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The application of total quality management in prepress

modern quality management has been mainly engaged in post check, and gradually changed to the whole process management focusing on prevention and control. Its characteristic is to change the previous case-based and decentralized management into a comprehensive management from a systematic point of view. Change the management result into the management factor, find out the factors that affect the quality, grasp the main contradiction, and make the whole production process under control, so as to achieve the purpose of ensuring product quality. In the overall management of printing, the quality control before printing is particularly important

if the prepress quality control is not strict, it will bring many disadvantages to the post process, which will affect the product quality, cause unnecessary waste, and even cause major quality accidents, causing economic losses to enterprises and workers. Therefore, taking preventive and control measures, strengthening prepress data and standardized management, strengthening the overall quality awareness of workers in various processes, finding out the factors that may affect the quality in the prepress process in the long-term use process, formulating process and quality standards, and taking preventive measures will greatly improve the quality of products and shorten the production cycle. Total quality management has been recognized by many enterprises as a management method to effectively enhance market competitiveness

1 total quality management

tqm refers to the total quality management of an enterprise, which is the abbreviation of total quality management in English. It is a business management model with customers and quality (including product quality and business quality) as the core, and enterprise leaders take the lead in implementing it. The idea of total quality management (TQM) was first put forward by general motors of the United States, and the book "TQM" was published in 1961. Definition of total quality management: in order to carry out market research, design, manufacturing and after-sales service at the most economic level and taking into account the conditions that fully meet the requirements of customers, the development quality, quality maintenance and quality improvement activities of all departments in the enterprise constitute an effective system. The idea of total quality management is to take quality as the center

in Japanese enterprises, managers take autonomy as the leadership principle to operate and manage under the guiding principle of paying attention to customers. Enterprise planners first put forward plans and suggestions to managers according to changes in the market environment; The manufacturing department actively produces, improves quality and efficiency; The task of marketing personnel is to develop the market, expand sales and improve service; The financial department actively improves the efficiency of funds, raising funds at low cost and using funds flexibly to meet the business needs. Among them, the production workshop and marketing department are the two pillars of the enterprise. The division system is also popular in large companies in Japan. The so-called business division system refers to the system of several accounting units responsible for their own profits and losses according to their respective markets and products. The division system is conducive to the flexible operation of all professional departments according to the actual situation, the production and operation according to the professional categories of products, strengthens the competitiveness of various products, and evaluates the business performance of the division minister through the target management system. Always follow the TQM management concept, put customer management, improving product quality and business quality first, become a part of corporate culture, and will also be the main source of core competitiveness

The basic characteristics of TQM are: 1) comprehensive quality management; 2) Management of the whole process; 3) Management with full participation; 4) Comprehensive management. The guiding ideology of total quality management is: everything is customer-centered and done well at the first time. Total quality management includes product quality, process quality and work quality. The basic idea of total quality management is mainly reflected in: serving customers, giving priority to prevention, speaking with data, and full participation in management

several principles that TQM should follow: 1) the basis of quality awareness TQM; 2) Continuously meet the needs of customers, market and society besides paying attention to the purchase of fatigue testing machine; 3) The basic characteristics of human centered TQM; 4) Continuous improvement of quality; 5) Clear quality policies and objectives; 6) Effective quality management system; 7) Whole process control; 8) Working procedure PDCA cycle of TQM; 9) Technical methods including statistics; 10) Quality cost management

As a management method of modern enterprises, TQM is being adopted by more and more enterprises. It should be noted that TQM refers to the comprehensive quality management of enterprises, which takes the emphasis on customer management as the premise, takes the improvement of business quality and product quality as the goal, and thoroughly and correctly implements and implements the established strategies of enterprises through the leaders' example

2 key quality management factors in prepress

manufacturing statistics show that in any manufacturing process, 85% of the downstream changes can be reduced by controlling the first 15% of the process. Total quality management can effectively control the early stage of the process and achieve more stability and accuracy in the whole manufacturing process

in silk printing, the goal is to accurately prepare and transfer the film to the printing department. To control the whole digital prepress process, stably control the following 13 key change points in printing production:

1 Image layout

2 Prepress setting time

3 Color matching

4 Moire

5 Overprint

6 Color change during operation

7 Point increase

8 Consistency in operation

9 Thickness of ink film

10 Ink consumption

11 Total ink limit

12 Ink stacking

13 Printing speed

managers and planners must learn how to carry out front-end weighting on the stability of the system, so that in the process of production and operation, they can achieve the goal of minimum interference with operators. Focusing on the first 15% of the whole prepress process can greatly reduce the dependence of image quality adjustment on the printing operator. Printers only need to focus on image adjustment, ink density and linear tone positioning. If the prepress operation is very accurate, these three functions will appear more or less automatically. As a result, we can achieve three benefits: printing becomes more efficient, waste reduction and printing quality improvement

