1、 Objective: to ensure the normal and orderly production and quality safety, so that our daily work is more relaxed and perfect, and the quality is more guaranteed. Improve our respective job responsibilities and work standards. Therefore, we must implement the method of division of labor and cooperation in our daily work. According to the responsibilities, according to the standards, we can make this machine work normally, efficiently and safely. The following standard operation procedures and standard operation instructions are formulated:
2、 Scope: this specification is applicable to the printing section of our company
3、 The standard operation is divided into nine stages: 1. Pre Press analysis stage; 2. Pre press preparation stage; 3. Pre start stage; 4. Pre press inspection stage; 5. Initial set proofing stage; 6. First article confirmation stage; 7. First volume confirmation stage; 8. Normal production stage; 9. End stage.
1. Pre Press analysis stage:
(1) Pre production analysis meeting: the captain must organize and hold a pre Press analysis meeting for all production personnel of the machine during the production of order change. The analysis meeting mainly refers to the standard sample, analyzes and reviews the parameters and precautions provided by the process sheet, and special process requirements, determines the detailed operation requirements, finds out the key and difficult control points, makes risk assessment, and implements various key control points to each Individuals should follow up the key points and make special instructions and reminders. And formulate the prevention plan and emergency treatment plan.
(2) Audit confirmation (Captain audit standards and details)
① Whether the production scheduling sheet is completely consistent with the production process sheet and standard sample.
② Confirmation of edition week, edition length, version number, taste, gram weight, bar code, shelf life, certification number, telephone number, ingredients, place of origin, origin code, customer name, etc.
③ Roller length, hardness, printing pressure required for different layout and substrate.
④ The length, hardness, angle and pressure required for different types of blade. Choose the type of scraper.
⑤ Substrate type, corona value and special material testing points, width, thickness and production quantity.
⑥ Different printing methods, printing process and material types need ink type and spot color ratio and dosage.
⑦ The type of ink used, layout level, ambient temperature and humidity, the type of solvent required for printing speed, and the most reasonable solvent ratio for volatile drying speed.
⑧ The initial viscosity of ink required for different layout, ink, printing speed, ambient temperature and humidity.
⑨ The thickness of ink, ink properties, substrate, oven temperature and air volume required for printing speed.
⑩ Substrate type, thickness, width, week, printing speed, ink, oven temperature required for the most reasonable unwinding, lead-in, lead-in tension.
11. Analyze the past quality abnormalities, special information and special process requirements marked and highlighted in the process sheet, formulate the prevention plan and emergency treatment method, and convey them to each operator, and emphasize and explain the personnel involved in the post.
2. Preparation stage
(1) The captain communicates the selection and installation requirements of the press roll and plate roller to the auxiliary shift leader (the selection and determination of the press roll must be made by the captain),
(2) According to the requirements of the auxiliary team, check and install the pressure roller and plate roller, and strive to ensure that there is no abnormal operation.
(3) The captain sets the parameters of the computer, installs the grinding scraper [mark shape, vertical and reverse direction, plate circumference, color sequence], and confirms the installed plate direction and standard.
(4) First, confirm whether the printing plate text and plate number meet the production plan and process requirements. According to the requirements of the process sheet, ask for and confirm the ink model and color from the ink team, filter the ink and allocate the spot color. Try to adjust the spot color once according to the order quantity, so as to avoid the color difference caused by repeated deployment in the middle of the process.
(5) Second, help to lay ink groove, solvent extraction, cleaning guide roller
(6) Three help to pave the floor and collar materials. Prepare paper tube and proofing waste.
3. Pre start phase
(1) The captain starts all equipment and electrical appliances, pre rotation of main engine, sets oven temperature of each color group, air volume of inlet and exhaust air, pressure of press roll, tension of unwinding, leading in, leading out and winding, and sets the deviation correction guide roller to zero, and then lower the scraper after the ink is put on the machine.
(2) One is to assist in inking, to install ink circulation device and to set ink mixing roller.
(3) Second, pack the plug, clean the layout, wait for a long time, and then add the ink baffle.

(4) Three help to pack proofing waste, paste tape, paper tube.

4. Prepress inspection stage
(1) The captain turns on the main engine to normal printing speed, and all electrical equipment are started. Use the strobe light to check whether there are abnormal knife lines, knife threads, scraping and ink overflow in the layout, and check whether all the electrical appliances such as heating, water supply and gas supply are working normally and make adjustments in time. [to track and confirm the effect after adjustment]
(2) First, check and clean the electric eye and reflector, and check whether the ink supply of the ink circulation pump is normal.
(3) Second, add the ink baffle to measure the initial viscosity.
(4) Three assistant inspection to determine whether the type and specification of the substrate meet the requirements of the process sheet, check whether the test items meet the requirements of the production, check whether the appearance meets the production requirements, and ensure that there is no abnormal operation, and then install the take-up tube of the same length as the material width.
