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Although the manufacturer has tested the material, the press operator must also test the material to determine if the material's performance is consistent with its standard specifications. A material may work well at Company A, but the first attempt at Company B failed, and Company B's staff may have to try several more times to find the cause of the failure, such as using water rollers. This problem occurs when paper is used. Whenever a new material or new product is put into use, such problems may occur to varying degrees.
In general, new things have a certain degree of difference compared with old things, and they also need to be modified in terms of processing methods. Therefore, there is a need for a learning and experimentation process. However, retraining or testing should not be performed on production jobs.
Many large companies have established their own quality control labs to test purchased ink, paper, and other materials. Quality control personnel also monitor the printing process of the job, the performance of new materials, and the operational performance of the equipment. Some large companies have installed small presses in their quality control labs to test materials because even a small offset press can provide valuable information about product performance.
1 Take pre-test as part of your preparation. Pre-testing the material can help reduce downtime and increase production efficiency. It is recommended that you should pre-test the new material before using it, whether it is on a small press or other methods, any pre-test of the material. They are all part of the preparation process and can provide the printing operator with valuable information on the operational properties of printing plates, paper, inks, blankets, blanket cleaners, cleaning materials and other printed materials. If the cost of testing and testing is not too high, the material should be tested first, rather than waiting for the production process to fail and affecting the production schedule.
2 Control the quality of the material. GATF Technical Service Report 7227 - Quality control of pressroom materials provides printers with many suggestions to reduce some of the unfavorable factors in the material procurement process by controlling plates, blankets, roll papers, inks, solvents, and lubricants. . To purchase, receive, process and verify, store it properly, use it properly, and accurately record operational performance, you must recognize the true difference between laboratory production and the actual production floor.
According to the technical service report, the following five basic contents need to be managed:
a. Standardization. Some vendors and selected materials should be standardized and managed based on operational performance, transportation, and cost.
b. Establish the required standards. Before the purchase order of raw materials can be made, the requirements for the materials must be specified in detail, and the suppliers must be informed of these requirements.
c. Inspection. Dimensions, quantities (or weights) of purchased materials need to be inspected, and external damage is checked. Some tests and tests are conducted in the workshop.
d, reasonable processing and storage. A first-in-first-out storage method should be used to avoid new materials used before older materials such as inks and plates. Also remember: Slight carelessness will damage the material.
e, save the record. It is important to record the status and operational performance of materials, which can provide feedback to suppliers. Records not only help printers identify existing problems and deviations from specified values, but also help suppliers solve problems in materials manufacturing.
IV. Ink Supply System and Wetting System It is generally considered that the cleaning of the ink supply and wetting system should belong to the commissioning stage, but the cleaning work should be considered as part of the preparation work. If the cleaning is not complete, it will cause the crystallization of the ink roller and other printing failures, may have to stop during the test run, and clean the printing unit again.
If the ink roller is crystallized, it will cause poor ink transfer, even ink imbalance, it is difficult to obtain a good quality print, let alone maintain the consistency of quality.
If the cleaning method is proper, the ink roller can be maintained in good condition for a long time. At the same time, due to thorough cleaning, no dirt and ink will remain on the roller, and the color of the newly injected ink will not be affected. Fortunately, on a four-color press, the color of the ink in each color group does not change, but it cannot be ignored or neglected.
If the cleaning is thorough, it not only reduces the incidence of crystallization failure of the ink roller, but also prevents "ringy white spots" due to the dried ink particles. These particles come from the ink tank and the end of the ink roller. These places often accumulate some dried ink and produce small debris on the surface of the crystallization roller. Good cleaning techniques can reduce and avoid the occurrence of such "ringy white spots" failures.
The condition of the wetting system is the same as that of the ink supply system, but it is simpler, safer, and time-saving. The wetting system should always be in a good state, and it is not necessary to search for trouble and solve the problem after a trouble has occurred.
V. Cooperative work In the operation process, the “printer operator†is a whole. Each member of the press should have a clear division of responsibilities and receive the necessary training to effectively perform the corresponding duties.
If each member is assigned a certain responsibilities and tasks, it can greatly reduce downtime. Each operator must know exactly what to do, how to do it, and when to do it; in the printing process, any work that can be done at the time should be completed in a timely manner. These responsibilities and tasks are also part of the preparation.