3 direction of prepress management efforts

knowing the goals to be worked on and the problems to be paid attention to, and with TQM as a weapon, we can work hard from the following aspects, grasp the prepress quality management work, and carry out strict quality control in all aspects

1. Printing enterprises should formulate a set of process standards that meet their own requirements and actual production level according to their own specific conditions, and the technologists should issue process construction sheets for all links from undertaking tasks to the whole construction process. It includes: raw materials used, operation methods, environmental conditions, equipment used, maybe this kind of comfort, and different construction schemes that should be adopted according to different equipment. All operators shall operate in strict accordance with this process construction sheet and cannot change it at will. Comprehensively start the data-based and standardized quality management, gradually improve the process standards, especially put forward some special process requirements for different equipment

2. In order to print high-quality printed matter, in addition to advanced printing equipment, we must first have high-quality plate making film. This requires plate makers to pay attention to the production and sorting of films, strictly control the quality of films, and provide high-quality films that meet the requirements of plate printing and printing

3. Strengthen the document inspection work, especially in the prepress process, the film should be calibrated in series to find problems and quality hidden dangers in time, and eliminate unnecessary waste. In printing, serial correction is indispensable. It is one of the effective means to control quality. In printing, the focus of serial correction should be on the control of printing quality, such as checking whether the opening sample, falling plate and the original sample are the same, checking the sequence of page numbers and the quality of graphics and texts, and checking whether there are phenomena such as word dropping, plate pasting, light flower, etc., so as to effectively control the printing quality and prevent various quality accidents

4. Printing is the last process before printing. The quality of printing directly affects the quality of printing products. Printing personnel must strictly comply with the process and quality requirements during operation, carefully check whether the original film meets the printing conditions, whether the plate is flat and clean, and whether the sand mesh, photosensitive coating and photosensitivity can meet the requirements. After confirmation, printing can be carried out

the operator should cooperate with the test strip to determine different exposure under different conditions according to the situation. The printing environment should be standardized and tidy. Before printing, the original and printing glass should be cleaned to avoid uneven air extraction caused by small foreign bodies and virtual graphics and texts. Secondly, the control of the development process is also an important factor to ensure the quality of printing. The developer must be prepared in strict accordance with the requirements, supplemented quantitatively, and the development temperature and speed must be strictly controlled to avoid the loss of dots due to the high concentration, high temperature or fast speed of the developer, or the dirty and paste phenomenon on the layout due to the low concentration, slow speed or low temperature of the developer

5. White material cutting is often an important link that is easy to be ignored in prepress quality control. The size and quality of cutting directly affect the rules and quality of printing. If the operation is not in place during cutting, the size will be wrong

6. Carefully focusing on image construction, document preparation, film imaging and eye imaging, this series of basic work can dramatically improve the whole printing quality. Every type of change or disqualification of print quality can be analyzed to determine whether it can be improved by changing a prepress treatment method

in order to illustrate how we can reduce the total cost in the whole prepress process by changing the working method, we can start from the first step of silk production. We can use digital templates, pinhole positioning and image trapping to improve the accuracy of color overprint sequence. At the same time, it also reduces the potential use cost of film. Typical and traditional color setting of each color takes about 6 ~ 20min (large printing machine takes longer), but in a precisely designed process, the time of color setting of each color can be reduced to 30s ~ 2min, sometimes even shorter

the purpose of reducing setting time is to simplify a single printer adjustment method to the level of image arrangement and positioning. The rubber roller angle, pressure, speed, distance and stripping settings can remain unchanged. Moreover, by introducing the pinhole positioning printing system, the position of the image can be accurately located, and the error range is within 0.002 inch, which greatly reduces the need for fine-tuning

7. In the process of printing, the characteristics of saving time and high efficiency before printing can also be continued. The trial printing and color matching are reduced to less than 10 pictures or less than 6 textiles. This can be achieved by adhering to strict document preparation and color separation parameters, combined with the reduction strategy of continuous tensile strength, lotion thickness, porosity, moire control and point increase

prepress is usually used to control the generation of moire, the increase of dots and the stability of gray balance. If these are not well controlled, the printing machine must be adjusted accordingly, which directly leads to a lot of unnecessary work. In printing, in addition to image adjustment, the only adjustment to be made is to adjust the ink film to the specified density level. Tone and color transfer are determined by prepress, and as long as they are reasonably linearized, they can be automatically linearized

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