5. Initial proofing stage
(1) Sampling procedure: run the machine to within 8-15 M / min, compare the plate with waste film, and the captain will make a horizontal and longitudinal rough set together. After the rough set is about accurate, paste a good film with adhesive tape, turn the machine to 40-50 M / min to make color samples, and then stop the machine to sample and check the color. After shutdown, the captain should turn off the electric heating and air inlet and exhaust switches in time.
(2) The machine speed is within 8-15 M / min. Confirm whether the substrate is in the center and make adjustment. Then the uneven wrinkling guide roller is leveled with paper strip to ensure the film moving balance.
(3) The second assistant and the third assistant use waste solvent rags to wipe the ink and dirt on the surface of the pressure roller to ensure that they are clean. And carry out the lateral positioning.
(4) First, it is used to calibrate the position of photo electric eye by longitudinal fine sleeve.
(5) The captain assisted in correcting the position of the photo electric eye and operated the computer to adjust the automatic positioning tracking system. After all color decks are adjusted to normal, the captain will increase the speed to 30-50 M / min, the second and third assistants will carry out the horizontal positioning, and the first assistant and the captain will fine set the longitudinal and side vertical errors with naked eyes.
(6) After all the above work is completed and the set position is accurate, stop the machine to take samples for 3-4 weeks. The captain and his assistant jointly check the horizontal and longitudinal items of the standard sample. The main content is whether the text is completely consistent, the color error, and the appearance of the printed matter, such as knife thread, knife line, scraping, ink overflow, double image, dry plate, blocking screen, missing printing, etc., and make adjustment and treatment. [this is the pilot's first piece].
(7) The captain must be calm and careful, do not start the machine blindly, otherwise it may cause abnormal printing quality and accidents. We should give full play to the ability to foresee problems. If we are not sure, we should find the on-site foreman or supervisor to help analyze and solve them.
(8) The second assistant and the third assistant prepare the production report, viscosity table, ink solvent consumption table, marking, tape and other normal production auxiliary supplies.
6. First article confirmation stage
(1) To prepare for normal start-up, the captain shall inform the on-site foreman and the on-site QC to confirm the first piece. The foreman and QC reconfirm the first article of the captain, and ask the captain to deal with the abnormal printing process and give guidance.
(2) Start all electrical switches in an all-round way, turn the main engine speed to the normal production speed (about 100 m / min), and all post personnel conduct a comprehensive re inspection on all pre press preparations. The re inspection contents include the following aspects:
(3) The captain shall check whether the parameters of the computer and the tension, temperature and pressure of the pressing roller are set correctly, whether the water supply, gas supply and heat supply work safely and normally, check whether the layout is normal with the strobe lamp, and adjust it in time to ensure the normal production.
(4) Help to check the plate immersion depth and ink supply cycle is normal, and confirm the initial viscosity.
(5) Second, three help to check the ink block and clean the layout.
(6) After all the preparations are checked and confirmed, it will be put into production. When the machine speed is 40-60 meters per minute, the monitor or supervisor shall cut samples to confirm the adjusted printing effect (including color). If the color deviation is large or printing defects are serious, the machine should be stopped immediately.
(7) After cutting, take 2-3m samples to the supervisor and QC for the first piece confirmation. The confirmation content shall be in accordance with the detailed rules of the first article confirmation of the quality control department, and conduct comprehensive and detailed inspection item by item in the horizontal and vertical direction, and timely feed back the information to the captain or Yizhu.
(8) The captain must control and register the key control points and products with high precision.
7. First volume confirmation stage
(1) According to the actual situation of current production and operation, confirm and adjust the viscosity, temperature, pressure, tension, speed and other parameters.
(2) After all adjustments are completed and normal production is started, the material is cut again within 500-700 meters, and the first volume is confirmed every week of edition 3-4.
(3) Track and confirm the abnormal handling results fed back from the first part confirmation.
(4) The confirmation of the first volume is jointly completed by the captain and QC. The main purpose is to reconfirm the changes in print quality after speed-up and adjustment of various parameters. The confirmation contents are divided into the following aspects (mainly based on reference to standard samples)
① The change of saturation, brightness and hue of spot color.
② To confirm the effect change of object level transfer overlay and image reappearance.
③ Confirm the surface condition of semi-finished products, such as anti sticking, missing printing, scraping, flying ink, skipping knife, knife line, ink overflow, tailing, ghosting, blocking screen, dry plate, water mark, indentation, adhesion, etc.
④ Confirm the tensile change of semi-finished products and ink adhesion.
