Cost control and print quality management
We are a big printing company in Shenzhen China . We offer all book publications, hardcover book printing, papercover book printing, hardcover notebook, sprial book printing, saddle stiching book printing, booklet printing,packaging box, calendars, all kinds of PVC, product brochures, notes, Children's book, stickers, all kinds of special paper color printing products, game cardand so on.
For more information please visit
http://www.joyful-printing.com. ENG only
http://www.joyful-printing.net
http://www.joyful-printing.org
email: info@joyful-printing.net
Today, as the global economy continues to slump and raw material costs continue to rise, how to achieve the greatest savings in printing costs and the greatest improvement in printing quality is of concern to many printers. The greatest cost savings and the greatest improvement in print quality will bring the greatest competitiveness to the company.
Cost is one of the most concerned issues for business managers. How to reduce costs, reduce the amount of materials used, and improve production efficiency will directly affect the survival and development of enterprises.
How to reduce the production cost of enterprises? The Golden Sheep Society, which has more than 80 years of history in Japan, has brought you some suggestions. How does Jinyang Society achieve cost reduction?
Let's take a look at the basic situation of Jinyangshe. From April 2008 to March 2009, we plan to sell 10 billion yen and operating profit of 800 million yen. There are 297 employees, including 93 business people, 56 management departments and 148 production departments. The average age of employees is 39 years old, and the proportion of women accounts for 26%. The average daily output is 1,100, of which CTP has an average daily output of 950, and the traditional PS version has an average of 150 per day. The CTP usage rate is 86%. The printing press has an average of 300 sets of printing per day, of which 2,800 are on average for each boot and 750 are for four.
How does Jinyang Society reduce costs and protect the environment?
Mainly based on inventory figures to manage and classify the company's waste, through these two aspects to reduce cost and environmental protection.
All inventory is managed by the number of stocks. So how do we manage the use of numbers to manage inventory? First, the position of the item is marked with the number 0 to 15. When the item is taken, it is taken from the largest number 15, for example, the ink, the ink must be at least three days of production, when the number 4 is used, it is just right. To reach the three-day inventory, you need to fill out the order card and then re-order the goods supplier to ensure that you have three days of inventory. Other production materials are managed in this way, managed according to the order, and thoroughly penetrated the appropriate number of libraries. There are some differences in the amount of stock guaranteed by different production materials. For example, the plate can guarantee the production amount of seven days. For example, some liquid medicines are originally ordered once a month and changed to half a month, or some liquid medicines. If the company's research is not used, there is no need to re-book, and the management of materials according to the delivery date of each order card. Reduce inventory management costs and reduce inventory capital.
Jinyangshe also aims to reduce costs and protect the environment by continuously reducing organic solvents. For example, Jinyangshe reduced the organic solvent from 28 to 26 in 2005. In 2006, the organic solvent was reduced from 26 to 24. In 2007, the organic solvent was reduced from 24 to 10, and the organic solvents still used so far are still available. Ten kinds, and several organic solvents are being tested to achieve the goal of continuous reduction.
The various wastes continuously produced by the factory are recycled and reused, which reduces the cost again and is more environmentally friendly. The Jinyangshe factory currently produces a total of 21 kinds of waste, including 13 kinds of paper phase and 8 related wastes. All 21 wastes are disposed of by specialized recycling companies that do not directly discard any waste. Some of these wastes need to be paid to the waste recycling company for disposal, and some wastes can be sold to waste recycling companies to make money, making waste into valuable substances. The amount of waste sold will be much greater than the cost of disposal of the waste. Thereby achieving economic benefits, reducing costs and protecting the environment.
How to improve and maintain stable printing quality while reducing costs and protecting the environment? I believe this is the most concerned about every business. Jinyangshe mainly manages and maintains the stability of printing quality through data management. If you want to differentiate yourself from other companies and surpass other companies and make yourself a competitive company, you must master the technology while pursuing profits. Both are equally important. How to implement it? First, we must build a printing technology foundation platform in the company, secondly engage in high production technology level and continuously accumulate experience in the production process, and thirdly raise the awareness of all responsible persons in all aspects. The fourth is how to ensure profit.
