printing quality management - muharrem yaşar
TRANSCRIPT
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PRINTING QUALITY MANAGEMENT
An overview to
in ZAMAN Newspaper
Prepared by: Muharrem YaşarQuality and Coord. Manager
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15.10.2014 Wan-Ifra World Publishing Expo 2014 Amsterdam, The Netherlands
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İstanbul, Turkey
Feza Gazetecilik A.S. known as Zaman
BS Newspaper, in Turkish
The most purchased newspaper, daily circulation > 1million
printed in 6 printing sites
«in English means TIME »
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Printing sites, Distribution areas, % Circulation
own
contracted
% 30
% 20
% 20
% 10
% 15
% 5
6 Printing Sites
5
1
İSTANBUL
İZMİR
ANTALYA
TRABZON
ANKARA
ADANA
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Zaman Head Office İSTANBUL
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Zaman Head Office İSTANBUL
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İSTANBUL
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Ankara Printing Plant
Printing Plant ANKARA
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Zaman (Time) & its weekly sistersCuma (Friday)Cumartesi (Saturday)Pazar (Sunday)
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Todays ZAMAN & its Sunday version Sundays Zaman
Daily English newspaper
10. 000 copies
BS size
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Weekly periodicals
50. 000 copies
Separately sold
250. 000 copies
magazinsize
Weekly magazine
Weekly news magazine
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Newspaper Machines 75.000 copies / h., single side-double around 40pages, 24pages colorful
+ Presetting ink keys+ Soft proofing- Automatic register control - Automatic density control- Automatic cut off register
Plate making RoomsCTP lines ( CTP s and P&Bs)
+ Ink saving program
What we have
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General MANAGER
Vice Manager Responsible for
Production
Printing Plant Director
Quality E.
. Quality E.
. Quality El.
. Quality E.
. Quality E.
Quality and Coordination
Dept. Director
Quality M.
Technical M.
Planning and Reports M.
Purchasing Dept. Director
Hierarchy
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Quality Management System
Environmental Management Systems (EMS)
14001
Occupational Health and
Safety (OHS)18001
(ISO) 9001 Printing Quality
Main Topics
Integrated Plant Management System
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Printing Quality (IFRA26)
Integrated Plant Management(EMS,OHS,ISO)
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15
2010
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2012
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2014
2014
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Printing Quality Management
To get ISO 12647/3
Check printing defects
Report consumabels
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Main target of INCQC is
International Color Quality Club Competition: Wan-IfraPrinting Quality competition between newspaper
19
to promote ISO Newspaper Standard
(ISO 12647/3 shortly IFRA26)
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A ) ISO 12647/3
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Dep. Property Set values
Electronic data delivery PDF/X-1 or PDF/X-3
Press profile ISO 12647-3 (IFRA 26)
C T P
Ink saving GCR
Ton value sum Max 240-260, Black >%85
Rips
Ton values 500 lpcmScreen frequency 40 L/ cmFM screen 40 micronScreen angle CMYK 15,75,0,135Dot shape elliptical dot,
link-ups %40,%60
Purchasing Newsprint La*b* 82,0,3 ( tolerances: 3,1,1 )
Adver. , Design, Prepress, Page Delivery
A ) ISO 12647/3
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A ) ISO 12647/3
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A ) ISO 12647/3
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• ISO color coordinates
• TVI dot gain curve
So the most critical parts of IFRA26;
( La*b* values )
• Dot gain and grey balance values
are informative only
A ) ISO 12647/3
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• ISO color coordinates
means decrease the ink
density ISO Lab (IFRA 26)
measuring mod : ISO-Check
A ) ISO 12647/3
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A ) ISO 12647/3 • ISO color coordinates
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• ISO color coordinates
* With black backing
ISO (IFRA 26) values
Red 52 41 25
Yellow 78 -3 58
Green 53 -34 17
Cyan 57 -23 -27
Blue 41 7 -22
Magenta 54 44 -2
Paper 82 0 3
Black 36 1 4
M
C
Y
gr
b
K
only Paper and CMYK used
A ) ISO 12647/3 • ISO color coordinates
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• Always black backing should be used, but it isn’t practical. So what?
