~ Eliminate setup ~
Setup is the biggest obstacle when printing high-mix low-volume products with screen printing.
There was an example of a high-mix, low-volume printing factory in which the time spent on printing on the printing machine was about 30% of the entire work day.
There was an example of a high-mix, low-volume printing factory in which the time spent on printing on the printing machine was about 30% of the entire work day.
For example, let's say the production lot is in six-color printing in 50 sheets. The number of screen versions is 6 because it is necessary for the number of colors.
Assuming that it takes 10 minutes to set up each color, for six colors it takes 60 minutes in total. If you print 50 sheets in 20 minutes, six colors will take 120 minutes. In total, 180 minutes and 30% of which is setup time.
But this example is a case in point. If you search for a screen version or color toning, the setup will be even longer. In addition, if the drying oven stagnate due to ink drying, waiting time will occur.
When many of these overlap, the operating rate is 30%...
Assuming that it takes 10 minutes to set up each color, for six colors it takes 60 minutes in total. If you print 50 sheets in 20 minutes, six colors will take 120 minutes. In total, 180 minutes and 30% of which is setup time.
But this example is a case in point. If you search for a screen version or color toning, the setup will be even longer. In addition, if the drying oven stagnate due to ink drying, waiting time will occur.
When many of these overlap, the operating rate is 30%...
To reduce the setup time, first unify the screen plate size and work size.
If the printing area is small, we would like to use a smaller plate, but this requires adjusting the conditions of the printing press each time, which increases setup time.
Even if it feels a little wasteful, it is better to give priority to reducing the man-hours required for setup.
If the printing area is small, we would like to use a smaller plate, but this requires adjusting the conditions of the printing press each time, which increases setup time.
Even if it feels a little wasteful, it is better to give priority to reducing the man-hours required for setup.
Next, standardize the work size into several types.
For example of when printing on lithographic film. 500 mm square, 330 mm square, and 250 mm square, these 3 types will be suffice. These are many of original film size: 1000㎜. And make it to 1/2, 1/3 and 1/4. If the work size is in the middle of these, there is no cost merit because the scrap material at the time of work cutting is added to the price.
It is a good idea to determine the work size after checking the original size of the work.
For example of when printing on lithographic film. 500 mm square, 330 mm square, and 250 mm square, these 3 types will be suffice. These are many of original film size: 1000㎜. And make it to 1/2, 1/3 and 1/4. If the work size is in the middle of these, there is no cost merit because the scrap material at the time of work cutting is added to the price.
It is a good idea to determine the work size after checking the original size of the work.
The pattern printing position on the screen plate should be the same position as much as possible. It is a good idea to discuss the printing position in advance with the plate maker. If the printing position is the same, it is possible to minimize the adjustment of the printing press at the time of setup change.
Fewer press adjustments means less set-up time.
Fewer press adjustments means less set-up time.
Use a screen printer with high repeatability. It is not possible to know the repeatability of a screen printer just by looking at its appearance. If the repeatability is low, the conditions will change while the printing press is running, so readjustment will be required during the process.
If you use a printer with high repeatability, you won't have to readjust it, so the operating rate will be high.
Screen printing involves a large variety of products in small lots, so it is a good idea to carefully analyze the current situation to see where there is wasteful work.
If you use a printer with high repeatability, you won't have to readjust it, so the operating rate will be high.
Screen printing involves a large variety of products in small lots, so it is a good idea to carefully analyze the current situation to see where there is wasteful work.
