Press Operations, Binding and Finishing

Transcription

1 Press Operations, Binding and Finishing PrintED Crosswalk PrintED, administered by the Graphic Arts Education and Research Foundation (GAERF ), is an accreditation program, based on industry standards, for graphic communication courses of study at the secondary and post-secondary levels. PrintED's Offset Press Operations, Binding and Finishing, and Advanced Offset Press Operations competencies are taught in this publication, as well as applicable competencies from Introduction to Graphic Communications. The first column of the following crosswalk identifies the PrintED competency and the second column identifies where that competency is covered in the MAVCC curriculum by noting the exact unit and specific objective, assignment sheet, or job sheet. For more information about PrintED, contact: Graphic Arts Education and Research Foundation, 1899 Preston White Drive, Reston, VA Toll free: Introduction to Graphic Communications G. Press Operations 1. Identify basic safety press procedures. 2. Identify basic press systems. H. Bindery Operations 6. Create an accurate master cutting diagram for making cuts. I. Measurement 3. Measure volume for mixing chemicals for pressroom operations. J. Basic Math 18. Solve basic paper cutting calculations. 19. Solve word problems that require an understanding of estimating. Unit 4, Objective 2 Essential safety precautions; Objective 4 Offset press operator control functions Unit 1, Objective 3 Basic systems of a typical sheet fed offset press; Objective 4 Basic system functions Unit 7, A.S. 4 Draw a cutting diagram Unit 2, J.S. 1 Mix dampening solution and test for ph and conductivity Unit 7, A.S. 1 Use the formula for cutting paper stock; A.S. 2 Use the formula to determine how many sheets will be required; A.S. 3 Calculate a combination cut using stock cutting formula Unit 6, A.S. 1 Estimate costs of printing jobs xxi

2 Offset Press Operations 1. Read and interpret production information on job docket/ticket. 2. Explain how an offset lithographic plate works. 3. Identify and demonstrate safe work habits in press operations. 4. Identify basic systems and parts of an offset press. 5. Describe the attributes of sheet-fed, web-fed, stream-fed, and perfecting presses. 6. Identify the printing processes used in the press segment of the printing workflow. 7. Identify basic types, sizes and weights. 8. Determine grain direction of paper and explain the importance of proper grain direction on press, including folds and scoring. Unit 6, Objective 6 Components of a job ticket; A.S. 2 Complete a job ticket Also covered in Unit 5 of Orientation to Graphic Communications, Objective 7, and A.S. 3 and 4 Unit 3, Objective 3 Types of offset plates and their characteristics Also covered in Unit 6 of Orientation to Graphic Communications, Objective 2, and A.S. 2 Unit 4, Objective 2 Essential safety precautions; all job sheets. Unit 1, Objective 3 Basic systems of a typical sheet fed offset press; Objective 4 Functions of basic systems of a typical sheet fed offset press Unit 1, Objective 2 Basic theory of offset printing; Objective 5 Basic systems of a typical web offset press; Objective 17 Perfecting press Unit 1, Objective 2 Basic theory of offset printing; Objective 3 Basic systems of a typical sheet fed offset press Also covered in Orientation to Graphic Communications, Unit 6, Objective 2 Major printing processes; Objective 4 Basic offset printing process; A.S. 1 Write a summary of an article on current printing processes Orientation to Graphic Communications, Unit 7, Objective 2 Basic paper grades and their uses; Objective 3 Basic sizes of paper; Objective 4 Factors affecting paper choice; A.S. 1 Identify basic grades of paper; A.S. 2 Choose the correct paper for various jobs Orientation to Graphic Communications, Unit 7, Objective 5 Tests and procedures for determining grain direction; Unit 9, Objective 5 How the characteristics of paper affect binding and finishing operations xxii

