PRINTING PRESS INSTRUCTION

Transcription

1 Page 1 of Purpose & Scope To provide instruction to pressmen regarding the proper operation of the printing presses. 2. Definitions Date/Time Stamp (DTS) Densitometer In Process Inspections Mark the Pile Pantone Book Personal Data Press Approval Sheets Press Check Secure Area A battery operated electronic Date/Time Stamping device which will be maintained at each press for the purpose of documenting QC inspections throughout our press runs. A electrical device that measures the density of the ink. See densitometer calibration record. (TGQ11.7, rev. 1, 2/24/03 yearly calibration) at 4 color press maintenance log. QC checks that are performed throughout the press run that are evidenced by the "Date/Time Stamp". In Process inspection standards are detailed in the "Press/Imaging Critical Success Check List" (form TG355). A process by which the Press Operator inserts a marker into the pile of printed material to identify some aspect of the job. A color matching formula guide for mixing and matching ink colors. Personally identifying or sensitive data that is not publicly available. Data includes, but is not limited to: health, criminal, financial, biological, race, ethnicity, religion, politics, and sexual orientation. This data requires disclosure control due to privacy issues and possibility of its use to commit fraud, identity theft, discrimination, etc. Client and regulatory requirements shall guide TGI's disclosure policies regarding affected inputs and outputs. The sheet that the press operator chooses to use as the quality record of the operator and second qualified associate sign off. A process where a third party may request that they check the press run prior to the production actually beginning. A "Press Check" form has bee created (Form TG 333) to assist in the requests. A physical location closely monitored to ensure that unauthorized persons are not allowed entry without direct supervision by an authorized person. Designated secure areas

2 Page 2 of 14 Definitions (Continued) shall be conspicuously posted with "Restricted Area - Authorized Personnel Only" signs within clear view of all entry points into the area. Locked areas requiring authorized access by key or passcode shall also constitute secure areas, and above signage must be posted. These areas shall remain locked at all times when authorized personnel is not present in the immediate area. 3. Responsibilities PRESS QA/TL/SUP Press Operator Qualified Associate/Team Leader/Supervisor 4. Authority SUP Supervisor 5. Revision History Revision 16 (10/30/08) - Change to Step 12. No re-training required. Revision 17 (5/4/10) - Changes throughout WI. Re-training required. Reivison (10/3/13) - Added Security definitions. Re-training is required. 6. Instructions 1. Review Job Sleeve for Instruction The qualified press operator will retrieve the Job Sleeve from the appropriate Printing/Imaging Staging Area. The Job Sleeve will contain the following: A client proof of the job with the customer sign off. The client approval may be an authorizing us to go forward attached to a final proof document In some cases a client may also authorize a TGI Associate as their on-site representative. If a TGI Associate is given this responsibility by the client then they must sign off just as a client would once they are satisfied.

3 Page 3 of 14 Instructions (Continued) In addition, the following forms will also be provided. A Press Layout/Closeout form (TGQ 6.72) [click here to view] will be provided by the Estimating area for new projects A Stock Order form (TG 146) [click here to view] from the Estimating area for projects that require special stocks. A Promail Pick Slip and Print On Demand (POD) order or an Manufacturer On Demand (MOD) may be used for E Store orders. A Press Check (Form TG 333) [click here to view] to request an additional press check. the press check details will be noted in Promail. The operator will review the contents of the Job Sleeve to make sure that they understand all aspects of the request. Review the cutting and production instructions. The operator should pay particular attention to any sub instructions within the task if there are any present they will be bulleted as individual items for consideration. The operator will initial each sub-bullet in the task indicating your understanding. Review the Stock Order form (TG 146) [click here to view] to find out what quantity of stock is required, what type, and whether it's in stock or ordered. Any questions/discrepancies concerning the instructions should immediately be referred to the Supervisor. 2. Ensure Art Dept Sign Off Ensure that there are two Art/Graphic Associate signatures on the Press Layout/Closeout, (form TGQ 6.72) [click here to view], or on the POD/MOD Promail form. If not, do not proceed. See the Art Director or another qualified Art/Graphics Associate to have them perform the required quality review(s), and approval(s). If there are any other concerns see the Press Supervisor. 3. Pull Stock The Press Operator will locate the proper stock as called for on the Stock Order Form (TG 146) [click here to view], or via the task instruction/pdo/mod form if the stock is a standard house stock. The Associate will pull the estimated quantity to the cutting area if it must be pre-cut, or they will pull it directly to the press if it is already cut to size. They will initial the stock order form and place the yellow copy of it in the Press Inventory Pull Basket at the Press Desk or they will note it on the "Stock Pulled Log" (Form TG 325) [click here to view] located at the Press Desk. The white copy Order Form (TG 146) [click here to view] will stay stapled to the Press Close Out Layout Sheet. The Press Associate may modify the Pull Quantity if they increase or decrease the press run. The pulls will be confirmed on a daily basis by a qualified Press Associate (see Internal Supplies/Forms Inventory Management Instruction WI ) [click here to view] thus

