A Presentation

onMAKEREADY OPTIMIZATION IN SHEET FED

OFFSET PRESS(A Case study of “Foil Printers”, Ludhiana)

Submitted To:

Sh. A.K. Baral (Project Supervisor)

Assistant Professor & Incharge

Deptt. Of Printing Tech.,

GJUS&T, Hisar

Submitted in partial fulfillment of the requirement for the award of the degree of

Master of Technologyin

Print & Graphic Communication

Submitted By:

Ravinder

M.Tech (P. & G.C.)

Final Year

Roll No. 10031001

Introduction

• Printing means presentation. Printing is the art, science and technology of reproduction of n number of copies from an original or manuscript with the help of suitable printing process on a suitable printing substrate.

• The substrates can be either paper, board, plastic films, metal foils, fabrics, laminated composites or other suitable materials.

• The printing process can be either sheet fed offset or webfed offset, Flexography, Gravure and digital printing etc.

• Time Magazine, at the end of the millennium elected Johannes Gutenberg’s work as the most crucial event of the millennium.

• In my project work, I have studied only make ready process of sheetfed offset process. Offset process is also known as lithographic printing.

• The basic principle of the lithographic printing is the mutual repellence of grease and water. Lithography is based on the principle that oil and water do not mix to each other. It essentially uses a planographic plate which is a type of plate on which the image areas are neither raised nor indented in relation to the non-image areas. Instead, the image and non-image areas lie essentially on the same plane or surface of the printing plate. They are chemically separated to each other.

Make Ready • In simple words, Make ready means makes the machine

ready for production of n number of copies. • Make ready includes all the operations carried on the machine

starting from the plate mounting to the first ok sheet.• Make ready is the procedure, in which all the adjustments are

made on the press, including proper colour registration and ink density, to achieve a reproduction equivalent to or comparable to the proof. This step may be the major source of waste from the printer's point of view, but it is essential for any type of jobs that are to be printed in the print shop. Make ready times can last from a few minutes to many hours and it depends on the nature of the job and the particular press environment. Make ready can be conducted at slow speeds or at press production speeds but mostly it is advised to perform the above operation at a slower speed.

• The printer's objective is to minimize both the time involved in make ready and the number of waste sheets during the process. Once the make ready has successfully generated an acceptable press sheet, the actual printing run starts.

• For short runs, make ready costs represent a significant percentage of the total printing cost and in long run jobs; the cost of make ready is justified accordingly.

Make Ready Steps

Following steps are generally followed for make ready in sheet fed offset press:

• Plate Mounting • Paper Loading• Feeder Setting• Ink Setting• Dampening Setting• Delivery Setting• Proof Reading• Registration & Colour Matching• Machine Stetting for OK Sheet

Research Objectives • Offset printing process is one of the major forms of printing

technique in India as well as worldwide printing market. It occupies more than 40 per cent of all the printing market and hence it needs special care and attention in terms of cost reduction and optimizing production efficiency. Continuous efforts are being made to optimize the make ready time and minimizing the press consumables and raw materials during the make ready operation. The objective of the above major project can be summarized as follows;

• Optimization of the make ready time in a sheet fed offset press is one of the major concern today and hence it needs detailed study and analysis, because this will be helpful to point out possible delays and savings of consumables also.

• To find out various functions of the make ready steps and their importance and significance in the press organizations, which will help us to attach value to each steps in the make ready operations.

• To calculate total time, resources, and cost involved in the make ready operations for different jobs in different machines and this will help us to optimize make ready in sheet fed offset presses.

• As most of the presses in India are small or medium in nature, this work will be helpful to them at large to set standards for their respective presses for maximizing profit. Besides this, the project work will be helpful to the students and researchers to move forward in this critical area. As most of the advancements are going on in this sector, adding findings in this section will be added advantage.

Research Methodology• This work was carried out at Foil Printers, Ludhiana, Punjab, India. This

press is one of the quality oriented press in Northern India. There are 06 sheet fed offset machines, varying from single colour to four colours and five colours are installed in this press for taking care of a wide variety of jobs and it helped me to collect data from these machines in relation to make ready operations on day to day basis. The complete make ready procedures for single colour and multi colour jobs on single colour machine and four colour and five colours machines was designed and the same format was used for collecting data for the various jobs that were undertaken in the press from day to day basis. These data were recorded with date, time, and machine number from job to job. This data helped me to find out the various techniques and means to optimize make ready in sheet fed offset presses.