3 Offset Press Operations 9. Handle and jog paper stock (wire/felt, watermarks, and carbonless sequence). 10. Locate paper weight, coating, and sizes on a ream, box, or skid. 11. Describe the importance of paper conditioning prior to running the press. 12. Demonstrate and correct paper problems prior to running the press. 13. Compare offset ink types and uses including oil-based, rubber-based, soy-based, and Ultraviolet (UV). 14. Identify ink ingredients. 15. Identify causes of ink problems and suggest appropriate solutions. 16. Explain the purposes of using spray powder on an offset press. 17. Explain the purpose of an infrared dryer on on offset press. 18. Describe the procedure for mixing and testing custom colored inks. 19. Explain the purpose and use of fountain solution and fountain solution additives. 20. Mix fountain solutions using appropriate ratios and demonstrate understanding and use techniques. 21. Perform make-ready steps for paper handling. Unit 8, J.S. 4 Jog paper, check for squareness, and demonstrate brick stacking Orientation to Graphic Communications, Unit 7, Objective 7 Information to specify when ordering paper; A.S. 2 Choose the correct paper for various jobs Orientation to Graphic Communications, Unit 7, Objective 6 Printing process requirements; Objective 9 Rules for handling paper Unit 5, A.S. 1 Use a troubleshooting guide to find the best solution to a paper stock problem Unit 2, Objective 4 Types of ink Unit 2, Objective 2 Main ink ingredients of offset inks Unit 2, Objective 5 Conditions influencing the printing performance of offset inks; Objective 6 Ink properties which affect the printing quality of offset inks; Unit 5, Objective 18 Conditions that create ink drying problems; Objective 19 Common ink problems on the press; A.S. 1 Use a troubleshooting guide to find the best solution to an ink and dampening problem Unit 2, J.S. 1 Mix dampening solution and test for ph and conductivity; J.S. 2 Mix PMS colors and conduct and evaluate an ink draw-down or smear Unit 2, Objective 11 Generally acceptable ph range for a fountain solution; Objective 12 Effects of using alcohol or alcohol substitutes in a fountain solution Unit 2, J.S. 2 Mix PMS colors and conduct and evaluate an ink draw-down or smear Unit 4, job sheets xxiii

4 Offset Press Operations 22. Perform make-ready of the inking system. 23. Perform make-ready of the dampening system. 24. Perform make-ready of the printing unit. 25. Print a single color one-sided job. 26. Print a single color properly registered two-sided job. Indicate gripper and side guides. 27. Print a single color properly registered job on carbonless stock (two parts or three parts). 28. Print a single color job on envelopes. 29. Print a job on heavy stock. 30. Describe sheetwise, work-and-turn, and work-and-tumble jobs, and how they differ. 31. Print a two-sided job using one of the following methods: sheetwise, work-and-turn, or work-and-tumble. 32. Explain the purpose of registration, crop, and bleed marks. 33. Explain the major functions of a densitometer as a quality control device. 34. Print a multicolor job with register marks and color bars. Maintain accurate registration and monitor ink density. 35. Print a multicolor, two-sided job. 36. Demonstrate the use of flags or count sheets during a press run. 37. Perform roller care and maintenance of inking and dampening systems. 38. Demonstrate ink roller, dampener roller, and cylinder pressure settings on a press. 39. Install a blanket and explain follow-up procedures. 40. Demonstrate proper wash-up techniques for the inking system, dampening system, and cylinders. Unit 4, job sheets Unit 4, job sheets Unit 4, job sheets Unit 4, J.S. 6 Print envelopes; J.S. 14 Print a job using photodirect, electrostatic, and/or computer-to-plate masters on carbonless paper Unit 4, J.S. 10 Print a work-and-turn; J.S. 11 Print a work-and-tumble Unit 4, J.S. 3 Operate an offset press from setup of systems through printed sheet delivery Unit 4, J.S. 6 Print envelopes Unit 4, J.S. 3 Operate an offset press from setup of systems through printed sheet delivery. Orientation to Graphic Communications, Unit 10, Objective 15 Types of imposition Unit 4, J.S. 8 Print a two-color, two-sided job; J.S. 11 Print a work-and-tumble. Advertising and Design, Unit 7, Objective 10 Color measurement devices Unit 4, J.S. 15 Print a four-color process job Unit 4, J.S. 8 Print a two-color, two-sided job Unit 5, J.S. 1 Adjust dampener rollers to plate cylinder; J.S. 2 Adjust ink form rollers to plate; J.S. 6 Deglaze ink rollers and blanket Unit 4, J.S. 3 Operate an offset press from setup of systems through printed sheet delivery Unit 5, J.S. 7 Change blanket Unit 4, J.S. 5 Perform a color wash on an offset press xxiv

