japanese - orientsogyo.co.jp · trouble shooting ... man-power shortage in gravure !! quality guide...

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OSG series 1

Press, impressively!

ORIENT SOGYO CO., LTD.

Hidenori Harada

AT INTERCONTINENTAL JAKARTA MIDPLAZA HOTEL

Nov 15, 2016

How many Japanese are required to change a light-bulb?

ORIENT SOGYO CO., LTD All rights reserved

1 : Read Instruction manual and understand 100% what to do

Answer : 4 people

2 : Call TOKYO headquarter for approval

3 : Skilled engineer change it with 3sec

4 : Send INVOICE with JPY100,000.-

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OSG series 2

How many European are required to change a light-bulb?


1 : Make sure they don’t have to do this work in Xmas holiday

Answer : 4 people

2 : Make sure Bulb follow ISO standard

3 : Develop Big trolley for Change-over

4 : Regret the bulb was Panasonic made

How many INDONESIAN are required to change a light-bulb?


1 : Compare Japanese or European bulb?

Answer : 3 people

2 : Decide to buy Taiwanese in last minute!

3 : Regret new light valve was made in China

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OSG series 3

Trend and Direction of Packaging

Flexible Packaging - Trends and Direction

Drupa2016 – Tokyo Pack2016

Japanese Converting (Japan Gravure Assoc.)

Trouble shooting and Solution

NISSIO solutions

ORIENT R&D

Trouble shooting


INDONESIA in the WORLD

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INDONESIA

SINGAPORE

VIETNAM

THAI

7%

6%

5%

4%

3%

2%

1%

0%

GDP GROWTH RATE

2014 2015 2016

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OSG series 4

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UNCERTAINLY

DRUPA is the largest

exhibition about Printing

in Dusseldorf Germany

held in June 2016. Next 2020

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OSG series 5

CI FEXO with 500m/min ＠ Water-base ink : TOYO INK [No Sample distribution] Gravure : Short run jobs : Dynastar [Behind curtain]

In-line UV flexo

Mid-web laminator Only Gravure unit

＝ Very Cautious to Japan!

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OSG series 6

Cerrutti

FILM OFFSET with UV INK

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OSG series 7

Nordmeccanica

★ W&H Nordmeccanica : shake-hand?

No.1 Coat

No2 Coat Lami&RW

営業連携?

ラミ特注

技術/製品組込み

技術/製品組込み

技術提携

同一資本

同一資本

技術提携

OEM

技術提携

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OSG series 8

ithe largest packaging show in Asia.

★ ORIENT second participate

with Medium Web Converting

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OSG series 9

ORIENT BOOTH PICS

MIDIUM WIDTH LAMINATOR

Super-Short run DRY LAMINATOR

MDL600

ONE MAN Operation

Save Space & Energy

Exempted JPN VOC regulation

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OSG series 10

State-Of-The-Art Convertor

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OSG series 11

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ORIENT SOGYO CO., LTD. All rights reserved. 2016

22

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Craftsmanship & Latest Machine-Tooling for better QCD

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OSG series 12


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Double-Increased Assembling Capability !!

ZEN GRA


Establish – Activities and Benefit of JGPA

Against Two Mega-size companies (D & T)

Business Network – Seminars - Assembling

Negotiate (Lobbying) with Government & Customers Standardization / guideline Insurance - Bank loans –Packaging customers/users

Youth Generation – Network & Leadership develop

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OSG series 13


Achievements VOC emit regulation More than 30% reduction from year 2000! Envrmnt VOC measure & consulting

“Green Printing Certificated Factory” Green Printing Criteria 56 Gravure factories Certified (as of Oct 2016) Issuing Monthly magazine Info sharing

ZEN GRA


KANTO (Tokyo area) district TOKAI (Nagoya area) district KANSAI (Osaka area) district and so on… == Over 350 mid - small size companies joined!! (including Suppliers)

Whole JPN Youth Assembling in Nagoya

ZEN GRA

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OSG series 14


ZEN GRA

Why Gravure Association is important?

Limitation of Middle-Small size business Change & Protection

Converting / Packaging business need to be localized

Uncertainty to your own business -

Next generation – who & how / M & A ?

Business is built on Human relationship

Labor force

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Population Decreasing!!!!!!!!!