• Data was collected on day to day basis with the help of designed format from job to job on different machines. Secondary data sources like books, magazines, journals, internet, research papers etc. were used getting knowledge and reference in this field.. The collected data was compiled and analyzed with the help of suitable statistical tools to find out total time consumed for makaready of single colour and multi coloured jobs and total paper wastage for the make ready operations. The information was finally presented in suitable graphical presentation formats for easy understanding.

Data Collection & Analysis

• The data was collected on day to day basis. Data was collected from six machines in which two were single colour, two machines were of two colour and two were four colour machines. The same work was repeated for 45 days continuously.

• Average of each step of makeready of each machine was calculated by using the data collected on day to day basis. Which is shown below in the form of table

Average Time of Make Ready Steps of Each MachineTwo Colour Machines Single Colour Machines 4 Colours

Machine

5 Colours Machine

Makeready Steps

Heidelberg 2c(Time in

minutes)

Adast Dominant 725 P

(Time in minutes)

Adast Dominant 414 (Time

in minutes)

Adast dominant 715 (Time

in minutes)

Polly 745(Time in

minutes)

Heidelberg 5c(Time in minutes)

Plate Mounting 9.37 3.72 1.04 2 7.32 16.72

Paper Loading 8.88 6.2 2.8 4.12 6.08 9.2

Feeder Setting 1.91 1.56 0.96 1.16 1.88 2.52

Ink & Dampening

setting

7.95 4.2 3.00 2.56 6.24 5.36

Delivery Setting 0.62 0.40 0.40 0.36 0.40 0.36

Proof Reading 1.58 1.08 1.00 1.00 1.28 1.84

Registration & Colour

Matching

10.91 5.00 2.64 2.16 9.68 13.76

Machine Setting for OK Sheet

21.29 11.88 6.44 5.16 18.24 26.12

Total Time(In Minutes)

52.44 29.36 15.96 15.20 43.4 62.2

• The following graphical analysis was done on the basis of data collected.

Figure 5.1.1 :- Average time taken for each step of make ready for AD414.

The machine used in this case is Adast Dominant 414, and for 40 days data related to makeready time were noted down. The graph shown above indicates average time taken for makeready of different jobs. During the above period, 25 jobs were scheduled in this particular machine. Average time taken for each job comes to 16 minutes and the major contributor for makeready time is the machine setting for getting OK sheet and it comes to 6.5 minutes, which is roughly more than one third of the total makeready time. Next to machine setting for OK sheet, comes ink & dampening settings, paper loading and registration & colour matching, and moreover it comes to 8 minutes. This accounts half of the total time devoted for makeready

Figure 5.1.2 :- Average time taken for make ready operation of AD715.The machine used in this case is Adast Dominant 715, and for 40 days data related to makeready time were noted down. The graph shown above indicates average time taken for makeready of different jobs. During the above period, 25 jobs were scheduled in this particular machine. Average time taken for each job comes to 15 minutes and the major contributor for makeready time is the machine setting for getting OK sheet and it comes to 5 minutes, which is roughly one third of the total makeready time. Next to machine setting for OK sheet, comes plate mounting, paper loading, ink & dampening settings and registration & colour matching, and moreover it comes to 8 minutes. This accounts half of the total time devoted for makeready.

Figure 5.1.3 :- Average time taken for each step of AD725P.The machine used in this case is Adast Dominant 725P, and for 40 days data related to makeready time were noted down. The graph shown above indicates average time taken for makeready of different jobs. During the above period, 25 jobs were scheduled in this particular machine. Average time taken for each job comes to 29 minutes and the major contributor for makeready time is the machine setting for getting OK sheet and it comes to 12 minutes, which is roughly more than one third of the total makeready time. Next to machine setting for OK sheet, comes plate mounting, paper loading, ink & dampening settings and registration & colour matching, and moreover it comes to 15 minutes. This accounts half of the total time devoted for makeready.