5 Offset Press Operations 41. Demonstrate a proper color wash. 42. Identify problems inherent in printing heavy solid work on a duplicator press. 43. Estimate small offset press labor costs to include make-ready, running, and clean-up. 44. Estimate ink and paper costs. 45. Observe offset press operations in a commercial printing plant either on site or online via a virtual tour. 46. Explain procedures for daily, weekly, and monthly maintenance on a press; explain importance of recording the information in a log. 47. Perform basic press maintenance and record the information in a log. Binding and Finishing 1. Read and interpret production information on job docket/ticket. 2. Identiy and demonstrate proper safety considerations when working with bindery equipment. 3. Practice safe work habits when working with bindery equipment. 4. Describe how to change the blade and perform preventive maintenance on an automatic paper cutter. Unit 4, J.S. 5 Perform a color wash on an offset press Unit 5, S.S. 1 Troubleshooting guide for ink and dampening problems; A.S. 1 Use a troubleshooting guide to find the best solution to an ink and dampening problem Unit 6, Objective 3 Cost items to consider when giving an estimate on a printing job; A.S. 1 Estimate costs of printing jobs Unit 6, Objective 3 Cost items to consider when giving an estimate on a printing job; A.S. 1 Estimate costs of printing jobs Orientation to Graphic Communications, Unit 1, A.S. 4 Visit a print provider Unit 5, Objective 5 Requirements for a preventive maintenance schedule in chart form; Objectives 6, 7, 8 Preventive maintenance procedures for daily, weekly, and monthly cleanup; Objective 9 Procedures for daily, weekly, and monthly lubrication; Objective 10 Daily and weekly adjustment procedures; Objective 11 Monthly adjustment requirements Unit 5, job sheets Unit 6, Objective 6 Components of a job ticket; A.S. 2 Complete a job ticket Also covered in Unit 6 of Orientation of Graphic Communications, Objective 7, and A.S. 3 and 4 Unit 7, Objective 2 Safety rules for operating a paper cutter, all job sheets; Unit 8, Objective 6 Troubleshooting and maintenance criteria for bindery equipment; all job sheets Unit 7, all job sheets; Unit 8, all job sheets Unit 7, Job Sheet 2 Change a blade on an automatic paper cutter xxv

6 Binding and Finishing 5. Estimate the cost of materials and production for performing various bindery operations. 6. Identify basic hand tools, equipment, and materials in bindery operations. 7. Demonstrate proper paper handling and storage procedures. 8. Demonstrate basic paper jogging techniques. 9. Demonstrate basic paper counting techniques; measure by ream marker, weight, caliper or other methods. 10. Demonstrate knowledge of paper types related to their grain direction, cutting, folding, and binding characteristics. 11. Calculate basic paper cuts from a parent sheet, considering job requirements and grain. 12. Describe how to use and set up programmable cutters. 13. Make accurate paper cuts using a mechanized paper cutter. 14. Demonstrate how to check the squareness of stock. 15. Collate sets in proper sequence. 16. Prepare folding dummies for commonly used impositions. 17. Define folding terminology and list different folding techniques. Unit 6, Objective 3 Items to consider when giving an estimate on a printing job; A.S. 1 Estimate costs of printing jobs; Unit 8, A.S. 1 Calculate savings by bindery operators Unit 7, Objective 4 Two types of paper cutters; Unit 8, Objecitve 6 Binding methods; Objective 8 Folding techniques; Objective 10 Anciliary finishing operations; Objective 11 Packing and shrink-wrapping equipment and materials Orientation to Graphic Communications, Unit 7, Objective 9 Rules for handling paper Unit 8, J.S. 4 Jog paper; check for squareness, and demonstrate brick stacking Orientation to Graphic Communications, Unit 8, J.S. 1 Count paper using various techniques Unit 9, Objective 5 How characteristics of paper affect binding and finishing operations; Orientation to Graphic Communications, Unit 7, Objective 2 Basic paper grades; Objective 4 Factors affecting paper choices; A.S. 1 Identify basic grades of paper; A.S. 2 Choose the correct paper for various jobs Unit 7, A.S. 1 Use the formula for cutting paper stock; A.S. 2 Use the formula to determine how many sheets will be required; A.S. 3 Calculate combination cut using stock cutting formula; A.S. 4 Draw a cutting diagram Unit 7, J.S. 1 Set up a programmable paper cutter and cut paper Unit 7 J.S. 3 Cut carbonless paper Unit 8, J.S. 4 Jog paper, check for squareness, and demonstrate brick stacking Orientation to Graphic Communications, Unit 8, J.S. 7 Collate multi-page printing jobs using a collating machine Unit 8, J.S. 5 Prepare a folding dummy for a 16-page imposition Orientation to Graphic Communications, Unit 8, Objective 3 Major paper folding styles; S.S. 2 Folding styles xxvi