Work such as retrieving the material, filling each container with the appropriate solution or chemical reagents is important, but not during the commissioning or cleaning process. The most effective way is to prepare the test run during the printing process. Various raw and auxiliary materials needed during the cleaning process. Prepare new blankets, inspect materials, transport materials to the pressroom, adjust inks, mix wetting fluids, clean the operator's station, and placement tools, all of which can be done during the printing process. The more responsibilities the operator performs, the more systematic the cleaning and commissioning phase will be.
Sixth, personnel training The training of the printing personnel is also part of the preparation work. The quality of printed matter is the embodiment of the overall quality of the printing staff. Each member must be very familiar with his or her responsibilities and reasonably allocate time to perform these responsibilities.
Any method that can improve the efficiency of the operator is a good way. The captain of the press should assign each member a specific responsibility and task. In addition, the captain must specify when each role should be performed.
New members may already have some knowledge of the operation of the press during school or in a small offset press company. However, when they operate a large sheet-fed offset press together, they cannot work very smoothly right away. Operators with lower operating levels are required to receive training. The captain is the teacher. The captain does not necessarily have to teach all the operating instructions himself, but he must supervise the training. The captain first trains the second member, then the second member trains the third member, and the third member trains the fourth member, and so on, until all members have received responsibility training. In other words, after training, all members can perform their duties and work together. With the development of technology, there are fewer and fewer personnel. For example, it may only require two operators on some highly automated six-color sheetfed presses.
It is also a good idea to encourage new members to read the printing press manuals and participate in training courses organized within the company or in schools. Reading articles in magazines and books about machine operations also helps operators familiarize themselves with their duties and prepare for the next job easily. Understanding knowledge of inks, paper, plates, and other materials can increase a member's ability to solve problems during the printing process.
VII. Arranging a reasonable schedule for scheduling work is also an important factor. If there is no reasonable plan, the whole company will be in an unordered state, which may waste a lot of production time, especially in the printing workshops that take longer to work. The phenomenon of waste of time is particularly prominent.
From the dispatch department to the transportation department, unified arrangements are made. Each department or workshop knows what to do, when, and when.
The most important thing is that the overall plan and reasonable arrangement can ensure that the raw materials and auxiliary materials needed for each job, such as paper and ink, are sent to the printing shop in a timely manner; there is plenty of time to inspect and cut the paper and make it available. Adapt to the environment within the pressroom; allocate time for ink matching, testing, and delivery to the company. If the press operator knows which ink to use for the next job, it can even eliminate some printer cleaning steps.
The next job should be considered at the time of printing the current job. The captain of the press or the designated member should check the next job and confirm the following questions:
1. Check the order requirements of the job.
2, check the next job number.
3. Check if the plate of the next job is ready.
4, check whether the paper has adapted to the environment within the workshop and stacked.
5. Check if the ink is ready.
6, check whether there can be used to set the printer waste paper.
7. Check if there is a spare blanket? Can it be used?
8. Check if the liner is suitable for the next job.
VIII. As long as careful and serious work is done in summarizing the work, it will be able to achieve a multiplier effect. Otherwise, it may result in less work and more harm than good. Preparation before commissioning allows us to reduce the number and duration of downtime during the commissioning process. In fact, if the machine is running, the various preparatory tasks performed in the workshop can help reduce downtime, for example, from prior storage. The raw materials are taken from the storage room. Waste paper can be used in subsequent jobs. Also, check whether the various tools and equipment that will be used during the cleaning and commissioning of the next job are ready.
To be on the safe side, the captain may list a list (may include more items than we mentioned here) from the end of one job until the completion of the next job. Should be listed one by one. Moreover, the entire press operator should collaborate with each other to work out a detailed and complete list, which may take a week or two. Once the list is established, the arrangement of the job, the distribution of the responsibilities of each member, the arrangement of the training plan, and the separation of the commissioning procedure from the preparation work, etc., can be completed very smoothly.
6, material testing and reporting On the surface, material testing and reporting does not seem to belong to the scope of preparation, it is not true, such as the beginning of the job, the plate's work performance is very poor, this type of plate is likely to be Caused a lot of downtime.