Quality management of the printing and binding of

Quality management of books and periodicals printing and binding

anyone who has done the quality management of books and periodicals printing and binding knows that the numerous processes of books and periodicals from printing, page selection to folding, pasting, bundling, waxing, sorting, gluing... Make you dizzy. Moreover, as long as there is a mistake in each process, the subsequent processes are generally difficult to find, so it will cause the occurrence of unqualified products, and the quality level of the whole batch of products will be reduced

the author has been engaged in the quality management of books and periodicals in printing enterprises for more than ten years. From the management experience of more than ten years, we have learned that to improve the overall quality of books and periodicals products, we must strictly start from the most basic process. The following are some experience and methods of quality management of each process summarized by the author in the work of the company for more than ten years. If the fixture is divided according to the structure, it can be used for reference by colleagues

1. Printing

the key to improving the quality of printing is to enhance the hearts of printing staff. The specific method is to print a sample sheet (this sample sheet must be confirmed by the captain first), and the quality inspector on duty will comprehensively proofread it, formulate the form, make records and sign it. If there is any error, he will take the first place

after signing the samples, in the process of normal printing in batches and teaching demonstration in Colleges and technical secondary schools, we stipulate that the captain should take a sample every 500 copies for comprehensive inspection, and the deputy should take a sample every 200 copies for inspection. If there is any doubt, the batch (500 or 200 pieces) should be separated and clearly marked, so that the next process (page selection) can make a smooth choice. However, we once found that nearly one-third of the printed posts were found to have quality problems when selecting the pages of a car of products after printing. It can be seen from the quality problem that it should be printed by one of the three shifts of a, B and C, but after selecting the page, it is impossible to distinguish which shift it is printed, resulting in those who cannot be investigated. However, through this incident, another provision was added to our quality management system: that is, at a certain place of each edition (the labeling place or other places that do not affect the finished products), add the words "a, B and C" as three job numbers, so that when there are quality problems, they can be traced to the finished books and periodicals before they are delivered from the warehouse. At the same time, this is also a powerful means to strengthen their hearts

2. Page selection (post)

friction and wear tester knowledge page selection seems simple, but it must be very careful and intentional people to be competent for this work. The work of selecting Posts focuses on "picking" and "dividing": "picking" is to pick out unqualified products, inferior products and waste products; "Fen" refers to the classification of products at various levels. Therefore, the page selection personnel are required to be very careful. After selecting the post, they must make a complete report on the quality of the selected products in the form of tables. Since the printed matter with problems in the previous process, that is, printing, is basically marked, it is easy to select the products with problems when selecting pages. In this way, our quality management personnel can know the quality grade of the products by checking the page selection form

3. Folding

the current folding includes manual folding and machine folding. No matter what kind of folding, the first requirement is not to take the wrong page, and then not to put the wrong page. According to our long-term quality problems, most of the errors caused by folding personnel are these two phenomena. Once the first phenomenon occurs, it is a major quality accident. This kind of mistake is most likely to occur in the same series of different books, which has occurred in our company. There was a series of English exercise books printed at that time, including grade one, grade two and grade three. Because the words under the posts are similar, the folding staff can't understand the content. In addition, these three kinds of book posts are placed together. When a careless folding staff goes to get the book post after folding the third post of the first day of the junior high school, he takes the third post of the second day of the junior high school, folds it and puts it together with the first day of the junior high school. The posts are aligned and the page numbers are just connected. As a result, after the book was finished, the quality inspectors in the factory did not check it out, sent it to the students and retreated, causing a very significant impact. The second phenomenon is that the pages of the book are placed upside down. If several pages are placed upside down, the folding personnel will fold them in if they are slightly careless. It is difficult to check them out if they are not very careful

to put an end to the above two phenomena, it must be done well before the printed pages are pulled into the folding workshop. Similar books should not be pulled together. Even if they are not put together, there should be very obvious signs, and these signs can be clearly seen in which direction of the books. Only in this way can we overcome taking the wrong post. As for the folding requirements, page numbers and other requirements are commonplace, so this phenomenon rarely occurs