7 Binding and Finishing 18. Demonstrate the use of folding equipment to produce a single fold, an accordian fold, and a gate fold. 19. Describe and identify the uses of right angle folding, knife folding, buckle folding, and combination folding. 20. Demonstrate the use of folding equipment to produce a right-angle fold job. 21. Demonstrate and properly use folding equipment to produce a high-folio lip signature and a low-folio lip signature. 22. Describe tipping-in procedures. 23. Demonstrate the use of folding equipment to perforate and score. 24. Demonstrate and perform preventive maintenance on a folder. 25. Describe and identify in-line finishing systems. 26. Describe and identify off-line finishing systems. 27. Produce correctly made pads of paper. 28. Describe the fundamentals and applications of saddle stitching and perfect binding. 29. Produce side and saddle stitched/stapled products. 30. Identify spiral binding and wire binding equipment and products. Unit 8, J.S. 1 Use folding equipment to produce a gate fold; J.S. 6 Set up and operate a paper fold consistent with job specifications. Also covered in Unit 8 of Orientation to Graphic Communications, Objective 3 and J.S. 5 Unit 8, Objective 8 Folding techniques Unit 8, J.S. 2 Use folding equipment to produce a french fold (double fold); J.S. 6 Set up and operate a paper fold consistent with job specifications Unit 8, J.S. 7 Use folding equipment to produce high-folio lip signatures Unit 8, Objective 7 Tipping Unit 8, J.S. 3 Using folding equipment to produce slitted, perforated, and scored sheets; also covered in Orientation to Graphic Communications, Unit 8, J.S. 8 Score a job Unit 9, A.S. 2 Set up a preventive maintenance schedule for a folding machine; J.S. 1 Locate and correct a feeding problem on a paper folder; J.S. 2 Perform preventive maintenance on a folding machine Unit 8, Objective 9 In-line finishing operations Digital File Preparation and Output, Unit 9, Objective 15 Descriptions of in-line, near-line, and off-line bindery and finishing solutions Orientation to Graphic Communications, Unit, 8, J.S. 2 Pad 20-pound stock; J.S. 3 Pad carbonless paper Unit 8, Objective 6 Binding methods; also covered in Unit 8 of Orientation to Graphic Communications, Objective 2 Orientation to Graphic Communications, Unit, 8, Hand fold, collate, and staple a booklet Unit 8, Objective 6 Binding methods xxvii

