First, increasing the machine's startup rate is the key to improving efficiency.
Reducing the time required for printing press setup is one of the most effective ways to boost overall production efficiency. For example, if a printing machine handles 20 orders per day and each order change takes 20 minutes, that’s 400 minutes of downtime per machine in a single day. If we can reduce the changeover time to just 10 minutes, we save 200 minutes daily, which increases productivity by 50%. To achieve this, it’s essential to organize all pre-printing tasks efficiently—from preparation to on-site commissioning and team coordination. Only by maximizing equipment uptime can we reach that 50% efficiency improvement. The question now is: how do we do it?Second, focus on efficient pre-press preparation with minimal effort.
Let’s dive into the details of what needs to be done during pre-press. What exactly should be prepared before starting the print job? How can we ensure everything is ready and in place?1. Prepare the ink required for the press
It’s important to receive and check the pH level, viscosity, and color of the ink to make sure it meets the standards. The pH value affects how the ink adheres to the paper, especially in multi-color or halftone printing. For instance, if the first color has a pH of 9 and the next overprint color has a pH of 8, the second color may not fully cover the first, leading to poor overprint results. Similarly, viscosity plays a critical role in print quality—too high and the image becomes blurry or deinks. Testing is necessary. Without checking the color, if the ink is incorrect, you risk losing 2 kg of ink and spending at least 15 minutes cleaning and replacing it. After confirming the print schedule, assign personnel to pick up the ink needed for the day and place it in the workshop. Stir the ink before putting it on the machine and recycle any leftover material.2. Prepare the printing plates
During the printing process, it’s common to find that the plate is wrong or damaged, causing unnecessary downtime. Each incident can cost 30 minutes of lost time and 2–4 kg of ink. To avoid this:- The printing room staff should take the plates according to the production schedule and deliver them to the press.
- The person receiving the plate should perform a basic inspection, such as verifying the text and layout for errors.
- Check for stains or wear, then send the plate to the machine and confirm the correct plate number.
3. Prepare the cardboard
Sometimes, after the plates and inks are set up, it turns out that the cardboard isn’t ready, forcing the machine to stop for cleaning. This can happen frequently. Here are some suggestions to prevent such issues:- Ensure the cardboard has been produced before starting the print run to avoid situations where the plate is ready but no cardboard is available.
- Sort the cardboard based on the production schedule to streamline the workflow.
Summary: By focusing on these three areas, on-site downtime can be reduced by up to 20%. Controlling every detail helps gradually improve the printing press efficiency.
3. Manage internal and external tasks simultaneously to increase printing efficiency by 50%
To improve printing efficiency, experts suggest recording your current workflow. Identify all adjustment actions and classify them into internal and external tasks. Convert as many internal tasks as possible into external ones and minimize the time spent on external tasks.1. Internal Tasks
Internal tasks are those that require the machine to be stopped, such as changing the printing plate or adjusting the impression cylinder. These tasks must be done when the machine is locked. To complete them faster, consider the following:- After finishing an order, employees often don’t know what to do next, leading to idle time. Reduce this waiting time to shorten the setup period.
- After the machine stops, employees might waste time searching for tools. Minimize the time they spend entering and exiting the machine to retrieve tools.
- When switching from one job to another, it’s common to waste 1–2 minutes washing the ink and finding the new plate. Instead, prepare the new plate, blanket, and ink in advance and place them near the relevant unit.
- Adjusting the parameters for the next job is crucial. Use the data from the process card to guide the adjustments. You can find detailed instructions on a WeChat group linked to a test machine.
- Teamwork is essential. If one person is stuck, others should step in to help, ensuring that internal tasks are completed quickly.
Summary: Following these steps can save 4–5 minutes per setup, which adds up to 100 minutes for 20 orders a day, boosting efficiency by 20%.
2. External Tasks
External tasks are those that can be performed while the machine is running, such as preparing plates, inks, or other materials. To reduce external task time:- As soon as the order starts, clean the paper feed area and begin adjustments. Pull the printed sheets, adjust the stacker, and prepare the tray.
- Use employee No. 4 to handle external tasks as much as possible. Properly assigning tasks among workers reduces waiting time and improves efficiency.
Summary: To achieve a 50% efficiency improvement, real-time on-site operations must be optimized. One practical method is to record the process using a camera and review it for improvements. After 2–3 rounds of discussion and refinement, significant time savings can be achieved.
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