4 Page 4 of 14 Instructions (Continued) reducing our paper inventory (this insures that the value of our inventory is correct affecting our departmental financials, makes sure that we have the proper stock on hand for future orders, and applies the cost of the materials to the job for billing purposes). 4. Pre-Cut Stock A Press Person or a qualified Associate will pre-cut stock if required per the Cutting Instruction for Raw Stock (WI ) [click here to view] 5. Plate Inspection Inspect each plate for defects such as punch alignment, lines, and scratches. If the plates do not pass the inspection, the failure should be noted on the Plate Remake Log (Form TGQ 9.4) [click here to view] which is located at the Press Desk along with the reasons for the failure. The Art Department should be notified, corrections made, and the plates reproduced. 6. Set Up Press Date/Time Stamp the Task Sheet or the POD/MOD order to indicate set up start time. Mount the plate(s). Load the stock. Load the ink. Re-set the counter to 00". Ensure conformance to PMS color specified in the task by using the Pantone Book to check the color. Operator may have to use a densitometer if printed piece isn't hitting Art sample. 7. Quality Check and Sign Off Run press sheets until ink and water balance to produce finished sheets that comply with customer specifications. A press operator may use a less expensive stock to set up with, as a means of reducing the cost of the set up for the run. A Press/Imaging Critical Success Check List (Form #TG 355) [click here to view] has been developed to assist Press Operators and is posted prominently throughout the Press/Imaging Area. Once the operator feels that everything is correct, the operator will pull a sheet that demonstrates conformance, "Date/Time Stamp" it, and physically sign off on the piece. This sheet becomes the "Press Approval Sheet" and is to be maintained as a principal quality record for the job in the job ticket. In the case of the Halm Jet there may be 1, 2 or 4 separate images on the plate depending on how the job was set up. The operator must sign off on an image from each plate. These shall be stapled together and "Date/Time stamped". The press operator will seek a second sign off on the "Press Approval Sheet" from another qualified associate. This second sign off will be required in all cases unless the Supervisor approves an exemption. 8. Second Set of Eyes Quality Check and Sign Off A second sign off on the "Press Approval Sheet" will be performed by the team leader, supervisor, or another qualified associate. The individual performing the second sign off will

5 Page 5 of 14 Instructions (Continued) also use the Press/Imaging Critical Success Check List (Form #TG 355) [click here to view] mentioned above to guide them through the approval process. This second set of eyes approval will be considered an authorization to print In the case of the Halm Jet there may be 1, 2 or 4 separate images on the plate depending on how the job was set up. The individual performing the second set of eyes inspection will need to sign off on each image from the plate. These should be stapled together and Date/Time stamped. 9. Client Press Check Occasionally clients want to perform checks of their job while they are actually on press. If a client or client representative press check is required the "Press Check" form (TG 333) [click here to view] will be attached to the order to notify the press operator. Any special instructions for the press check will be contained in the task instructions for the job. The client should be notified after the operator sign off and the second set of eyes sign off to inspect the job. The client should be invited to physically sign off on the sheet as well. Occasionally the client requests that a TGI Associate perform as the client's authorized representative. Typically this is a client requesting that their TGI Sales Rep perform a press check. As in the above case, The TGI Client Representative should be notified after the operator sign off and the second set of eyes sign off. Occasionally a Sales Representative, Management, or a Graphic Artist may request that to perform a press check. As in the above case, The TGI Client Representative should be notified after the operator sign off and the second set of eyes sign off. 10. Mark the Pile/Note Beginning Count The Press Operator will "mark the pile" indicating where the set up sheets end and the good product begins. A green "Start of Good Pieces" (Form TG 356) [click here to view] will be used to indicate good product after the mark. The Press Operator will "Date/Time Stamp" the Task Sheet and note the press counter reading for the end of set up and the beginning of production. The counter reading allows the operator to calculate how many good sheets must be run to complete the client's order. Continuing to run the counter from the "0" setting allows TGI to calculate the total stock consumed including the waste created by set up sheets. 11. Samples Occasionally the client will request samples for their records or for internal distribution to their people. The instruction for the client samples will be contained in the Press task. The Press Operator should select the very best pieces for the Client Samples. The Press Operator will isolate the samples by "marking the pile" with the yellow Hold For Samples (form #TGQ 12.2b) [click here to view]. The yellow Hold For Sample (form #TGQ 12.2b) will be used at the beginning and at the end of the area which the Press Operator thinks is the best of their work. [click here to veiw] The client samples will be pulled from this area in subsequent finishing processes.

