As a leader in the global printing machinery manufacturing industry, Heidelberg has been vigorously advocating standardized equipment operation and maintenance, helping users to grasp from the production base, steadily and steadily, and strive to create high efficiency with high quality and high efficiency. Cultivating the habit of standard operation and maintenance has undoubtedly paved the way for the steady development of printing companies. Hebei Langfang Huaxi Printing Co., Ltd. (hereinafter referred to as Huaxi) confirmed this with personal experience. At the same time, they also played a leading role in the majority of Heidelberg user groups.
Huaxi is a commercial printing company, founded in 2006. In 2008, they bought two Heidelberg Infiniti PM52 four-color offset printing machines in one fell swoop. In 2009, they introduced the third Infiniti PM52, which became a local story for a while. Dong Xi, General Manager of Huaxi, has a deep understanding of Heidelberg's brand effect. He said that customers trust Heidelberg and often come here admirably to designate Heidelberg machines for printing. Dong Donghai himself was inspired by this brand appeal, determined to make Huaxi a brand enterprise of Langfang printing.
As the saying goes: sharpening the knife does not cut the woodworker by mistake. The emerging Huaxi has strict system and unique management model in equipment operation and maintenance. By strengthening equipment maintenance and reducing revenue for enterprises, it brings a fresh wind to today's printing industry.
Operating specifications and process specifications
For commercial printing companies, from the manager to the leader, all are proud of the superior work volume. However, while giving full play to equipment capacity, the maintenance of equipment is often overlooked-in fact, this has not been an insignificant impact on the quality of printing and the life of the printing press.
At Huaxi, the act of blindly seeking and simply seeking fast is strictly forbidden. With the help of Heidelberg engineers, Huaxi has broken through obstacles and developed good equipment operation and maintenance habits. They have a complete set of daily operating standards, such as:
• Do not wipe the plate paste after the new version is installed, to prevent the water and ink balance from being damaged by the water quality pollution of the water tank, resulting in a decline in printing quality;
• In the humid summer, increase the temperature of the water tank (for example to 12 degrees), and at the same time, double check to prevent the rust of the parts due to dripping or breathing of the waterproof disk and pipeline;
• Adjust each fan to an appropriate speed to reduce the extra loss caused by high speed;
• Try to avoid emergency shutdown and reduce damage to the machine;
• Eliminate the use of rollers and other operations that reduce work efficiency.
Strictly implement the equipment operation and maintenance specifications, so that Huaxi later came to the top. From the introduction of high-quality plate-making machines, plate-making machines, positioning punchers to the installation of purified water devices and booster pumps, from the deployment of the correct concentration of developer and protective glue to high-quality plate-making and plate-making ... Huaxi did it There is no dirty on the machine version, no bad ink, no roller, almost no dirty spots. It is precisely the grasp of all the details in daily work that keeps their equipment at a low failure rate, production maintains high efficiency and high quality, and enters a virtuous circle. [next]
15 minutes: maintenance per shift linked to performance
Liu Changhai is a senior leader of Huaxi. He told us that in the past, in other units, people were basically restless, and the machine continued to rotate for 24 hours. "I haven't heard of any company like us. In addition to the routine shutdown maintenance every month, each shift also needs to devote 15 minutes to equipment maintenance."
Indeed, Dong Xihai, the head of Huaxi, never believed that shutdown maintenance would affect production efficiency. "In the long run, good daily maintenance can reduce the wear of machine parts, extend the life of equipment, and reduce the cost of spare parts purchases. It has a positive effect on the improvement of production efficiency and the economic efficiency of enterprises. Just like driving, if we I usually take care of it and work hard and maintain it. Then, a car that has been driven for seven or eight years is better than a car that has been driven for three years but lacks maintenance. It is also stronger and safer to drive. "
At Huaxi, 15 minutes before handover every day is the prescribed equipment maintenance time. Leaded by the lead machine, in accordance with the rules in the maintenance manual, everyone strictly performs each procedure: 1. Wash the shoulder iron; 2. Wipe the impression cylinder; 3. Wipe the bucket roller and metering roller; 4. Add oil to the paper collection chain ( Follow the guidance of Heidelberg engineers, no longer use gasoline or kerosene to clean the paper collection chain, instead add oil); 5. Wipe the appearance of the machine, scrub the rubber rollers of the plate-making machine, clean the workshop ... After the work is completed, the workshop director must also check Pass or fail and sign to confirm. As Liu Changhai said, Huaxi ’s monthly shutdown maintenance and 15-minute maintenance of each shift are part of normal work, and these 15 minutes have a "one vote veto" on the output value-if the inspection finds that the maintenance is not in place, then the entire The output value of the shift will be reset to zero. "Things have their roots, things have always". In just 15 minutes, uninterrupted care, not only cultivated the professional quality and professionalism of the Huaxi team, but also helped them practice their extraordinary skills in the market. [next]
High-quality consumables are not equal to rising costs
The use of high-quality printed materials is also one of the reasons for the excellent maintenance of Huaxi. In the era of low-profit competition, many printing plants are very sensitive to the cost of consumables. But Dong Donghai realized that even if he wanted to control the cost of consumables, it could not be at the expense of printing quality and production efficiency. For example: Huaxi always insists on using high-quality first-level printing plates. Compared with the third-level printing plates selected by some factories, under the same conditions, Huaxi can print 100 sets of plates in one shift, while some factories have the most Only 50 sets can be printed, the difference is self-evident.
