Perfect book printing quality management system

Beijing Hualian Printing Co., Ltd. has positioned its product quality in the high-end market since its inception. In order to continuously improve the printing level, it has actively participated in the selection of various international printing awards, won a number of international awards and national awards, and printed the country. There are 10 kinds of key books, and millions of books are printed overseas. Actively carrying out comprehensive quality management work within the company, for the past four years, it has produced a large number of exquisite albums, magazines, and made remarkable achievements in product quality. Advanced technology equipment and perfect process control make Hualian Printing become one of the most large-scale boutique printing production bases in China.

New technology puts high demands on the process

The technical progress of the printing process equipment for books and publications has changed. This change has been reflected in prepress, printing and postpress, but it is prominently reflected in prepress and postpress.

1, the process runs through prepress, printing, postpress

Prepress plate making technology has gradually changed from the traditional film printing mode to computer direct plate making, but it has not been completely replaced in recent years. The most realistic method is still the coexistence of two kinds of technologies. The quality advantages brought by the CTP technology are obvious, and the digital work flow supporting the CTP platemaking technology not only requires the control of the stability of the process, but also requires the support of a mature color management system to ensure that the customer's requirements are truly restored and reproduced. Printed on.

In the post-press industry, bookbinding is becoming more and more mechanized, and the productivity of advanced bookbinding equipment is very high. Compared with previous manual or semi-mechanized operations, the determination of the pre-production process and its emphasis on the production process must be emphasized. The predictability of quality issues emphasizes prior art planning. At the same time, the post-printing process is also springing up. The endless application of new processes and several processes raises new requirements for the process flow.

2, quality management is the basis of process control

In 2003, Hualian Printing took the operation of the ISO9001 and ISO14001 systems as the main line, and carried out work such as establishment of processes, assignment of functions, sound systems, key positions of human resources, 5S management, etc., and established and improved consciously, controlledly, and stably. Quality control processes and operating mechanisms, which stabilize and standardize the entire process of finished product packaging, transportation, and delivery, establish a standardized operation method and a standard to be achieved for all quality-related processes. The advantages of continuous improvement, improvement, and quality management have gradually emerged, and Hualian's product quality has quickly and steadily improved.

Establish and improve the process control process

The basic process of the book printing process is to determine the processing technology, release production tasks, process control (prepress, printing, binding, packaging) and finished product control. However, due to the differences in equipment technology and product features, such a process has different management methods and priorities. There is no fixed model to follow. Only the basic work is well done, and several important links are identified and responsibilities are clearly defined. Combining the characteristics of the company with "tailor-made" is the most optimized and reasonable process.

1, process management duties

Hualian Printing's huge production throughput determines that its production and quality system is very large. It involves many departments, many processes, and many personnel. In terms of management structure, the company is led by the production department vice president of the factory department to lead all production Links, including production planning and scheduling, production monitoring at each workshop, quality control throughout the company and the entire process, equipment maintenance and management, logistics delivery, etc., can coordinate production relationships to the maximum extent in the shortest possible time to ensure that production scheduling is direct and effective. The shortest response time of equipment failures. That is, each product's implementation process is completed under the direct control of the factory department. In response to this feature, the responsibility for the quality control of production processes used by Hualian Printing is also a direct responsibility system, ie, large-scale operations departments, small-to-shift teams, or direct operators. Each person has full responsibility for production management and quality management.

2, raw and auxiliary materials control and preparation

Whether the quality of raw and auxiliary materials is stable is an important prerequisite for smooth production process. In terms of raw materials, in addition to paper, inks, plate materials, and supporting materials that match printability should be determined based on the model, and should not be changed at will. As far as the main sheet of paper is concerned, brands of stable quality products are selected as far as possible, and the proportion of paper that the customer brings with them is reduced. Because the customers bring their own paper, they often hinder the smooth progress of the process because they do not know their specific conditions. At the same time, sales personnel and customer service personnel can inquire at any time the amount of paper in stock, bulk or special paper in advance to inform stocking, in order to ensure timely supply, production smooth.

3, color management system

Color management is the language of communication between digital prepress and printing, and it is also the bridge between printing companies and customers. The level of color management is an important technical issue for the printing company's production process flow. Only by establishing a color management system that meets the characteristics of the company itself, can we provide customers with proofs that can predict the printed color results, so that production can be unimpeded.

According to the characteristics of the company's products, Hualian Printing puts forward the pre-press color reference based on the status of the printing press and the effects that raw materials can achieve, and the characteristics of different models (commercial rotary press and sheet-fed press) and different papers. Clear requirements. Prepress standard samples are determined according to such requirements, and evaluated and corrected on a regular basis. The same standard platform is always used for printing and prepress to ensure that production is not hindered by color problems. Of course, perfect color management also requires digitization and standardization of output linearization. management.

4, the development process

The technology of regular journals is directly developed by the customer service department. Special products or complex prints need to be developed by the craftsmanship department, and by making white samples, the difficulty of processing is foreseen and the process route is determined. Due to the numerous applications of various new processes, especially the post-printing process, the phenomenon of simultaneous application of several processes has become commonplace. Therefore, the process development department determines the process flow in advance, uses corresponding papers, and requests the production of white or woolen samples. It is an important link to guarantee the smooth implementation of the book printing process in mass production.

5, issued a single project

The engineering bill is the carrier that conveys the quality requirements of the process, and is an important basis for the production and management of production and management departments. Hualian Printing's construction list is issued by the Customer Service Department, and the Customer Service Department and the business staff are part of a larger department, which is conducive to accurately and directly communicating the customer's requirements. The engineering bill is issued by the computer so that many requirements can be clearly and accurately reflected. Under normal circumstances, multiple copies of engineering bills are required to ensure that all production process supervisors, operators and quality inspectors can obtain written requirements. At the same time, the process management department, the quality management department, and the workshop supervisors can also get a project sheet to facilitate the understanding and control of the entire print, that is, to ensure that all production and management personnel who directly participate in the job will receive a certain amount of time. Written requirements for the event.

6, process control

The process control of the product is based on the production engineering line as the main line and the process supervisor is responsible for the system. That is, the supervisors of all production processes are responsible for the production and construction, and both have the functions of the process and quality control of the process. Because multiple printing products run across the various processes, the Factory Affairs Department adjusts the schedule at any time and holds daily production scheduling meetings. It can solve production bottlenecks at any time, optimize the scheduling process, optimize time management, and maximize labor productivity. Make the production orderly. The workshop supervisor is to control the key process of the product, including the first sample inspection, process inspection, production personnel self-inspection and production supervisor sampling to complete the control of product quality.

In short, the technology should emphasize the solution of process and quality issues in the process, and ensure that the next process provides qualified, process-compliant products.

7, finished product inspection

Finished product inspection is an important part of ensuring that customers are provided with qualified products. The technical quality department under the company's factory department has a batch of full-time quality inspectors who perform sampling inspections on finished products. The production department is relatively independent, ensuring the independence and authority of quality inspection.

Reprinted from: "Printing Technology", author Hu Guimian