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OSG series 15

3K

KITANAI

(Dirty)

Kusai (Smelly)

KITSUI

(Heavy work)

MAN-POWER Shortage in Gravure !!

Quality Guide lines

Let your customer have better understanding about Flexible packaging

Film quality : Resin spots

Exceeding-quality

e.g. Recognizable defect by Consumer? e.g. Color : ΔE 3~6 … Numerical control? e.g. Fogging, Streak = Gravure destiny!

HOW Bigger Voice with More members

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OSG series 16

What we producing are industrial products, We are NOT artist!! Products tolerance should be determined by the “harmony” of Environment, Quality and Cost aspects.

ZEN-GRA Chair-man : Mr KAORU TAGUCHI

COMPANY PROFILE

Establishment: April 1954

CEO: Mr. Masayuki AKOH

Address: Yachiyo, CHIBA

Engraving & Plating system Cylinder proofer / Cylinder Grinder / UV color-proofer Gravure printing machine: 5 (Latest 7-color / ORIENT) Dry Laminator: 1 (Latest with Accumulator / ORIENT) Slitter / Bag-making

Others : Inspection Rewinder / VOC treat / CCM

From Up-stream to Down stream!! + ORIGINAL R&D equipment

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OSG series 17

GRAVO-PLOOF MULTI

(8-Colors proof)

GRAVO-PLOOF GN (1-color proof)

GRAVO-PLOOF CM

(Desk-top proof)

What is GRAVO’s advantage? On-Site Printing Audit by customers (Tachi-ai)

1. Can save time and printing materials

2. Increase production rate of printing presses

3. Waste-reduction

e.g. Press uses 200m film &10kg ink.

⇔ Proofer uses 3m film & 0.05kg ink only

1. Can print before inspection

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OSG series 18

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Desk-top Color Proofer

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ONE-CYLINDER PROOFER

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OSG series 19

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MULTI-CYLINDER (Max 8) PROOFER

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CYLINDER GRINDER

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OSG series 20

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CYLINDER FLANGE GRINDER


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Press, impressively Golden Cylinder Award

a) FUJITOKU (Nagoya) 200m/min in Water-base Gravure

http://www.fujitoku.net/images/news_gs2.jpg

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OSG series 21


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b) CHUKYO KAGAKU (Nagoya)

Short-run (Less 4000m x 8 items) within 8hour

by ALL CMYK process printing with 250lpi engraving


Private brand items are sold cheaper than National brand !!

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OSG series 22

Orient’s Challenging – Converting Sustainable Growth

Challenging

ORIENT SOGYO CO., LTD. All rights reserved. 2016 43

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Solvent-Free

LAMI

Solvent 0%

Water-based

FLEXO

Alcohol 5% only

Water-based

GRAVURE

Alcohol 20-30%

On-going


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OSG series 23


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What is Short – run job ?

Only 2kg rice consumption!

Job become Shorter than shorter 2000m/job ??

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OSG series 24


What is Private brand items ?

Private brand items are sold cheaper than National brand !!

Flexible Package trends and key words


Save Food

VOC emit

Food Safe

Energy save

Carbon foot print

Easy peel Easy cut

Display effects

High barrier materials

Bio Material

Microwave pouch

Resent Issue (last 10yrs)

Traditional Issues

Packaging Value & Quality

Work Efficiency & Environmental

Universal Design

Private Brand

Retailer Logistic

Variable print

Material Tractability

48

Short run (Less 4000m)

Waste reduce Automation

Clean room

Toluene free

Water-base

Shortage man-power

Cylinders stock

Material cost

M/C Maintenance

Super Short run (Less 2000m)

Labor health

Fire Accident

Static spark

Foreign objects

Doctor streak

Color variance

Missing dots

Weak white

Color Management

Short delivery lead time

Process Tractability

Balance ink

Solvent retention

Labor Safety

Color matching

: Printing Machine-related

Green Printing

Sustainable growth

http://www.7netshopping.jp/spc/shop/7premium/

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OSG series 25

Products design Background

Gravure

quality

defects

Material

Machine

Method ManIndustrious worker

Rule follow

Judgement

Color matching

Cylinder

Film

InkSolvent

Cylinder

Drying system

Inspection systemUnwinder /

Rewinder

Printing unit

Color-conUtilities

Drive system

Dryer setting

Job changeover

Tension settingDoctor setting

Ink setting

Training

Continuous

improvement

Paper core

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Japanese unique mentality, culture Man & Method