Figure 5.1.4 :- Average time taken for each step of make ready of Heidelberg(2C)The machine used in this case is Heidelberg two colour, and for 40 days data related to makeready time were noted down. The graph shown above indicates average time taken for makeready of different jobs. During the above period, 25 jobs were scheduled in this particular machine. Average time taken for each job comes to 52 minutes and the major contributor for makeready time is the machine setting for getting OK sheet and it comes to 21 minutes, which is roughly more than one third of the total makeready time. Next to machine setting for OK sheet, comes plate mounting, paper loading, ink & dampening settings and registration & colour matching, and moreover it comes to 27 minutes. This accounts half of the total time devoted for makeready.

Figure 5.1.5 :- Average time taken for make ready preparations of Polly 745.The machine used in this case is Polly 745, and for 40 days data related to makeready time were noted down. The graph shown above indicates average time taken for makeready of different jobs. During the above period, 25 jobs were scheduled in this particular machine. Average time taken for each job comes to 43 minutes and the major contributor for makeready time is the machine setting for getting OK sheet and it comes to 18 minutes, which is roughly more than one third of the total makeready time. Next to machine setting for OK sheet, comes plate mounting, paper loading, ink & dampening settings and registration & colour matching, and moreover it comes to 23 minutes. This accounts more than half of the total time devoted for makeready.

Figure 5.1.6 :- Average time taken for make ready preparation of Heidelberg (5C)The machine used in this case is Heidelberg five colour, and for 40 days data related to makeready time were noted down. The graph shown above indicates average time taken for makeready of different jobs. During the above period, 25 jobs were scheduled in this particular machine. Average time taken for each job comes to 62 minutes and the major contributor for makeready time is the machine setting for getting OK sheet and it comes to 26 minutes, which is roughly more than one third of the total makeready time. Next to machine setting for OK sheet, comes plate mounting, paper loading, and registration & colour matching, and moreover it comes to 31 minutes. This accounts half of the total time devoted for makeready.

Figure 5.2.1 :- Average Plate Mounting Time of each machine.This graph shown above indicates plate mounting time for different sheet fed offset machines installed at Foil Printers, Ludhiana. From the graph it is observed that Heidelberg five colour machine consumes maximum time in comparison to other machines. It takes 17 minutes and for two colour Heidelberg machine it is 9 minutes. For other machines, as far as plate mounting is concerned, it is not a major issue.

Figure 5.2.2 :- Average Paper Loading Time.This graph shown above indicates paper loading time for different sheet fed offset machines installed at Foil Printers, Ludhiana. From the graph it is observed that Heidelberg five colour machine consumes maximum time in comparison to other machines. It takes 9.2 minutes and for two colour Heidelberg machine it is 8.8 minutes. For other machines, as far as paper loading is concerned, it is not a major issue.

Figure 5.2.3 :- Average Feeder Setting Time.This graph shown above indicates feeder setting time for different sheet fed offset machines installed at Foil Printers, Ludhiana. From the graph it is observed that Heidelberg five colour machine consumes maximum time in comparison to other machines. It takes 2.5 minutes and for two colour Heidelberg machine it is 1.9 minutes. For all machines, as far as feeder setting is concerned, it is not a major issue.

Figure 5.2.4 :- Average Ink & Dampening Setting time.This graph shown above indicates ink & dampening settings time for different sheet fed offset machines installed at Foil Printers, Ludhiana. From the graph it is observed that Heidelberg two colour machine consumes maximum time in comparison to other machines. It takes 8 minutes and for Polly 745, it is 6.2. For other machines, as far as ink & dampening settings is concerned, it is not a major issue.

Figure 5.2.5 :- Average time taken for Delivery Settings .This graph shown above indicates delivery setting time for different sheet fed offset machines installed at Foil Printers, Ludhiana. From the graph it is observed that Heidelberg two colour machine consumes maximum time in comparison to other machines. It takes 0.62 minutes. For all machines, as far as delivery setting is concerned, it is not a major issue.

Figure 5.2.6 :- Average Proof Reading Time.This graph shown above indicates proof reading time for different sheet fed offset machines installed at Foil Printers, Ludhiana. From the graph it is observed that Heidelberg five colour machine consumes maximum time in comparison to other machines. It takes 1.84 minutes and for two colour Heidelberg machine it is1.6 minutes. For all machines, as far as plate mounting is concerned, it is not a major issue.