After listening to the suggestions of Heidelberg engineers, Huaxi also paid more attention to the selection of consumables for daily maintenance. For example, in order to prevent parts (including air compressor parts) from being corroded, they no longer use gasoline to wipe rubber, but instead use regular car wash water; in addition, use high-quality isopropyl alcohol, water bucket fluid, lubricating oil, etc. A good horse with a good saddle. Fact description: High-quality consumables make equipment maintenance more efficient, and also allow customers to be 100% confident about printing quality.
"Choose three and choose four"
In order to ensure the maximum capacity of the equipment, Huaxi not only strictly maintained, but also made an article on the live source. In the eyes of most printing companies, the more varieties of jobs, the better. Dong Donghai didn't think so. He likened the jobs absorbed by the printing plant to the food people eat in his stomach. "If a person is always uneven in meat and hot and cold all day long, the digestive system will have to protest sooner or later."
The so-called food is not tired, Huaxi pursues the "picking three picking four" strategy-when ordering, we must consider factors such as equipment performance and capacity, for example, involving cardboard, kraft paper, stickers Waiting for the work of the substrate is not connected. Doing something wrong is not without risks. However, Huaxi ’s business volume has not been affected in the slightest. On the contrary, due to the guarantee of equipment, technology, quality, efficiency and other aspects, they gradually won the customer base. Trust, establish a good reputation, orders follow one after another.
Recognize the present and look at the long term. Dong Donghai said: Huaxi has benefited from solid equipment maintenance. What impressed him most was that Heidelberg engineers tailored a series of regulations for them according to the actual situation in the factory: daily inspections, timely correction of irregular operations, speaking with data, and employee training ... Heidelberg ’s The concepts of "high efficiency" and "super value" made them feel a lot, and encouraged them to keep striving forward, and determined to let the brand of Huaxi spread all over Yanshan. [next]
Comments from Zhu Lei, a senior engineer at Heidelberg:
In China, it is not uncommon for printing plants to operate and maintain irregularly. Under the pressure of market competition, corporate managers seem to value short-term benefits more and pursue high output, high speed, and low cost. This not only damages the medium- and long-term interests of the enterprise and sacrifices the vitality of sustainable development, but also the enterprise is very easy to fall into the misunderstanding of price wars and its vicious circle and cannot extricate itself.
Taking Langfang printing as an example, in the past, it often left the impression of being super fast, super low price, and low quality. The excessively fast approach and the lack of standardized operations (such as always cleaning the plate after the release, using fake isopropyl alcohol, etc.) have caused irreparable damage to the equipment over the years, and the seriousness of the actual problem makes the People are shocking.
Hua Xi's performance was surprising. As soon as I started contacting, I found that they had many valuable qualities. Not only did they do a good job in equipment maintenance and printing process, but also rigorous management, stable staff, clean and orderly workshop, even the air conditioner was cleaned regularly. Therefore, we worked hard on the details, for example, correcting the action of lifting the hood that caused the machine to stop suddenly, controlling the temperature of the water tank, turning off the suction pump that was previously too large, and developing and modifying the plate processor with the correct concentration. High water pressure to wash the printing plate and so on. From the general manager to the frontline employees, everyone is very cooperative with our adjustment and improvement work. The management's attention, strict system and true implementation are the key to the success of equipment operation and maintenance. Huaxi is very distinctive in management, with detailed system and daily inspection and supervision.
It is not difficult to see from the above case that adhering to standard equipment operation and maintenance, strengthening daily supervision and management, saved considerable operating costs for the enterprise, fully utilized the advantages of high efficiency and high quality of Heidelberg equipment, and effectively extended the service life of equipment. In short, standardized equipment maintenance and operation is "profitable", I believe more and more user companies will benefit from it.
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