Modern quality management has been engaged in post-checking, and gradually changed to full-process management with prevention and control as the main feature. It is characterized by turning the previous deliberative and decentralized management into a comprehensive comprehensive governance from a systematic perspective. From the results of the management to the management of the factors, the factors that affect the quality are detected, the main contradictions are grasped, and the whole production process is under control to achieve the purpose of ensuring product quality. In the overall management of printing, quality control before printing is particularly important.
If the pre-press quality control is not strict, it will bring many disadvantages to the post-process, which will affect the product quality, cause unnecessary waste, and even cause major quality accidents, causing economic losses to enterprises and employees. Therefore, preventive control measures are adopted to strengthen pre-press data and standardized management, strengthen the overall quality awareness of employees in each process, detect possible factors affecting quality in the pre-press process, formulate processes and quality standards, and prevent them from happening. , Will greatly improve the quality of products, but also help shorten the production cycle. All-person quality management has been recognized by many business circles as a management method to effectively enhance market competitiveness.
1 All staff quality management
TQM refers to the company's "all staff quality management", which is the abbreviation of "Total Quality Management" in English. It is based on customer and quality (including product quality and management quality) as the core, and is led by enterprise leaders to implement the management mode. The idea of ​​total quality management was first proposed by General Motors of the United States, and the book "Total Quality Management" was published in 1961. Definition of total quality management: In order to be able to conduct market research, design, manufacturing and after-sales service at the most economic level and taking into account the full satisfaction of customer requirements, the activities of various departments within the enterprise to develop quality, maintain quality and improve quality It constitutes an effective system. The idea of ​​total quality management is centered on quality.
In Japanese companies, under the guiding principle of paying attention to customers, managers take independent responsibility as the principle of management and management. Enterprise planners first put forward plans and suggestions to managers according to changes in the market environment; the manufacturing department actively produces, improves quality and improves efficiency; the marketing staff's task is to develop markets, expand sales, and improve services; the finance department actively improves capital efficiency , Through low-cost financing and flexible use of funds to meet business needs. Among them, the production workshop and marketing department are the two pillars of the enterprise. Big companies in Japan also have a business division system. The so-called business unit system refers to a system of several self-financing responsible accounting units based on their respective markets and products. The business department system is conducive to the flexible operation of various professional departments according to the actual situation, production and operation according to the professional categories of products, strengthened the competitiveness of various products, and through the target management system to evaluate the business performance of the business minister. Always in accordance with the philosophy of TQM management, putting customer management, improving product quality and operating quality in the first place, becoming part of the corporate culture, it will also be the main source of core competitiveness.
The basic characteristics of TQM are: 1) comprehensive quality management; 2) management of the whole process; 3) management of all participants; 4) comprehensive management. The guiding ideology of total quality management is: "Everything is customer-centric" and "Do it right the first time." Total quality management includes three aspects: product quality, process quality, and work quality. The basic idea of ​​total quality management is mainly reflected in: serving customers, focusing on prevention, speaking with data, and all employees participating in management.
Several principles that TQM should follow: 1) Quality awareness-the basis of TQM; 2) Continuously meet the needs of customers, markets and society; 3) People-oriented-the basic characteristics of TQM; 4) Continuous improvement of quality; 5 ) Clear quality policy and objectives; 6) Effective quality management system; 7) Whole process control; 8) TQM working procedures-PDCA cycle; 9) Technical methods including statistics; 10) Quality cost management.
As a modern enterprise management method, TQM is being adopted by more and more enterprises. It is particularly important to note that TQM refers to the company's "comprehensive quality management" with the emphasis on customer management as the premise, to improve management quality and product quality The goal is to thoroughly and correctly implement and execute the established strategy of the enterprise through the leadership of the leader.
2 Key quality management factors in prepress
Manufacturing statistics show that in any manufacturing process, 85% of downstream changes can be reduced by controlling the 15% at the beginning of the process. All-person quality management can effectively control the process early and achieve more stability and accuracy throughout the manufacturing process.
In screen printing, the goal is to transfer precisely prepared films and screens to the printing department. If you want to control the entire digital pre-press program, you can control the following 13 key changes in print production:
1. Image layout
2. Set time before printing
3. Color matching
4. Moire
5. Overprint
6. Color changes during operation
7. Increased outlets
8. Coherence in operation
9. Thickness of ink film
10. Ink consumption
11. Total ink limit
12. Pile of ink
13. Printing speed
Managers and planners must learn how to emphasize the stability of the system front-end, so that in the process of production operations, they can achieve the goal of minimal interference with the operating workers. Focusing on the first 15% of the entire prepress process can greatly reduce the dependence of image quality adjustment on printing operators. Printers only need to focus on image adjustment, ink density, and linear tone positioning. If the pre-press operation is very accurate, these three functions will appear more or less automatically. The result is that we can realize three benefits: printing becomes more efficient, waste is reduced and print quality is improved. [next]
3 Directions of prepress management efforts
Knowing the goals to be worked on and the issues to be aware of, and with the weapon of TQM, we can start our efforts from the following aspects, do a good job in pre-press quality management, and perform strict quality control on all aspects.
1. Printing companies should formulate a set of process standards that meet their own requirements and actual production levels according to their specific circumstances, and the process staff should issue process construction orders for all links from undertaking tasks to the entire construction process. It includes: raw materials used, operation methods, environmental conditions, equipment used, and different construction schemes that should be taken according to different equipment. All operators should strictly follow this process construction order, and can not be changed at will. Fully start the data-based and standardized quality management, and gradually improve the process standards, especially for different equipment, some special process requirements should be put forward.
