Pressroom Maintenance Quality Audit

Report
O Estado de S. Paulo Newspaper
Metro Users Group Webinar 2010
PRESSROOM MAINTENANCE
QUALITY AUDIT
Speaker
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Roberto Dias Da Costa is the Industrial process supervisor at the
Newspaper S.A. O Estado de S. Paulo, Brasil . He is a mechanical
engineer with a specialization degree on maintenance
management. He has been with S.A. O Estado for over 15 years.
During this time he has worked as a mechanical maintenance
supervisor and pressroom supervisor. On 2007 he coordinated, as
a key user,
the SAP ERP production planning module
implementation on the industrial area. He was responsible for the
Housekeeping (5S) implementation and coordination. He is also
part of the waste recycling coordination group of the Newspaper.
In his current position, he works in the Support and Analysis
Department, being responsible for the industrial process definition
and standardization, quality standard definition, work group
coordination (waste reduction, operational training, parts, etc). He
is also responsible for production data analysis and input in the
SAP - PP module.
Webinar Agenda
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“O Estado” Organization
Industrial Department
Quality Audit – Why and How
Audity Group
Actions Toward Quality
Results
Future Plan
“ O Estado” Organization
“O ESTADO” Organization
“O ESTADO” Organization is one of the biggest and most respected Media group in Latin America, acknowledged by its
seriousness, objectivity and by its engagement of over one century of credibility in rendered information.
Number of employees
2.850
Paper consumption per year
50.000 tons
Plate consumption per year
840.000 (broadsheet)
Ink consumption per year
744 tons
“O Estado” circulation
240.000 Monday – Saturday / 350.000 Sunday
“Jornal da Tarde” circulation
70.000 (110.000 Wednesday)
Total Subscribers
304.000
Net Revenue per year
US$ 540 MM
“O ESTADO” Organization
“O Estado de S. Paulo” Newspaper
“ESTADÃO”, as known today, was created in 1875 with the
name of “A Província de São Paulo” and one ideal:
“To establish a republican regime in Brazil, under democracy
and without slaves”.
After 135 years, “ESTADÃO” is today, one of the most
important newspaper in Brazil, is among the 20 most important
around the world and the main newspaper in São Paulo.
Its revenue is composed by:
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Subscriptions = 20%
Newsstand = 5%
Advertisement = 75%
Circulation :
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Monday to Saturday - 240.000
Sunday Edition – 350.000
“Jornal da Tarde” Newspaper
Launched in 1966, as an evening paper.
It covers the life in São Paulo, its inhabitants and
services.
Its revenue is composed by:
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Subscriptions = 16%
Newsstand = 14%
Advertisement= 70%
Circulation :
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Daily Edition Average - 70.000
Wednesday edition – 110.000
Agência Estado
Biggest News Agency in Brazil.
Leadership in information quality.
Real Time Information through Internet, Satellite and FM.
“Eldorado” Radio
“Nova Eldorado AM” Radio Station is one of the most important news source
in São Paulo.
“Eldorado FM” has a qualified audio program, playing Jazz, Blues, MPB and
etc. Focus on AA public audience.
“OESP Mídia” Company
Since 1984, “OESP Mídia” is especialized in
telephone directory and sectorial guides
publications, focusing small to medium
business.
OESP Gráfica
Commercial
newspaper
printing
services.
Internet Portal
One of the biggest Brazil portal
news, joining content from O
Estado, JT, Radio Eldorado,
classified and editorial.