4. Baling

the process of flattening and baling mainly requires strict control of the process and attention to the correct and appropriate operation methods of employees, which generally will not cause quality problems

5. Post matching

the error probability of the post matching process is large, and there are often wrong posts, more posts, less posts and other phenomena. However, as long as the self inspection and mutual inspection (employees check each other) are carried out after the post is prepared, it is easy to make mistakes. It is also easy to take wrong posts when matching posts, so the quality management of matching posts is also required to be consistent with the folding requirements to avoid taking wrong posts

6. Waxing

in the past, waxing was manual waxing. After technical transformation, now many enterprises use waxing machines to brush wax. Whether it is manual waxing or machine waxing, generally speaking, the solubility of wax and the wax brushing gap of book posts are the most noteworthy. The quality management personnel should also pay special attention to this point. If the operators do not do a good job at this point, the next process will cause difficulty or wrong division. Therefore, this process needs to be operated by some experienced people (especially manual waxing) in order to avoid such errors

7. Glue brushing and book sorting

glue brushing is the same as waxing process, and some enterprises have also used automatic glue brushing machines. Like the waxing machine, the glue brushing machine also needs to consider the drying temperature and the consistency of glue. Only by doing these two things well can it be conducive to the division of this process

8. Flat binding, glue binding

flat binding (now books are generally no longer flat binding, which is no longer discussed here), glue binding is a major focus and difficulty in the quality management of books and periodicals. Many problems such as degumming, blistering, air leakage, wild glue, back wrinkling, etc. are very easy to occur in this process, so before large-scale glue packaging, small batch tests should be carried out first. After the test articles come out, the quality management personnel should carry out some excellent adaptability tests on the test articles packed out of the glue (such as placing them in the refrigerator and drying room) to see whether the glue is brittle and loose when the temperature is low (-20 ℃); Whether the glue will be soft and blistered when the temperature is high (40 ℃), so that the books can be sent to hot or cold areas and cause quality accidents. In addition, whether the wild glue, glue hole and spine are square can be produced in large quantities only after the small batch test is solved. Before mass production, the quality management personnel should recognize and sign the samples. In the process of mass production, they also need to regularly spot check, and pay attention to whether there are changes in various technical indicators such as the back glue temperature, side glue temperature and splint pressure on the glue loader. A large number of quality problems such as book degumming caused by the change of a certain data also often occur, so this point needs special attention

9. Finished product cutting

finished product cutting is the final process. The completion of this process marks the successful completion of a book. If all the previous processes are in good condition, but there is a mistake in the final cutting, the previous efforts will be wasted and a lot of human and material resources will be wasted. Therefore, the sample signing system must be strictly implemented in this process, and the manuscript must be strictly compared to see whether there is dimensional deviation, hanging angle, etc. During batch cutting after sample signing, the cutting assistant (the book receiver behind the machine knife) should formulate an inspection system. For example, our company stipulates that after cutting 20 books, we should stop the machine for book inspection. If there are problems such as size deviation, hanging angle, knife flower and so on, we should correct them in an emergency, otherwise we should investigate the assistant

10. Baling and packaging

baling and packaging are auxiliary processes, which generally have no impact on the quality of books. It should be noted that the quantity is enough and the binding is solid, but it should not be too tight, so as to avoid loosening or being too tight and damaging the book. Quality management personnel should also not forget to check the appearance of the packaging to ensure that each process is qualified

11. Sampling inspection of finished products

the batch sampling inspection of finished products should be set up in the warehouse of the company (public factory), and should be carried out by special quality management personnel in strict accordance with the sampling method of books (Textbooks). The internal standard of the company can be higher than the national standard. If an index fails to meet the national standard or the internal standard of the enterprise in the sampling inspection, it should be reworked, repaired and screened immediately, and strive to make the qualified rate of the ex factory books reach 100%

the above are the experience and methods used by the author in the quality management of books and periodicals printing and binding in the company. The company has achieved good results. During the sampling inspection of the quality of our company's books and periodicals by superior competent departments and industry departments for many times, the products are recognized as good products (first-class products) every time. Of course, other enterprises may have more advanced quality management experience and methods, depending on the specific situation of the enterprise