Print managers always have two basic goals: making money and saving money. How can we manage to achieve these two goals? Sales is a must, but quality production is also the most common way to answer this question. 　　 Maintenance refers to the protection of printing equipment and test instruments used in prepress, printing, and postpress so that they are in the best working condition. This step requires the completion of the following tasks: These involved contents are all necessary for an effective program. The behavior should include the following aspects: * Create a maintenance plan 　　 Calibration involves the testing and adjustment of equipment (such as scanners, laser imagesetters, displays, vacuum frames, printing presses and die cutters, etc.) and characteristic processes that meet industry and manufacturer-specific conditions. The goal is to provide accurate display and output of image reproduction for the device/process. 　　 Process control activities involve the use of operational and technical system feedback to manage equipment and processes. According to the specified rules and "best" industry practice, the input and output data are displayed in a list and compared with the specific standards and control limits. If necessary, equipment and tools have to be adjusted to comply with specific standards and control limits. 　　 The key to GATF TPM quality control procedures is maintenance, calibration and quality control. The company's major TPM development activities should focus on eliminating the loss of six major equipment. Considering these behaviors in conjunction with equipment and systems can reveal many hidden issues that can affect the loss of six major devices. Efforts to improve quality and yield are worthwhile. * Maintenance behavior: Maintain or protect printing equipment and test equipment - prepress, printing, and finishing, so that they are always kept in optimal and initial working condition.
How can a printing company make the operation process reach the optimal production quality? Many companies choose to use a quality management system. This approach is considered one of the best practices for maximizing operations.
But there is still some doubt: How can a printing company precisely control its process? What kind of laws do workers follow?
GATF has developed TPM (Total Production Maintenance) - a comprehensive production maintenance inspection and registration program. The program includes three basic elements: maintenance, calibration, process control activities and procedures for the entire production process including prepress, printing and postpress all production equipment. This idea is to combine all print production processes to maximize the quality and yield.
Subsequent descriptions of maintenance, calibration, and process control activities that are critical to the improvement of processes and production are considered from the perspective of implementing the requirements of the GATF TPM process.
maintain
* Schedule diagnostics to use correct and commonly used test charts and test samples to test equipment performance. For example: Many printing companies test their presses in half a year. The results of the diagnosis should be written to record the quality level of equipment production.
* Return the equipment to the optimal level Do not wait for the equipment to do these things. Whenever necessary, the device should be restored to its optimized state as soon as possible. There must be appropriate data support to allow the recovery maintenance process to be processed and completed as soon as possible.
* Use autonomous maintenance procedures to avoid equipment damage.
The damage process of the equipment can be effectively prevented by using an effective autonomous maintenance system. In an autonomous maintenance program, the responsibility and behavior of the equipment operation and maintenance personnel should be involved.
1. Calibrate the operation of the device (correctly adjust the device)
2. Maintaining basic working conditions (cleaning and oiling the machine) are all helpful in preventing equipment damage.
3. Monitor equipment conditions regularly to test for damage.
All of these aspects need to be documented in order to support the implementation of self-maintaining behaviors and to help steadily establish maintenance arrangements.
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), six months, or one year. Based on the recommendations of equipment producers and best industry practices, establish a dedicated activity cycle and provide clear documentation of the maintenance plan.
calibration
The required behavioral activities are as follows:
* Stage calibration and test equipment * Use correct instruments, scales (eg, specified linear scale, transmission densitometer, plate control scale, gray scale, registration detector, PH/conductivity meter, and printer Test tables, etc.) to ensure that the device produces an optimized product.
* Use manufacturer-specific calibration tools based on equipment, materials, and industry acceptable targets such as SWOP, ShOPS, SNAP, GRACoL, PROP, and FIRST.
* Calibrate and test under the guidance of the manufacturer and industry guidelines defined for accuracy and cycle time.
Process control
The required activities are as follows:
* Use pre-printing and printing every day using manufacturers and industry-recognized technologies and instruments, visual observation methods, approved measurement scales, industry-recognized lighting conditions, prepress copy scales, densitometers and hygrometers, color control boards, etc. And the production quality of equipment in the postpress production field.
* Place documents next to the equipment to support proper quality monitoring process control.
* Based on quality process control standards consistent with manufacturers, industries, printing companies, and user-approved features such as SWOP, ShOPS, SNAP, GRACoL, PROP, and FIRST.
* Use process control that controls the company's quality practices or the quality of the product that the user specifically requires.
* In the TPM's inspection list, the cycle of monitoring quality conditions is listed in the form of a file, and the inspection list is placed next to the equipment. For example, a pre-press checklist may indicate that the prepress person tests the working condition of the camera and the image-setter, and the vacuum frame and monthly record of the single-step repetitive operation of the device; the inspection list of the printer may record the press. The condition of the printed sample observed by the operator during the specified cycle, the test density of each printing process, the dot gain status, and the pH and conductivity of the fountain solution are checked daily, the installation of the drum is checked weekly, the monthly printing shop Lighting conditions etc.
The main TPM behavior
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What is maintenance, calibration and process control activities?
* Calibration behavior: Test and adjust equipment and processes such as scanners, monitors, laser imagesetters, vacuum frames, printers, or die cutters according to industry and manufacturer conditions, and acceptance characteristics, so that they provide duplicate images Accurate display and output.
* Process control behavior: feedback from operational technology systems to displays and management equipment and processes.
Maintenance, Calibration, and Process Control: Key Issues for Optimizing Print Production and Production