Industrial Department
Industrial Department
INDUSTRIAL
DIRECTOR
José Odair Bertoni
PREPRESS
MANAGER
Jean Franco
PRESSROOM/
MAILROOM
MANAGER
Eduardo de Sales
PROCESS
MANAGER
Antonio Tadeu
MAINTENANCE
MANAGER
Lúcio Lima
Industrial Department
Prepress
Classified Pagination
Advertising Reception and
Preflight
Plateroom
Graphic Tech Support
Film Making Room
Industrial Department
Pressroom
2 GOSS HEADLINER - 1991
Average production speed - 42.500 IPH
08 page color and 24 page black
2 GOSS NEWSLINER – 1997
Average production speed - 45.000 IPH
20 page color and 04 page black or
12 page color and 20 page black
2 COLORMAN - 2000
Average production speed - 50.000 IPH
48 page color or
40 page color and 16 page black
Quality Audit- Why and How
Quality Audit- Why and How
The Brazilian newspaper market was facing a big challenge concerning to printing quality and
readers demandings. Our newspaper has change its layout to accomplish those market changes
and be more competitive with the other information technologies as the internet, palms and
more. As a consequence, the printing quality, productivity and waste reduction became the most
relevant issues in the Industrial area.
Therefore we decided to hire Goss Quality Audit services to help us achieving these
objectives.
O Estado de S. Paulo and Goss teamed up to conduct the Quality Audit to improve print
quality, productivity and reduce waste.
Our efforts started with a lengthy team meeting to understand issues and identify objectives.
The following is the summary:
Quality Audit- Why and How
1. Optimum ink/water balance was needed and was regarded as priority one. The goal
was that the operators didn’t adjust ink, at all, during make-ready. This required the
following sub-categories:
a. Modifying the control parameters;
b. Investigating presets;
c. Spray-bars evaluation;
d. Dampening solution pumping system;
e. Ink pumping system;
f . The Newsliner’s ink train settings;
g. The Newsliner’s dampening train settings;
h. Consumable.
2. Registration optimization:
a. Side-lay;
b. Circumferential.
3. Waste savings reduction:
a. Operational methodology.
4. The human factor:
a. Press and Prepress.
Audit Group
Audit Group
To accomplish the Quality Audit
program we have created a multidisciplinary
group,
formed
by
professionals
from
Maintenance,
Engineering, Pressroom and Prepress
areas.
From left to right:
Marcal Santos Barbosa – Pressman Trainer; Valter Craveiro dos Santos – Prepress Support; Edson Silva Lima – Mechanical
Maintenance Supervisor; Roberto Dias da Costa – Process Supervisor; Jamir Correa Pupo – Pressroom Supervisor; Rinaldo
Francisco da Silva – Prepress Support; Vitor Nicolau Teixeira – Electrical Maintenance Supervisor; Edson Lino dos Santos –
Engineering Supervisor.
Group Methodology
- Multi-disciplinary Group;
- Goss coordination;
- Six Sigma oriented.
Actions Toward Quality
Quality Group Spreadsheet
We have created an spreadsheet with over 90 actions covered during and after the
Quality Audit program. It was divided into Prepress, Pressroom, Engineering and
Management categories .
Actions Toward Quality
Prepress (8 actions)
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Rip Interface
PAR
Test Form
Color Management
Pressroom (72 actions)
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Dampening System
Inking System
Meridian
Operation
Engineering (8 actions)
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Dampening Curve
Inking Curve
Blanket
Fountain Solution
Management (5 actions)
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OPB
RIP
Six Sigma
Pressman Training
Mechanical Audit
Actions Toward Quality
Prepress – Some actions examples:
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Rip Interface
 Possibility of linking the RIP to the Newsliner.
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PAR
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Adjusted the Meridian presets;
Overall maintenance;
Corrected film pattern.
Test Form
 Created a new test form to check ink and registration.
Goss TestForm
Based on the Quality program we have created this
new testform to set up our Newsliner Presses. It has
Solid bars with 75 and 40% of coverage in each
color and also registration marks.
Actions Toward Quality
Pressroom – Some actions examples:
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Spray bar Nozzle Tip, Plunger, chamber and Valve body
 Model standardization:
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We have found some nozzle tips with the wrong model in stock as well some
plungers with different rubber material and body valves with different o’ring
channel dimensions.