Figure 5.2.7 :- Average time taken for Registration & Colour Matching.This graph shown above indicates registration & colour matching time for different sheet fed offset machines installed at Foil Printers, Ludhiana. From the graph it is observed that Heidelberg five colour machine consumes maximum time in comparison to other machines. It takes 13.7 minutes and for two colour Heidelberg machine it is 11 minutes. For Polly 745 it is 9.6. For other machines, as far as registration & colour matching is concerned, it is not a major issue.

Figure 5.2.8 :- Average time taken for Machine Settings for OK sheet.This graph shown above indicates machine setting for ok sheet time for different sheet fed offset machines installed at Foil Printers, Ludhiana. From the graph it is observed that Heidelberg five colour machine consumes maximum time in comparison to other machines. It takes 26 minutes and for two colour Heidelberg machine it is 21 minutes. For Polly 745 it is 18 minutes & for Adast Dominant it is 12 minutes. For other machines, as far as machine setting for ok sheet is concerned, it is not a major issue.

Figure 5.2.9 :- Average Total time taken for make ready.This graph shown above indicates total makeready time for different sheet fed offset machines installed at Foil Printers, Ludhiana. From the graph it is observed that Heidelberg five colour machine consumes maximum time in comparison to other machines. It takes 62 minutes and for two colour Heidelberg machine it is 52 minutes. For Polly 745 it is 43 minutes. For other machines, as far as total makeready time is concerned, it is not a major issue.

Result & Discussions• Single Colour Machines

There were two single colour machines AD414 & AD715 the total make ready time was found almost same in both the machines. The machine setting for OK sheet consumes the maximum time of the total make ready time in both the machines. The AD715 consumes less time as compared to AD414 for the machine setting for OK sheet. As far as plate mounting and paper loading is concerned AD 414 consumes half time than the AD715. All other steps of make ready takes almost same time in both the machines. Proper care should be taken to set the machine for OK sheet which will help to reduce the make ready time considerably. Automatic workflow system may also be adopted for reducing possible make ready time.

• Double Colour Machines• There were two double colour machines AD725P and

Heidelberg 2C. In comparison to the two machines AD725 P takes less time for make ready than the Heidelberg 2C. As far as plate mounting and paper loading is concerned AD725P consumes half time than Heidelberg 2C and same is true for machine setting for OK sheet. Proper care should be taken to set the machine for OK sheet which will help to reduce make ready time considerably. In case of Heidelberg 2C the time taken for registration and colour matching is also higher than considerable. For this the machine operators should be well trained. Automatic workflow system may also be adopted for reducing possible make ready time.

• Four Colour and Five Colour Machines• There were two four colour machines Polly 745 & Heidelberg (5C).

In comparison to both machines Polly 745 takes less time for make ready then the Heidelberg. The machine setting for OK sheet consumes the maximum time for total make ready for both the machines. The time for the registration and colour matching and machine setting for OK sheet is higher than the considerable in the Polly 745. Proper care should be taken to reduce the time of these two steps. In case of Heidelberg the plate mounting ,registration and colour matching and machine setting for OK sheet takes more time than the considerable. Proper care should be taken to reduce the time for these steps. It will help to reduce the make ready time. For this machine the operators should be well trained. Automatic workflow system may also be adopted for reducing possible make ready time

Conclusion• Make ready is one of the major activity in a sheetfed offset

organisation and hence needs special care and attention. From the research work it is concluded that two colour machines and Heidelberg (5C) consumes more time for make ready. And three major components are ;

• Plate Mounting• Machine Setting For OK Sheet• Registration and Colour Matching• These three points need special care and attention in order to

optimize make ready time. Innovative techniques should be followed in order to reduce plate mounting time, and colour management system also should be followed to reduce time for press adjustment for OK sheet.

Future Perspective

• Due to time constraint, it was not possible to cover all the aspects of make ready and more research related activities can be initiated in this area like ;

• Standardising the press makeready activities and noting down various intricate factors for optimizing press makeready.

• This work can be carried out at different companies and Press organisation for more accurate data collection and for better results also