PRINTING QUALITY MANAGEMENT

Transcription

1 An overview to PRINTING QUALITY MANAGEMENT in ZAMAN Prepared by: Muharrem Yaşar Quality and Coord. Manager Wan-Ifra World Publishing Expo 2013 Berlin, Germany 1 / 56

2 Feza Gazetecilik A.S. known as Zaman İstanbul, Turkey BS Newspaper in Turkish daily 1 million circulation printed in 6 printing sites

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4 Zaman Head Office İSTANBUL

5 Zaman Head Office İSTANBUL

6 Ankara Printing Plant Printing Plant ANKARA

7 Printing sites, Distrubiton areas, % Circulation % 30 % 10 % 20 % 15 % 5 % 20 6 Printing Sites 5 1 own contracted

8 Zaman & its weekly sisters Cuma Cumartesi Pazar

9 Daily English newspaper copies Todays ZAMAN & its Sunday version Sundays Zaman

10 magazin size Weekly magazin copies Weekly news magazin copies Separatly sold

11 What we have Newspaper Machines 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 Rooms CTP lines ( CTP s and P&Bs) + Ink saving program

12 Hierarchy Printing Plant Director Quality Eng.. Quality Eng.. Quality Eng. General Vice General Production. Quality Eng.. Quality Eng. Quality and Coordination Director Quality Manager Technica Manager Purchasing Dep. Director Planning and Reports M.

13 Main Topics Quality Management System Environmental Management Systems (EMS) Occupational Health and Safety (OHS) (ISO) 9001 Printing Quality Integrated Plant Management System

14 Integrated Plant Management (EMS,OHS,ISO) Printing Quality

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16 Printing Quality Management To get ISO 12647/3 Check printing defects Report consumabels

17 A ) ISO 12647/3 :2005

18 Dep. Property Set values Adver., Design, Prepress, Page Delivery Electronic data delivery PDF/X-1 or PDF/X-3 Press profile ISO (IFRA 26) C T P Ink saving Rips GCR Ton value sum Max , Black >%85 Ton values 500 lpcm Screen frequency 40 L/ cm FM screen 40 micron Screen angle CMYK 15,75,0,135 Dot shape elliptical dot, link-ups %40,%60 Purchasing Newsprint La*b* 82,0,3 ( tolerances: 3,1,1 )

19 A ) ISO 12647/3 :2005

20 A ) ISO 12647/3 So; ISO color coordinates TVI dot gain curve

21 ISO color coordinates A ) ISO 12647/3 and technology develops density ISO Lab (IFRA 26) measuring mod : ISO-Check means decrease the ink

22 A ) ISO 12647/3 ISO color coordinates g Y K * With black backing ISO (IFRA 26) values Red Yellow Green Cyan r Blue Magenta Paper M Black C b only Paper and CMYK is used

23 A ) ISO 12647/3 ISO color coordinates BUT ; not practical Our referance values? Why not? First : determine perfect dots in ISO Second: measure Lab with no b.backing Only yellow b* value changed

24 A ) ISO 12647/3 ISO color coordinates You can put your new referance values ISO-Chek mod ISO Lab values has already loaded ColorScale mod for new ref. values

25 Dotgain A ) ISO 12647/3

26 A ) ISO 12647/3 Dotgain old.. new.. 4,5 mm 3 mm

27 Change the apparatus with a smaller one and make tests A ) ISO 12647/3

28 A ) ISO 12647/3 Dotgain %100 %40

29 A ) ISO 12647/3 Dotgain %40

30 A ) ISO 12647/3 Dotgain density 0,78 66,8 0,81 69,5 0,82 67,8 1,14 63,6 % dot gain *Recordings are done by automatic measurement mode

31 Video-1 : While the Q. Engineer measures and records the dots to ERP Picture.

32 Daily Printing Quality Report Production Name Ref. densities difference Operator succes DG

33 WEEKLY P. OPERATOR DENSITY SUCCES REPORT

34 Averages The values to be applied to CTP rips DG average

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36 Plate Scale For consistence Printing DG, plate controls is obligatory Every week produce a test plate which has a plate scale job on it. /25 36

37 Measurements are done and recorded by a plate measurement device. Then the program calculates the dot gain of the plate

38 Plate Quality Report /25 38

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40 Daily Plate Checking A tone scale stays on the bended side of the plates is checked daily. Plate is taken before P&B machine for measurement. Applied dot gains Plate + Press only Plate %2, %98 and % 50 tone values are measured with plate densitometer by the prepress man to understand if there is an abnormality or not. If the values are seem to be changed, he produce a test plate for exact measurement and calibration

41 Video-2 : B Printing Defects Checking While the Q. Engineer evaluates and records the print defects to ERP

42 Printing Quality Report Main target: Solve mains Notice news

43 B Printing Defects Checking DEFECTS INCQC points PAGES

44 B Printing Defects Checking INCQC defects table is used

45 B Printing Defects Checking So ; we are checking ourselves like we are in competition INCQC everyday

46 B Printing Defects Checking First run or restart - following a stop copies: Customers complains mostly : from the startup newspapers or restart - following a stop newspapers. Because mechanically they are the worst. salable, low quality, not salable,

47 C Consumabels Reporting a) are being used (Current) Ex: Newsprint Evaluation Report b) Test metarials Target is; To prepare a list to our purchasing department. Show preferred and not preferred So we ask: not to bought unwanted, instead, the preferred if possible much

48 every month automatically produced by ERP

49 Printing plant / Type of newspaper -IFRA reel code- / Newsprint making machine number Weight is for weighted average

50 forms to the chief of printers Point are given as ; 5 Better 4 Good 3 Normal 2 Bad 1Worse

51 QE records to ERP

52 Described by our personals; Ink and water adjustments criterions, weights 4 different working areas Ex: Register and tension control Reel Stand Ex: Cleaning

53 Ex: 45gr. Std Newsprint Newsprints from top to bottom GOOD they are in 3 groups GOOD, BAD, WORSE BAD

54 AS a SUMMARY Printing Quality Management Try to get ISO Newspaper standart check printing defects Report newsprint

55 Thanks for listening

56 for contact: any questions? Muharrem YAŞAR ZAMAN Newspaper Quality & Coord. Manager Ahmet Taner Kışlalı Cad. No:6 Yenibosna / İstanbul / Türkiye +90 (0) m.yasar@zaman.com.tr 56 /56