Chemical compatibility test;
Maintenance procedures;
Receiving inspection and analisys;
Tester development .
Flow Metering Device
This tester device was created to analise the nozzle tip flow and the plunger
performance prior to enter in our stock and during regular maintenance.
It performes a predetermined flow test. Based on the volume variance (± 3%) the
nozzle tip and plunger is accepted or rejected.
Digital Microscopy
Dampening uniformity is critical to waste savings. We created a procedure to evaluate the nozzle tips,
chambers and plungers through digital microscopy before it enters our stock and during regular
maintenance. With this test we can evaluate the nozzle tip diameter and encrustation, chamber
scratches that can alter the magnetic field and plunger rubber surface condition that can alter the “On
Time” value.
Ultrasound Cleaning Device
Equipment used to clean the spraybar nozzle tip.
Actions Toward Quality
Pressroom – Some actions examples:
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Dampening System
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Spray bar Tester device;
Change of the dampening solution unit regulator;
Modify Spray bar to reflect the actual web width (54” to 50”);
Adjust the water form roller to not slip.
Spray Bar Tester
Based on the Quality program information we
have built this spraybar tester in order to
balance and equalize the nozzle spray.
Dampening Fluid Regulator
As a recommendation from the Goss
audit program, we have changed the
Dampening fluid regulator. The new
regulator in use is from Technotrans.
With the previous regulator we could
not get a uniform dampening pressure.
The pressure variation range was ± 20
psi during the press running. With the
new model the pressure variation range
is ± 5 psi, resulting in a more uniform
dampening flow during the run.
Actions Toward Quality
Pressroom – Some actions examples:
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Inking System
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Dry Solid Ink test on units;
Overall maintenance on digital page pack and fountain roller;
Equalization of Ink pressure line (30 to 40 psi).
Actions Toward Quality
Pressroom – Some actions examples:
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Ink and Water curves optimization;
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Ink and dampening uniformity.
Actions Toward Quality
Pressroom – Some actions examples:
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Register pin Optimization:
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We are still working on the register pin optimization. We have done some
measurements with the test form and created some statistical graphs, showing
the deviation to be corrected.
Actions Toward Quality
Engineering – Some actions examples:
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Discussed the science and technology of emulsion behavior, and
the interaction between ink, dampening solution, plate design and
the press roller train;
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Plate room temperature and humidity control;
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Press Parameters review:
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Cold Autoflood Duration;
Warm Autoflood Duration;
Warm Start Autoflood Duration;
Ink Form On Delay.
Actions Toward Quality
Management – Some actions examples:
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Mr. Ragy Isaac provided two and half hours Six Sigma overview;
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Study of a CTP viability for the Prepress area.
Results
Results
After this period the Audit Group was able to achieve
the following objectives:
Results
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Reduced start-up waste:
Newsliner 2008
Average – 860 copies
Newsliner 2009
Average – 690 copies
Results
- Web breaks reduction:
2008 Web Break Rate - 4,17%
2009 Web Break Rate – 3,51%
2008/2009 comparison:
On start-up – 64%
During the run – 32%
During the paste cycle – 21%
On press stop – 53%
Results
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Established new Ink Curves:
Results
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Established new Dampening Curves:
Results
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Produced drier printed product with a stable ink and water balance;
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Trained all press crews on the use of Percent Mode to set density if required;
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Provided details of the spray-bars technology’s pitfalls and how to avoid
it. The discussion included the theory of operations of a spray-bar,
controls required;
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Identified the proper dampening solution pressure at the Newsliner’s unit
regulator (60 psi);
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Identified, and corrected, the PAR as the major cause for inking
unpredictability.;
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Improved the overall print quality.
Future Plans
Future Plan
- Lean Six Sigma implementation;
- CTP and OPB for Goss Press;
- Goss Pressman training;
- Goss Mechanical Audit;
- Newsliner/Headliner controls upgrade.
O Estado de S. Paulo Newspaper
THANK YOU!
[email protected]

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