How to break through the inherent thinking and creative problem solving?

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Engaged The printing industry has been around for a long time, and many people feel tired. It seems that every simple action is repeated every day: the last version, calibration, ink color, sampling, cleaning machine... even some new employees who have worked for a few months, basic The operation has been learned, and when it is fresh, it feels boring immediately. However, as the time of employment grows, the more you experience, the more you will be in awe of the printing industry. Indeed, printing can cultivate a person's multi-faceted ability. The rotary printing press runs fast, requires the operator to be responsive, and the adjustment is accurate and fast. The sampling inspection needs to be careful enough to find the problem in time, to deal with it quickly, and to avoid waste. For the various faults that occur in the printing press, it is not only necessary to accumulate a long time of experience, but also to actively think in the face of new problems, to be good at breaking through the inherent thinking and creatively solving the problem.

Innovative printing process to increase efficiency and reduce consumption

In the current work of printing diaries with a rotary machine, I have a deep understanding of the importance of innovative thinking. The paper used by customers often changes, such as writing paper without wood pulp, ivory paper, environmentally-friendly recycled paper, etc. The quantitative changes in paper and paper will inevitably affect the quality of printing and folding. While we are trying to cope with these changes, we must also consider saving paper as much as possible and reducing waste.

Once we received such a batch of orders, there are three work orders of the same type, the layout content is basically the same, the paper and folding methods are the same, and all are printed with monochrome ink, the difference is in the first single layout. Need to print the FSC forest certification mark, remove the mark to print a second order, the third single and the second single print the same content, but need to use a special blue ink instead of black ink.

After the first one completes the printing, the logo can be removed directly by the revision, and then the second order is printed. Although it is troublesome, it can save a whole set of printing plates, and the amount of ink does not change much, so after the revision is completed, It can be turned on immediately, the ink is easily balanced, and there is very little paper wasted at boot. However, it is not easy to replace the black ink with the blue ink in the third order, because the A4 size diary is designed to be one page per day, and the inner page has 384 pages, one printing two paper paths at a time, and folding into each The 32 pages, a total of 12 posts, because the content of each page is different, the content of each post is not the same, so a diary has 12 sets of plates, each set has 4 versions. If the first two sheets of black are printed, the third one is washed and the third one is printed. After printing, the car is replaced with a black one. This will require dozens of washings after printing three orders. Obviously this approach cannot be used. If you print the first three single-wash and color-changing prints, you will waste 48 plates, and you need to repair the plate once more (or more film), otherwise you will need to print the first two. After the single, very careful dismantling, and can not be broken, obviously this is very difficult.

Since it is a double paper path, the front and back sides are simultaneously printed with a single color, so we have thought of printing black with the second and fourth units of a printing tower, and the first and third units are printed in blue. That is, black is printed on the second and fourth units of the printing tower. After the first single printing of each post is completed, the logo is directly repaired and the second order is printed; after the second single printing is completed, The plate is directly changed to the first and third units, and the corresponding ink control setting is made on the console, and the third sheet is printed by the ink roller of the unused printing unit. This not only saves time, reduces the amount of work, but also minimizes the waste of plates and paper. Of course, this only applies to presses that are able to detach the ink roller system. If the ink roller cannot be disengaged, the ink roller will idling when the printing unit is not in use, so that the ink on the rubber roller will quickly dry and become sticky due to mechanical friction, which will bring additional load to the printing machine or even damage. The rubber roller, and the ink dries out, the ink is difficult to rebalance after printing, resulting in a great waste.

The other time is to process two A5 size diary orders. The layout and folding methods of the two diaries are exactly the same, but you need to use Daolin paper and ivory paper separately. The conventional processing method is also divided into two printings. After completing one order, the next one is made, or two sets of printing plates are made, or after each printing is completed, the printing plate is removed and cleaned, and the protective layer of the printing plate is stored and left. Go to the next order and use it again. Obviously this routine approach leads to wasted time and materials. If after printing a post, replace the paper on the paper tray with another type of direct printing. Although there is no need to make adjustments on the printing and folding, it is necessary to keep the paper on the paper tray. In exchange for it. Finally, we chose to use two paper holders, one for the forest paper and the other for the ivory paper. After printing one, we only need to switch between different papers before the paper tape exits the paper tray and enters the secondary tension roller. Just fine. This approach greatly increases productivity and reduces waste.

Of course, when printing newspapers, because the materials used, folding methods, etc. are relatively fixed, the above problems will not occur, but it does not mean that everything is the same, such as how much the printing paper path changes, paper changes. Etc., also need to make corresponding adjustments to the machine. The operator is generally told that after the machine is adjusted, the machine cannot be easily changed except for the daily operation, so the operator will get used to the usual printing operation. Once the problem is encountered, after the ordinary adjustment is invalid, It becomes overwhelming. In fact, the fact that it cannot be easily changed does not mean that it cannot be moved. Under the premise of fully understanding and mastering the structure of the machine and the principle of adjustment, there is no place that cannot be moved. What's more, the general process glitch, as long as the small adjustment of the relevant components, can solve seemingly difficult problems, or greatly improve production efficiency and improve product quality.

Innovative folding process to improve quality

Folding is also a part of the problem. The specifications of the book are different, the design is different, the folding method will also change, and the problems such as wrinkled paper, broken paper, and folding are almost always appear every time the material or folding method changes, which requires us to broaden. The idea is to solve these problems well.

Once we received an order for a A5 specification diary print, due to design changes, the non-overlapping portion was kept smaller than the normal diary at the last double fold. This results in the folding knife on the double folding cylinder being adjusted to the extreme position during production, but the non-overlapping portion of the folding sheet is still too large, resulting in a false folding. According to the ordinary idea, after adjusting the folding knife and the teeth, the outer casing on the folding cylinder is also reduced to a minimum, there is still a slight deviation, and the folding quality is still unsatisfactory. Since the position of the clip gripping clip is fixed, the outer shell will raise the top of the signature, so we boldly remove the adjustment cover on the double folding cylinder to make the signature on the double folding cylinder. The position is lowered, so that the center of the signature is moved backwards, so that the folding knife has a larger adjustment space, thereby achieving perfect folding quality.


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