Complete Press - CR\T UpdateJune 17, 2010 Not Updated
Product Families Varnish Process steps identified by varnish type.
Product Families Dispersion Process steps identified by dispersion type.
Work Content Matrix Dispersion Process steps have process times (manual and machine) by dispersion type.
First Attempt Product Families Ink Process steps identified by ink series and color.
Work Content Matrix Ink Process steps have process times (manual and machine) by ink series and color
Product Family “A” Hot Varnish Varnish flow times in seconds Total Processing Time (compounding ) in minutes These series and colors share similar resources, similar steps and are within 30% process times. Hot varnish pumped from extruder determines product family. as well as cold varnish.
Product Family “B” Total Process Time (compounding) in minutes Varnish flow time is seconds Low Tab blue and all series yellows have slow varnish flow rates do to thickness as well as higher volumes of varnish thus putting them in a product family of their own. Again, flow rate and volume of varnish put these four in a family within 30% process time of their own.
Product Family “C” Total Process Time (compounding) in minutes No varnish flow time for cold varnish All colors all series fit into one product family when varnish is dumped cold from inventory.
Varnish Type and Amount by Series Varnish type Varnish amount in lbs
Cycle time to Takt Time Bar Chart Low Tab Hot Compound time is constraint for all series do to varnish flow times.d
CT to TT Low Tab “Cold” Even process flow is achieved when dumping cold Mixing time shifts to constraint when cold varnish is dumped for all series all colors.
Standards for 59 Ink Making Steps Check do Check Each standard follows the “check do check” Total Quality Management standard.
Q4 Problem Solving Q4 (A3) data base set up and trained to create a “problem solving” culture.
CR\T – Press Update Overall – Key Criteria for Ink • Start - Up • Run ability • Reproduction • Cost
CR\T – Press Update Press Requirements (listed by importance - #1 being the top priority) • Pumping • Clean Ink • Print numbers • Unit control • No picking • Scuffing • Ink buildup • Gloss • Misting
CR\T – Press Update PUMPING / CLEANING INK • Sussex remove filters (fountain mains) • Moving to 1001 ink, which is easier to pump • Monitor AW Wedgewire filter (300 microns)
CR\T – Press Update No Picking • Change black tack to 8.5 • Lower pigment cyan • Black lower toner (alkali blue)
CR\T – Press Update Scuffing • Add Teflon (cost!) R&D • More durable resin system (cost!) R&D • Use Polyethylene wax R&D • Silicone QG
CR\T – Press Update Ink build-up • Silicone • Thinner ink film will help • Low energy curable resin system R&D • Optimize wax R&D
CR\T – Press Update Gloss • 3 roll mill (cost!) R&D • R&D
CR\T – Press Update Misting • Modify ink Rheology (increase viscosity)
Ink Manufacturing Variation Reduction
Variation • 9th type of waste • Constant change – Moving target • Lessen the chance of finding the Root Cause • What was the original reason for the ink change?
Ink Type Variations • Tack variances within same ink type • Pigment loadings (Toner) • Varnish Types • Oil Type • Tack variances within same ink type • Pigment loadings (Toner) • Varnish Types • Oil Type
Insert Series Early 2010 – 5 Insert Ink types
Insert down to 3 types 2010 Current State Going to single insert formula
Conditions that Effect Ink Performance Variables that can make an ink perform poorly • Temperature • Fountain Solution • Misc. Press Variables
Temperature • Fountain Solution • Blanket • Plate • Roller Settings • Ink Ball • Vibrator
Fountain Solution • pH • Conductivity • Surface Tension • Bacterial Growth • Water Setting
Misc Variables • Paper • Alkalinity/Acidity • Paper surface • Blanket Condition • Plate Condition • Job Coverage • Light/Heavy