2. In order to print high-quality prints, in addition to having advanced printing equipment, first of all, there must be high-quality plate-making film. This requires the plate-making personnel to pay attention to the production and finishing of the film, strictly control the quality of the film, and provide high-quality film that meets the requirements of printing and printing.
3. Strengthen the document inspection work, especially in the pre-press process, the film should be collated to find problems and quality hidden dangers in time to prevent unnecessary waste. String correction is indispensable in printing, it is one of the effective means to control quality. The focus of string correction in printing should be on the control of the printing quality, such as checking whether the printed samples, the printed version are the same as the original, check the page number sequence and the quality of the graphics, and check whether there are any missing words, pasted pages, light flowers, etc. In order to effectively control the printing quality and prevent the occurrence of various quality accidents.
4. Plate printing is the last process before printing. The quality of plate printing directly affects the quality of printed products. Plate printing personnel must strictly abide by the process and quality requirements during operation, and carefully check whether the original film meets the conditions of plate printing and whether the plate material Smooth and clean, whether the sand mesh, photosensitive coating, and sensitivity can meet the requirements. After confirming that they are correct, then proceed to plate printing.
The operator should determine the different exposures under different conditions with the test strip according to the situation. The environment for printing should be standardized and neat, and the original and the printing glass should be cleaned before printing to avoid uneven suction caused by tiny foreign objects and false graphics. Secondly, the control of the development process is also an important factor to ensure the quality of the printing. The developer must be prepared strictly according to the requirements, supplemented quantitatively, and the development temperature and development speed must be strictly controlled to avoid the loss of small dots due to the high concentration of the developer, high temperature or fast speed, or the low concentration, slow speed or low temperature of the developer Dirty and pasted-up phenomenon on the layout.
5. White material cutting is often an important link that is easily overlooked in prepress quality control. The size and quality of the cutting directly affect the printing rules and quality. If the operation is not in place during cutting, it will cause the size to be wrong.
6. Carefully focus on image construction, document preparation, film imaging, and mesh imaging. This series of basic work can dramatically improve the entire printing quality. Each type of change or disqualification of print quality can be analyzed to determine whether it can be improved by changing a pre-press processing method.
In order to illustrate how we can change the working method to achieve a reduction in the total cost of the entire prepress process, we can start with the production of the first screen. We can use digital templates, pinhole positioning and image trapping to improve the accuracy of the color overprint sequence. It also reduces the potential cost of using film. The typical and traditional color setting for each color takes about 6 to 20 minutes (large presses require longer time), but in an accurate design process, the time for setting each color can be reduced to 30s to 2 minutes, sometimes Shorter.
The purpose of reducing the setting time is to simplify the single printing machine adjustment method to the level of image arrangement and positioning. The rubber roller angle, pressure, speed, as well as the mesh distance and stripping settings can all remain unchanged. And through the introduction of pinhole positioning printing system, the position of the image can be accurately positioned, and the error range is within ± 0.002 inches, which greatly reduces the need for fine adjustment.
7. In the process of printing, the time saving and high efficiency features before printing can also be continued. Trial printing and color matching are reduced to less than 10 pictures or less than 6 textiles. This can be achieved by insisting on strict document preparation and color separation parameters, coupled with the use of continuous stretch-strength strength, emulsion thickness, opening ratio, moiré control and dot reduction strategies.
Prepress is usually used to control the generation of moiré, the increase of dots and the stability of gray balance. If these are not well controlled, the printer must be adjusted accordingly, which directly leads to a lot of unnecessary work. In printing, in addition to picture adjustment, the only adjustment to be made is to adjust the ink film to the specified density level. The transfer of hue and color is determined by pre-press, and as long as it is properly linearized, the linear level can be automatically obtained.
8. The total ink consumption is controlled by the color separation program, the mixed use of black plates and the total ink volume limit. If we can well understand the relationship between hue saturation gray balance, background color gain, background color removal, and gray component substitution, we can reduce the amount of ink in the uncontrolled system by as much as 50%. For large-format image printing, these reduced ink volumes can save companies hundreds of thousands of material costs each year.
9. Stability is a key factor that must be firmly grasped at all stages before printing. If every step is grasped as usual, many quality changes will be eliminated. Once the change is eliminated, its value increases. When printing workers carry out a series of identical operations, they will be extremely familiar with the important key points that will change. In this way, since the place where changes can be made is limited, they can more easily grasp the performance of the machine.
4 Conclusion
For all aspects of control, there must be a corresponding quality assessment system, and quality management personnel should strictly implement these systems so that pre-press employees in all processes strictly control the quality of their products in accordance with their own quality standards and prevent unqualified products from flowing down. Processes create good working conditions for each process in and after printing, enable overall quality management to proceed smoothly, and lay a solid foundation for improving the quality of the final product.
Faster conversion, more efficient operation, lower scrap rate and less total cost are just some of the benefits of the quality management of all employees in pre-press. All these improvements and improvements directly lead to more effective production time, that is, more time to create value.
With the advancement of screen printing technology, the quality management of all employees will not be developed overnight. This requires from high-end management to the initial use and maintenance must be carried out according to standards, which involves Everyone should also clearly understand their responsibilities.
Because members of an enterprise organization need sufficient training and an adaptation period to be proficient in TQM's new corporate culture, TQM generally requires a long time investment to begin to bear fruit. But it is undeniable that TQM has been widely used by enterprises as a weapon to enhance competitiveness, and its changes to the printing industry will be inestimable.
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