8 Binding and Finishing 31. Describe the case binding process. 32. Identify packaging and shrink wrap equipment and materials. 33. Identify specialty bindery processes; foil stamping, embossing, die cutting, and thermography. 34. Identify common production problems encountered in the bindery area. 35. Describe and identify basic mailing equipment. 36. Demonstrate an understanding of United States Postal Service (USPS) standards (sizes and mail class rates). 37. Observe a commercial bindery operation (live or virtual). Advanced Offset Press Operations A. Press Mechanics and Printing Systems 1. Describe the major systems of a web offset press. 2. List the advantages and disadvantages of a web offset press vs. a sheetfed offset press. 3. Describe digital printing and the advantages and disadvantages compared to offset printing. 4. Describe and identify direct imaging technologies. 5. Identify various press feeding systems. Unit 8, Objective 6 Binding methods; Also covered in Unit 8 of Orientation to Graphic Communications, Objective 2 Unit 8, Objective 11 Packing and shrinkwrapping equipment and materials Unit 8, Objective 3 Embossing and foil stamping. Also covered in Unit 8 of Orientation to Graphic Communications, Objective 4 Unit 8, Objective 4 Common problems encountered in foil stamping and embossing Unit 8, Objective 11 Packing and shrinkwrapping equipment and materials Unit 8, Objective 13 Mail class guidelines; Objective 14 Mail class rates Orientation to Graphic Communications, Unit 1, A.S. 4 Visit a print provider Unit 1, Objective 5 Basic systems of a typical web offset press Unit 1, Objective 2 Basic theory of offset printing Unit 4, S.S. 1 Automated advancements; S.S. 2 Digital impact on press activities Orientation to Graphic Communications, Unit 10, Objective 14 High-end output devices used for digital file output; S.S. 2 Overview of digital history in printing; S.S. 3 Moving from traditional prepress to electronic prepress Unit 1, Objective 5 Basic systems of a typical web offset press; Objective 7 Components of the feeder system; Objective 8 Functions of components of the feeder system; Objective 9 Types of feeder systems and their operations xxviii

9 Advanced Offset Press Operations 6. Identify various drying and dampening systems. 7. Explain the difference between conventional, compressible, and sleeve blankets, and their applications. 8. Perform preventive maintenance procedures on an offset press. 9. Remove, replace,and reset rollers, ensuring proper roller pressure and durometer. 10. Select and install a blanket and appropriate packing. 11. Describe antistatic and anti-marking systems and explain why they are used. B. Offset Press Operations 1. Read and interpret production information on job docket/ticket. 2. Select the proper stock according to job specifications. 3. Describe and demonstrate the operational procedures for each of the controls and adjustments on the offset press. 4. Identify and use a mechanical control of registration on an offset press. 5. Identify and resolve mechanical press problems as they relate to quality controls. Unit 1, Objective 19 Components of a conventional dampening system; Objective 20 Functions of components of the inking/ dampening system; Objective 21 Types of dampening systems Unit 1, Objective 15 Types of offset blankets Unit 5, all job sheets Unit 5, J.S. 1 Adjust dampener rollers to plate cylinder; J.S. 2 Adjust ink form rollers to plate; J.S. 3 Adjust plate cylinder to blanket cylinder; J.S. 4 Adjust blanket cylinder to impression cylinder Unit 5 J.S. 7 Change blanket Unit 6, Objective 6 Components of a job ticket; A.S. 2 Complete a job ticket; also covered in Unit 5 of Orientation to Graphic Communications, Objective 7, and A.S. 3 and 4 Unit 4, job sheets; also covered in Unit 7 of Orientation to Graphic Communications, A.S. 2 Choose the correct paper for various jobs Unit 1, Objective 3 Basic systems of a typical sheet fed offset press; Objective 4 Functions of basic systems of a typical sheet fed offset press; Unit 4, Objective 4 Offset press operator control functions; Objective 5 Typical operator control features of offset press systems Unit 1, Objective 3 Basic systems of a typical sheet fed offset press; Objective 4 Functions of the basic systems of a typical sheet fed offset press; Objective 10 Components of the new register system; Objective 11 Functions of components of the register system Unit 5, A.S. 6 Use a troubleshooting guide to find the best solution to a mechanical problem xxix