⇔ You can BUY machine & material but …


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Gravure Printing quality – FISH BONE

Film

Printing press

Printing

techniqueCylinder Ink

Color densityResin adhesion

Balance ink

recycle

Rewetability

Doctor

Work & setting

Standardization

Color management

Film types

Wettablity

Stock &

Delivery

Size &

thickness

Changeover

Delivery &　logistics

Factory design

(Clean enviromnt)

QC/QA

Stock & Delivery

Process

method

DTPPlating

Accuracy

Ink/solvent type

ViscosityMaintenence

Paper coreWeb Handling

Air Handling

Ink HandlingRegister ctrl

Cylinder drv

Drv Sys

Rollers

UW/RW/IN/OUT

High

quality

Gravure

Printing

Machine

Handling

Easy Cleaning

Heat

Air Supply

Air Suction

Ducting & Nozzles

Doctor

Impress

Inking

Setting

Five (5) Factors need to FUSION to make quality

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OSG series 26


51

What does Gravure Printing Press consist of?

Transfer pattern-shaped ink on Web thru Gravure cylinder = Ink Handling

Let film run straight and rewind it neatly = Web Handling

Drying ink transferred on surface of web = Air Handling

Operation, Set-up, Cleaning, Maintenance = Machine Handling


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What does Gravure Printing Press consist of?

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OSG series 27

f) Split System

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TREND : MACHINE SPECS

e.g. 8-color split type

4+4, 5+3, 6+2, 7+1 color at the same time!

or even Starlight mode operation

~ This is the technology based on Well sophisticated Web handling and Sequential program

New Trend in INDONESIA (South East Asia) Market

TREND : FIRE ACCIDENT

Press, impressively

http://www.nitibou.co.jp/en/

Reaction 92℃

http://www.nitibou.co.jp/en/

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OSG series 28

Re : ORIENT SOGYO CO., LTD.

【KAIZEN base – improvement】

Fire Accident measurement ORIE

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Re : ORIENT SOGYO CO., LTD.

【KAIZEN base – improvement】

Face to Face Cylinder chucking ORIE

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For Easy tape rewinding

For less ink invasion inside of cylinders

For faster cleaning at cylinder flange

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OSG series 29


~ Whole Stainless Floor (Mirror-finish) ~

Air-con outlets and Dry-Fog sprinkle nozzles

Clean floor immediately when Ink dripped.

Pic : SEIKO Co.,Ltd. (Tsukuba Fac)

Typical problem(5) : Static

Xpress with S.W.I.M. concept

<Xpress Main feature

Machine speed ：200m/min

Web width：300-620m

Structure：Inline Unit type

Print repeat：280-600mm

Drive system：Sectional drive

Kiss touch：All AC servo motor

Drying : By Hot air blowing

Dimension：(L)14000mm x(W)2800mm x(H)2800mm (at 6C straight)

(*excld. blowers)

Inline Unit type Mid-web FLEXO printing press

Xpress = Unknown X ＋ Printing Press

= Orient Express (Train between Asia to Europe)

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OSG series 30

New era of Flexo Printing Press

S.W.I.M. concept

Unique concept FLEXO can co-exist with Gravure

Not CI drum, Not UV…

new achievement from ORIENT, Japan

Super short run 極小ロット多品種インラインユニット型

水性インキミドル(中間巾)ウェブ

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Inline unit

Water based ink Mid width web

Gravure vs. Flexo

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Flexo Gravure

Color- reproduce range /

Resolution GRAVURE > FLEXO

Ink & Solvent usage GRAVURE > FLEXO

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OSG series 31


1) What happening in JAPAN / World Common and Uncommon Can learn and intake JAPAN solution

2) Gravure Technologies look slow progress Can digital Override Gravure? == NO Accumulated knowledge in Long history 3) Flexible Packaging in Indonesia 4) Need watch out Changes closely

japanese - orientsogyo.co.jp · trouble shooting ... man-power shortage in gravure !! quality guide...

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