6 Page 6 of 14 Instructions (Continued) Eventually ten finished samples (10) are also to be pulled from this group with every job to be turned in with the Press Layout/Closeout (Form TGQ 6.72) [click here to view]. These will remain in the job ticket. 12. Run the Job/In Process Inspections The Operator may now proceed with the run. Throughout the run, the Press Operator will pull sheets and inspect the run for conformance to the original client specifications. They will "Date/Time Stamp" each Pull Sheet to provide on going evidence of their In Process Inspections. The Press/Imaging Critical Success Check List (Form TG 355) [click here to view] is provided to assist the operators. At a minimum, the Press Operator will pull 3 sheets per cart on the Hamada's and one per carton on the Halm Jet. In the case of the Halm Jet, there may be 1, 2 or 4 separate images on the plate depending on how the job was set up. The press operator should perform in process inspections on each image from the plate. Each sheet will be "Date/Time Stamped". These will provide the evidence that the operator has reviewed the piece throughout the run and accepts the quality. The Press Operator may pull more sheets than 3 per cart or 1 per carton if they feel the job requires them to so that they can guarantee the quality of their output. The operator will write the job number and version if applicable on top of each pallet or lift as they complete it so that it is identified, and can not be confused prior to moving the job to the next work in progress staging area. Run the job until the counter reaches the final order quantity specified. 13. In Process Inspection Failure If a failure/blemish is identified during the inspection process the Press Operator will isolate the suspect material by "marking the pile" with the red "Hold Tag" pile marker (form TG 357) [click here to view]. The "Hold for Inspection" pile marker will be used at the beginning and at the end of the area which the Press Operator thinks the suspect material is located. The failed material will be pulled from this area in subsequent finishing processes. The Press operator will write the counter count down on the task sheet for the beginning at the end of the suspect material. The quantity of failed material will be deducted by the Press Operator in their calculations to achieve the finished count required for the job. 14. Job Completion/Next Process Finished printing will be routed to one of three areas. The instructions will be called out in Promail via a task. They are as follows Route to the next processing area Package and route to the client s inventory at TGI Direct. Package and ship to the client via TGI Direct driver or via shipping. Finished pieces routed to the next processing area will be identified by job number. The