How to achieve the above four goals, Jin Yangshe's method is to establish printing quality management techniques. In order to ensure the printing quality, Jinyang Society implements a pyramid-shaped management method:
1. Standardization: Grasping the characteristics of printed materials
2. Standardization of printing press: Grasping the operation process of daily work and early detection of bad conditions
3. Data management of printed matter: Correctly grasp the conditions of the printing environment
4.CMS color standard: regular maintenance and inspection of the printing press
The main factors affecting the printing quality are 12 factors such as materials, equipment and environment:
1. The material aspect is mainly reflected in the four aspects of printing paper, ink, humidity and reproducibility of printing plate making.
2. The equipment aspect is mainly reflected in printing registration, dot overlap/paste, printing area, overprinting rate, solid density, reproducibility of dot, and control of gray balance.
3. The environment is mainly reflected in the control of temperature and humidity in the environment. The temperature of Jinyangshe is controlled at 23±2°C and humidity is 55±5%.
First, we must standardize the materials, grasp the characteristics of the materials used and frequently change, and obtain a sufficient data to change the characteristics of the materials and its changes under the maximum conditions. Grasping the characteristics of the printed material and the temperature characteristics have the following four points:
1. Temperature changes and characteristics of the ink. Ink transferability, fluidity, emulsifying properties
2. Temperature change and characteristics of dampening solution. Low viscosity and impact on print quality
3. Characteristics and degradation of the roller. Stabilize the film of ink and fountain solution
4. Ageing of dampening solution. The dampening solution is sampled periodically to confirm the accuracy and stability of the concentration of the H solution.
Once the standardization of the material is completed, standardization of the printing equipment is required. This is a very important part. Jinyangshe standardizes the printing press through data. The specific data of Jinyangshe is carried out through the following five points:
1. Determine the temperature and humidity values around the machine
2. Number of inking rollers and actual measured data (calculated data and actual measured data)
3. Actual measured data of the ink roller (width and hardness of contact, pressure of contact surface)
4. Ink cooling / dampening solution cooling set temperature and actual measured temperature
5. Management of dampening solution (quantitative accuracy IPA added accuracy conductivity)
How is the above data specifically carried out? Jinyang Society is testing the printing conditions and conducting an actual measurement once a month. The left and right temperature changes of each part of the roller and the drum were tested under the condition of stopping and running the machine. The most important is the temperature and hardness of the surface of the drum and the roller. If the temperature and hardness are unstable, it will definitely cause various problems. Some equipment is required for temperature and hardness measurement, such as hardness tester, conductivity PH meter, thermometer. Based on the results of the measured data, some charts were created for analysis. Promptly resolve the problematic part. Jinyangshe's printing equipment has two hours of maintenance every Monday to ensure that the printing press is in a stable state.
The next step is to manage the data in print. The data management of the printed matter is controlled by the Color bar. The Color bar can manage the density and color difference of Dot gain, dot reproduction, gray balance, collision net, Over print, etc. The four-color solid density of Jinyangshe is (C: 1.6, M: 1.5, Y: 1.3, K: 1.8) monitored according to Color Tool: dot enlargement, density, color gamut, printing dot enlargement rate controlled at 15% ± 3% . The Color bar used is the minispot of Heidelberg, and then the Minispot is determined according to the information control. It is a system of overall circulation (by printing to the minispot and then measuring the Minispot according to the information control, and monitoring the control dot expansion according to the Color Tool, Density, color gamut).
CMS color standard
CMS color standard Jinyangshe uses Fuji's I Color QC system. The I Color QC system is not only a management of printing, but also a good promotion system for prepress. It is a good service system.
There are three elements for print quality data management: setting standard data, setting the scope of the error permit, and exceptions are also acceptable.
Data management is not an end, but a good way to ensure print quality. Our data management is not managed by data, but we need to manage the data and grasp the changes in the data. Simply put, data management is a means of ensuring quality. Through the above methods and means, Jinyangshe has achieved a good quality and stability guarantee.