment manufacturers and the best industry behavior, establish a special activity cycle, and provide clear maintenance plan documents


calibration involves the testing and adjustment of equipment (such as scanners, laser imagesetters, displays, vacuum frames, printers and die-cutting machines, etc.) and characteristic processes that meet the special conditions of the industry and manufacturers. Its goal is to provide accurate display and output of image reproduction for equipment/process. The required behavior activities are as follows:

* periodically calibrate and test the equipment

* use the correct instruments and scales (e.g. designated linear scale, transmission densitometer, printing plate control standard, gray scale, registration detector, ph/conductivity meter, printer test table, etc.) to ensure that the equipment produces optimized products

* use manufacturer's specification calibration tools based on equipment, materials and industry acceptable goals (such as swap, hoops, snap, gracol, prop and first, etc.)

* calibration and testing are conducted under the guidance of manufacturers and industry guidelines defined for accuracy and cycle

process control

process control activities involve the use of feedback from operation and technical systems to manage equipment and processes. According to the specified rules and "best" industry practices, the input and output data are displayed in a list and compared with the special standards and control limits. If necessary, the equipment and tools shall be adjusted to conform to the special standards and control limits

the required activities are as follows:

* use the manufacturer's and industry recognized technologies and instruments, visual observation methods, recognized measurement scales, industry recognized lighting conditions, prepress replication rulers, densitometers and hygrometers, color control boards, etc., to monitor the production quality of equipment in the prepress, printing and post press production fields every day

* place documents next to the equipment to support correct quality monitoring and process control

* based on quality process control standards consistent with the recognized characteristics of manufacturers, industries, printing companies and users (such as swap, shutts, snap, gracol, prop and first)

* use the process control of quality products that control the quality practice of the company or the special needs of users

* in the inspection list of TPM, the cycle of quality monitoring is listed in the form of documents, and the pump list in the hydraulic system is placed next to the equipment. For example, the prepress inspection list may indicate the working conditions of the prepress personnel testing the camera and imagesetter every day and half a week, as well as the records of the vacuum frame and the monthly single step repeated operation of the equipment; The inspection list of the printing plant may record the printing sample situation observed by the printer operator in the specified cycle, the test density and dot expansion of each printing process, and the pH value and conductivity of the fountain solution are tested every day, the installation of the drum is tested every week, and the lighting of the printing workshop is tested every month

main TPM behaviors

the key of GATF TPM quality control program lies in maintenance, calibration and quality control. The company's main TPM development activities should focus on eliminating the losses of six major equipment. Combining these behaviors with equipment and systems can reveal many hidden problems that will affect the loss of the six major equipment. Efforts to improve quality and output are very worthwhile

attachment: what are maintenance, calibration and process control activities

* maintenance behavior: maintain or protect printing equipment and testing equipment - Prepress, printing, and post press processing, so that they are always in the best and initial working state

* calibration behavior: Test and adjust equipment and processes such as scanners, displays, laser imagesetters, vacuum frames, printers or die cutting machines to provide accurate display and output of copied images according to industry and manufacturer conditions and acceptance characteristics

* process control behavior: feedback of operable technical system to display and management equipment and process

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