7 Page 7 of 14 Instructions (Continued) material should be neatly organized using the most appropriate transportation cart, mail tray, carton, or bulk wrap pallet. Consideration should be given to preventing damage to the material, ease of use, and access by the next department, as well as the elimination of scrap wherever possible. It shall be delivered by the Press Operator to the Staging Area for the next processing area. The Sup/TL/QA of the next process area shall be told by the Press Operator that the material is available for the next process. Finished pieces that are to routed to the client's inventory at TGI Direct will be packaged. The material should be neatly organized using the most appropriate cartons or bulk wrap pallet. Consideration should be given to preventing damage to the material, ease of use, and access by the next department, as well as the elimination of scrap wherever possible. Approved filler material shall be used if there is any chance that the finished material could be damaged via shifting or compression. A sample of the material shall be taped to the outside of each container. Each box will be marked wit the Job Number, Client Name, Item Name, and the quantity per box. If there are multiple containers they will be marked 1of 3, 2 of 3, 3 of 3, etc. The operator will complete the "Material Transfer Form" (TGQ 37) to advise the Receiving Desk of the quantity per carton, and the overall quantity of material. This will help facilitate the receiving process. The material shall be delivered by the Press Operator to the Receiving Area for the next process (See Receiving WI ). The Receiver shall be told that the material is available for the next process. Finished pieces that are to shipped to the client via a TGI Direct driver (Pick Up and Delivery WI ), or via shipping (See UPS Worldship Shipping System Instruction WI ) will be packaged for shipping using the most appropriate cartons or bulk wrap pallet. Consideration shall be given to preventing damage to the material, ease of use, and access, as well as the elimination of scrap wherever possible. Approved filler material shall be used if there is any chance that the finished material could be damaged via shifting or compression. Each box will be marked with the Job Number, Client Name, Item Name, and the quantity per box. If there are multiple containers they will be marked with the job number and 1of 3, 2 of 3, 3 of 3, etc. The material shall be delivered by the Press Operator to the Shipping Area for the next process. The Shipping associate shall be told that the material is available for the next process. 15. Job Completion/Jobs that Collate When the next stage in the job requires collation, it is the Press Operators responsibility to line out, fold, assemble and cut to size two (2) finished samples if the bindery is being outsourced and one finished sample if the bindery is going to be done in-house. Once completed, the operator will fill out our "Collating Instruction Form" (Form # TGQ 36.0) [click here to view] and attach it to these completed samples. 16. Job Completion/Quality Records When job is completed all of the Pull Sheets are to be placed in the proper months Quality Records Container. The Containers are identified by month. Pull Sheets will be maintained for a minimum of 3 months. Sign and date the task sheet. Initial each sub-bullet in the task indicating completion. Note

8 Page 8 of 14 Instructions (Continued) the counter count. On the Press Layout/Closeout (form TGQ 6.72) [click here to view], note any problems encountered. Move the Stock and the ticket to the next Work in Process Staging Area as required. If the next process area is Production Control then provide 10 finished samples. Date/Time Stamp the task/pod/mod slip to indicate the end time of production. 17. Clean Work Area and Perform Preventative Maintenance After the job is completed, the Press Operator will clean up area as he/she deems necessary to keep the area orderly. The Press Operator will check and perform maintenance tasks as needed. Periodic maintenance will be performed as required by the manufacturer's machine specifications. The Press Operator will update the Press Maintenance Log (TGQ 9.63) [click here to view] as maintenance is performed. Our equipment is the lifeblood of our company and must be kept in top condition. 7. Procedure References Control of Production and Service Provision QSP Infrastructure QSP 6.3 Monitoring and Measurement of Processes QSP Planning of Product Realization QSP 7.1 Work Environment QSP Instruction References CUTTING INSTRUCTION FOR RAW STOCK WI INTERNAL SUPPLIES/FORMS INVENTORY MANAGEMENT INSTRUCTION WI PICK-UP & DELIVERY INSTRUCTION WI RECEIVING INSTRUCTION WI

9 Page 9 of 14 Instruction References (Continued) UPS WORLDSHIP SHIPPING SYSTEM INSTRUCTION WI Records ProMail Comments PMC Retain for a minimum of one year Sample SAM Retain for a minimum of 3 years Art/Graphics Incoming Media TG yrs Stock Order Form TG days Press/Layout Closeout TGQ 6.72 Retain for a minimum of one year Press Maintenance Log TGQ 9.63 Retain for a minimum of 1 year Work Ticket WT Retain for a minimum of 30 days

10 Page 10 of Addendum - Flow Chart Review Job Sleeve for Instruction Ensure Art Dept Sign Off Pull Stock Pre-Cut Stock a

11 Page 11 of 14 Addendum - Flow Chart (Continued) a Plate Inspection Set Up Press Quality Check and Sign Off Second Set of Eyes Quality Check and Sign Off b

12 Page 12 of 14 Addendum - Flow Chart (Continued) b Client Press Check Mark the Pile/Note Beginning Count Samples Run the Job/In Process Inspections c

13 Page 13 of 14 Addendum - Flow Chart (Continued) c In Process Inspection Failure Job Completion/Next Process Job Completion/Jobs that Collate Job Completion/Quality Records d

14 Page 14 of 14 Addendum - Flow Chart (Continued) d Clean Work Area and Perform Preventative Maintenance