While using ISO Lab measurement mode there is a difficulty
• There can be any way to use it without black backing ?
A ) ISO 12647/3 • ISO color coordinates
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Only yellow b* value changed
First : determine perfect dots in IFRA26 Second: measure Lab with no black backing and look at the differences
A ) ISO 12647/3 • ISO color coordinates
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• ISO color coordinates
You can put your new referance values
ColorScale mod for new ref. values
ISO-Chek mod ISO Lab values has already loaded
A ) ISO 12647/3 • ISO color coordinates
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• Dot gain
A ) ISO 12647/3 • Dot gain
The most tone value increase is between 40-50 % area
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old ….. 4,5 mm
new ….. 3 mm
A ) ISO 12647/3 • Dot gain
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Change the apparatus with a smaller one and make tests
A ) ISO 12647/3 • Dot gain
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• Dot gain
%100
%40
A ) ISO 12647/3 • Dot gain
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• Dot gain
%40
A ) ISO 12647/3 • Dot gain
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0,78 66,8 0,81 69,5 0,82 67,8 1,14 63,6
density
% dot gain
*Recordings are done by automatic measurement mode
A ) ISO 12647/3 • Dot gain
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While the Q.E. measures and records the dots to ERPVideo-1 :
Picture
.
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Daily Printing Quality Report
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Daily Printing Quality Report
Operator success
Ref. densities
differences
Dot gain
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Weekly density succes report
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The most tone value increase value of each color is stored in RIP for compensation
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For consistency in Printing quality Plate related quality control jobs are
also crucial
in daily production
weekly, monthly, & when necessary
Check and control
Calibrate
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Daily Plate Checking
only Plate
Plate + Press
Applied dot gains
Only %2, %98 and % 50 tone values are measured
Plate is taken before P&B machine for measurement.
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Every week a test plate which has a “plate scale” jobon. produced
Plate Scale
Weekly Plate Calibration
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tone value increase values of each color are stored in RIP for compensation
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While the Q. Expert evaluates and records the print defects to ERPVideo-2 :
B Printing Defects Checking
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While describing defects names INCQC defects table is used
B Printing Defects Checking
in INCQC 2010-2012There were 28 different defects name
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DEFECTS INCQC points PAGES
B Printing Defects Checking
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Printing Quality Report
Solve mainsNotice news
Main target:
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50Later, with experiences it reached 57
B Printing Defects Checking
Point are given as ;
3 Huge 2 Standard1 Small
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C Consumabels Reporting
To prepare a purchasable products list for our purchasing department.
Types of quality test : Start-up testsContinuity test
START UP test levels : Beginning, Middle and Long term
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Quality Test Request is evaluated for convenience
If everything is OK, it is converted into Quality Orders for printing plants
In the order, the amount of consumable needed for test is also given
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Point are given as ;
3 Huge 2 Standard1 Small
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For different consumables there are different number of criteria
Ex: criteria for cleaning agent
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every month automatically produced by ERP
Continuity Test (Automatically produced Quality Orders)
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Quality Experts give their records
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Printing plant /- ifra reel code- brand name of newsprint / Newsprint machine number
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*All criterions and weightsdescribed by our personals;
*Each area is filled by its related personnel
Register and tension control
Cleaning
Reel Stand
Ink and water adjustments
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Ex: for 45gr. Std Newsprint
for Purchasing Department
Actual Newsprint quality reportsfrom best to worst GOOD
BAD
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Printing Quality Management
To get ISO Newspaper standart
check printing defects
Report consumabels
AS a SUMMARY
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Thanks for listening and attention
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____________________
For communication
Muharrem YAŞAR
ZAMAN NewspaperQuality & Coord. Manager
Yenibosna / İstanbul / Türkiye
+90 212 454 87 [email protected]