quality of printed products course 2/ 1 quality_print product_2015a...your process. – internal...

Quality of Printed Products 1

Quality of Printed Products R. Chung, Professor

Quality of printed products are determined by customers. Customers who have to manage complex supply chains rely on standards to specify their requirements.

(Rev_2015)

Copyright 2015 RIT – May not be reproduced without permission

Topics

!  What is a customer

!  Print quality factors –  Product quality –  Process quality –  Material quality

!  Process improvement

2



Quality of Printed Products

!  Criteria –  How effectively the entire

product meets the customer’s expectations.

–  Keywords -  Customer -  Expectations

3


What is a Customer?

!  A customer is a person who brings us his/her wants. –  Not an outsider to our business.

-  They are a part of it. –  Not a cold statistic.

-  They are a flesh and blood human with feelings and emotions like our own.

–  Not an interruption of our work. -  They are the purpose of it.

4



Who Are the Customers?

!  The customer is the person who receives your process. –  Internal customers

- Colleagues

–  External customers - Not just the one who

writes the check.

!  Internal customers –  Prepress is customer services

representative’s customer. -  Job jacket has been filled out

accurately and completely. –  Pressroom is prepress

customer. -  Color proofs and plates are

done correctly. –  Postpress is pressroom’s

customer. -  Color-to-color registrations

were held consistently.

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External Customers

!  External customers –  Purchaser/buyer

-  Those who handle the product in assembly lines, e.g., packaging labels

–  Final consumers -  Their expectations are based

on their experiences and advertising claims.

-  Quality: As in print quality -  Service: Promptness, meeting

deadlines -  Price: Buy more or cost less

!  The customer is the person who receives your process. –  Internal customers

- Colleagues

–  External customers - Not just the one who

writes the check.

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Print Quality Factors

!  Three aspects –  Product quality

- External customers know plenty about

–  Process quality -  Internal customers

know plenty about

–  Material quality - Suppliers know plenty

about

!  Product quality are those which print buyers care about. –  Size –  Appearance

-  Pleasingness -  Color match

–  Functionality -  Scuff resistance -  UPC scannability -  Correct binding

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know plenty about


about

!  Process quality –  Those parameters

which printers must learn how to manage to achieve process consistency and accuracy. - Density - Dot gain - Trapping - Color

8







know plenty about


about

!  Material quality –  Characteristics of raw

materials that define the product grade - Paper -  Ink - Plate / cylinder - Other components - Fountain solution - Doctor blade - Anilox roll

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Quality Challenges

!  Material quality defines the product grade. –  Coated / uncoated /

newsprint

!  Process quality drives product quality. –  Conformance to product

specifications -  Industry accepted

standards -  Custom standards

–  Packaging graphics / brand colors

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Paper Grades

!  Defines material quality

Paper Grade Important Properties Major UsesUncoated Print well; has good

opacity at minimum cost

For printing type and line copy

Coated Smooth printable surface, good opacity and color

For magazine and all types of printing where good halftones are required

Newsprint Low cost, prints well Used mainly for newspaper

Paperboard Whiteness, rigidity, printability

For cartons, printed packages, etc.

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Property Attributes Paper-making FactorsColor Lightness,

hue, saturation

Dyes on fibers and colored pigments in coatings and between fibers provide the absorption responsible for color

Brightness Blue-light reflectance

Fiber and pigment scatter light. Dye and impurities absorb blue light

Opacity Ability to obscure underlying copy

Fiber and pigment scatter light. Dye and impurities absorb light. All contribute to opacity

Gloss Shininess Paper surface and its smoothness

Uniformity Formation Fiber and pigment uniformity of distribution

Optical Properties of Paper 12




Productcharacteristics

Pressvariables

Color

Sharpness

Pleasingness

Mechanical defects

PACKING

TENSION

INK

FEED

WATERFEED

REGISTER

Scannability

WEIGHT

WHITENESS

PSE

COLOR

TACK

PAPER INK

STRENGTH

PROCESS

Relationships ⊕ Strong WeakΔModerate

⊕

⊕

⊕ ⊕

⊕

Δ Δ

Δ

Δ

Δ

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Press-related Factors

!  Subjective / visual - Print defects - Dot distortion - Two-page spread

!  Objective / quantitative –  Solid ink density, TVI

-  Uniformity of ink coverage

–  Trapping

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Finishing-related Factors

!  Print-to-cut register

!  Crack at fold

!  Squareness

!  Flatness

!  Creeping

Do you think Pontiac

will pay for the ads?

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Customer’s Expectations

!  What are customer’s expectations? –  Functionality –  Usability –  Reliability performance –  Supportability –  Availability –  Fair price

!  Based on –  Needs –  Past experiences –  Change over time due to

technology changes and advertising claims -  Higher quality -  Less tolerance for poor

quality -  Shorter time between

order and shipment

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Customer’s Expectations

!  Increased customer satisfaction will come when –  A state of continuous process

improvement exists for the product.

–  The rate of product improvement process occurs faster than the customer expectation change.

–  Customer delight factors are recognized and addressed.

3.Generate potential solutions

4.Select & plan

solution

5.Implement

solution

6.Evaluate solution

1. Clearly define

problem2.

Analyze problem

ProblemsolvingProcess

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Process Improvement

1.  Beginning with a team and a major product –  Team building

-  Motivation -  Training -  Resource allocation

–  Develop the process flow chart -  From the internal and external customer’s view.

–  Identify critical product characteristics -  At each step of the production process.

–  Identify material characteristics that affect the product quality in some way. -  Ink tack, viscosity, gloss, color, etc.

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Process Improvement

2.  Identify the process variables that are measurable and controllable. –  Solid ink density –  Dot gain

3.  With the use of a quality table, relate variables –  Product characteristics –  Material characteristics –  Process variables

Infeed Roll Festoon Printing Units Oven Dryer Rewind Roll

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Process Improvement

4.  Assess current capabilities –  Measurement capability –  Quality information system capability –  Process capability

5.  Develop solutions to bridge key quality gaps –  Define process input and output, and measurement methods –  Develop standard operating procedures –  Acquire instrumentation and quality information system –  Train the work force for each of the critical steps

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Process Improvement

6.  The PDSA cycle –  Plan / Do / Study / Act

-  Based on the teaching of Dr. W. Edward Deming

PLAN

DOACT

→→

→→

STUDY

PLAN

DOACT

→→

→→

STUDY

Suppliers ofMaterials andEquipment

Managing the Extended Process A Printer's View

Planning Pre-press Press Bindery Shipping CustomersCustomers

CustomersCustomers

Customers

CustomerResearch

Design andRedesign

• Paper• Ink• Film• Plate• Chemistry

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