10 Advanced Offset Press Operations 6. Print a job on lightweight paper. 7. Print a multi-color, two-sided job on coated paper. 8. Print a job on card or board stock. 9. Print a heavy solid coverage on coated paper. 10. Describe various impositions for sheetfed and web offset presses. 11. Print a series of jobs using a variety of different impositions. 12. Explain how an infrared (IR) dryer works and the advantages and disadvantages of its use. 13. Explain the advantages and disadvantages of (UV) coating/printing. 14. Describe the use of color-controlled lighting in press sheet evaluation. C. Process Color 1. Describe the difference between process and spot color inks. 2. Identify common problems in color reproduction and describe the solutions. 3. Describe the differences encountered in printing a process color job on coated and uncoated paper. 4. Print a process color job on uncoated paper. 5. Print a process color job on coated paper. 6. Interpret color bars on a press sheet to determine corrective actions, if necessary. Unit 4, J.S. 12 Print halftones and screen tints Unit 4, J.S. 8 Print a two-color, two-sided job Unit 4, J.S. 12 Print halftones and screen tints Unit 4, J.S. 13 Print solids Orientation to Graphic Communications, Unit 10, Objective 15 Types of imposition Unit 4, J.S. 6 Print envelopes; J.S. 8 Print a two-color, two-sided job; J.S. 10 Print a workand-turn; J.S. 11 Print a work-and-tumble; J.S. 15 Print a four-color process job Unit 8, Objective 5 Advantages and disadvantages of laminating and coating techniques Orientation to Graphic Communications, Unit 11, Objective 13 Basic categories of color printing Unit 2, Objective 5 Conditions influencing the printing performance of offset inks; Objective 6 Ink properties which affect the printing quality of offset inks; Unit 5, Objective 18 Conditions that create ink drying problems; Objective 19 Common ink problems on the press; A.S. 1 Use a troubleshoot guide to find the best solution to an ink and dampening problem Unit 4, J.S. 15 Print a four-color process job Unit 4, J.S. 15 Print a four-color process job Unit 4, J.S. 15 Print a four-color process job Unit 4, S.S. 1 Automated advances xxx

11 Advanced Offset Press Operations 7. Using color bars and a densitometer, measure solid ink density and tone value increase (TVI). D. Printing Standards/Color Management 1. Describe color densitometry/ spectophotometry principles and applications. 2. Describe and apply industry standards, such as Specifications for Non-Heatset Advertising Printing (SNAP) General Requirements for Applications in Commercial Offset Lithography (GRACoL), and Specifications for Web Offset Publications (SWOP), etc. 3. Adjust inking and/or dampening systems so that solid ink density matches print specifications (SNAP, GRACoL, SWOP, etc.). 4. Understand fountain chemistry requirements, including conductivity and ph. 5. Demonstrate the use of ph strips or meters and modify fountain chemistry accordingly. 6. Use conductivity and ph meters and interpret readings. 7. Set up, mix, and test ink for printing using color chart for mixing requirements. E. Workflow and Automation 1. Describe the use of a press console in offset press operations. 2. Describe the use of Job Definition Format (JDF) in offset press operations. Unit 4, S.S. 1 Automated advances Digital File Preparation and Output, Unit 8, Objective 3 Color and printing terminology; Objective 4 Purposes and applications of quality control devices for color management Unit 5, Objective 21 Printing industry standards Unit 5, J.S. 1 Adjust dampener rollers to plate cylinders; J.S. 2 Adjust ink form rollers to plate Unit 2, Objective 11 Acceptable ph range for a fountain solution; Objective 13 Importance of measuring conductivity of a dampening solution Unit 2, Objective 10 Two methods of measuring ph; J.S. 1 Mix dampening solution and test for ph and conductivity Unit 2, J.S. 1 Mix dampening solution and test for ph and conductivity Unit 2, J.S. 2 Mix PMS colors; conduct and evaluate an ink draw-down or smear; J.S. 3 Mix two colors of ink to produce a third color Unit 4, Objective 4 Press operator control functions; Objective 5 Typical operator control functions; A.S. 1 Compare control features of offset and digital presses; J.S. 3 Operate an offset press from setup of systems through printed sheet delivery Digital File Preparation and Output, Unit 8, Objective 6 Computer Integrated Manufacturing (CIM) xxxi

12 Advanced Offset Press Operations F. Paper Characteristics 1. Describe paper characteristics as they relate to offset printing. 2. Identify various varnishes and coatings and describe the reasons for using each. Unit 5, S.S. 2 Troubleshooting guide for paper stock problems; A.S. 2 Use a troubleshooting guide to find the best solution to a paper stock problem Also covered in Orientation to Graphic Communications, Unit 7, Objective 2 Basic paper grades; Objective 3 Basic sizes of paper; Objective 4 Factors affecting paper choice; Objective 5 Tests and procedures for determining grain direction; A.S. 1 Identify basic grades of paper; A.S. 2 Choose the correct paper for various jobs Unit 2, Objective 2 Main ingredients of offset inks; Objective 4 Types of ink; Unit 8, Objective 5 Advantages and disadvantages of laminating and coating techniques xxxii