⑤ Adjust and deal with the above abnormalities immediately, and track the treatment results. If the problems can not be solved timely and effectively, stop the machine immediately, make a calm and comprehensive analysis, formulate an effective solution for effective treatment. If you are not sure, you should actively seek the help of the on-site foreman or supervisor to ensure the normal start-up. It is not allowed to put into production blindly and waste time.
⑥ It is necessary to strengthen the awareness of communication and cooperation with QC, and immediately solve the abnormality required by QC to adjust and deal with it, instead of being slack, contradicting or being treated negatively. If QC puts forward problems that can not be solved by the on duty captain, they should be fed back to the on duty foreman or supervisor for coordination and treatment.
8. Normal production stage
(1) In the normal production stage, the personnel of each post must enter into the working state according to their duties.
(2) The captain is fully responsible for the handling and feedback of unexpected abnormalities in the production process, and the monitoring of equipment operation status, printing quality and assistant work quality.
(3) The monitoring contents include
① Observe whether the computer automatic positioning system works normally, move the static phase instrument to check whether each pattern is normal, and observe whether the winding end face and winding surface are scratched, knife line and color difference. Observe whether the tension of each section is normal, and whether there is film scraping phenomenon in the oven and guide roller.
② Supervise the safety and standard operation of each assistant, supervise the operation quality of each assistant post, supervise the 5S maintenance status of the responsibility area on site, and supervise the implementation of labor discipline of each assistant.
(3) Yizhu is responsible for checking the layout of printing plates of various color groups with strobe light (ink scraping is not clean on the knife line, water marks on the dry plate, missing printing and overflow) and the correction of horizontal and vertical sleeve position. It is also responsible for checking the safety of ink immersion and circulating supply, observing whether the pressure and temperature indicator of pressure roller and scraper are working normally, observing whether the film is flat and whether there are foreign matters in the pressing roller, and is responsible for the allocation and addition of ink The ink type must be confirmed before dispensing and adding. During the process, the spot color must be confirmed after scraping. After adding the new ink, it is necessary to cut the volume and check the standard sample in time, preferably when changing the volume. At the same time, he should be responsible for assisting the captain in guiding and supervising the quality of the second and third aid work.
(4) The second assistant is responsible for the preparation and extraction of solvents, and the type and proportion of solvents must be confirmed before allocation and extraction. After the first volume is confirmed to be qualified, the standard viscosity shall be measured immediately and marked on the color plate in accordance with the standard. In the process, the constant viscosity shall be controlled by cyclic measurement 20 minutes per time. In special cases, the individual viscosity shall be adjusted according to the requirements of the captain. It is not allowed to adjust or change the standard viscosity without authorization according to the captain's instructions. Responsible for checking the safety of ink supply and blocking of each color group. Observe whether the scraper is missing or damaged.
(5) The third assistant is responsible for the on-line inspection of raw materials, checking whether the type and specification of each roll of materials are correct, whether the testing items meet the standards, and check the winding surface of each coil end face. If there is any abnormality, immediately ask the captain to handle it to ensure that there is no abnormal operation. Responsible for the sampling of semi-finished products. The off machine semi-finished products should be handled with care and placed vertically on the pad paved with paper. Fill in the flow sheet correctly and attach it on the surface of semi-finished products, including order number, material type, specification, product name, customer name, Captain number, date, taste, gram weight, place of origin, article number and other important text information, as well as the volume quantity, description of abnormal conditions, location and quantity. Be responsible for the cleaning of the working face of the machine. (the semi-finished label filled in by the new worker can be pasted on the semi-finished product only after it is confirmed by the captain)
(6) in the process of adjustment, the scraper can only be adjusted by the pilot or captain, and the adjustment should be as small as possible.
(7) in adjusting the spot color and the color of the object in the process, we must first confirm the viscosity of the ink, and select the dilution or solvent to adjust according to the viscosity. Because the solvent is a volatile liquid, it changes greatly in the instant and process, which is not easy to control and is not conducive to color stability.
(8) All post personnel must mark any abnormality in the process, mark it in detail on the process sheet and timely feed back to the captain. The semi-finished products with abnormal conditions shall be isolated and submitted for inspection in time.
(9) After the film cutting and sampling of each roll, the captain's assistant shall immediately check and confirm the quality of the printed matter and sign his name. If any abnormality is found, it shall be adjusted and handled as soon as possible. The problems that cannot be solved in time and effectively shall be stopped immediately for analysis and treatment. It is not allowed to continue production reluctantly or blindly.
(10) During the production process, the captain and the first aid must have a person at the post inspection office to track and check the quality during the whole process. If there is any special reason to leave the post, it is not allowed to leave the post for more than three minutes.
(11) In the process of "three assistant" or "second aid", the left and right positions of the film should be adjusted immediately after the film is replaced, and track and check whether there is broken film brought into the guide roller and pressure roller, and whether there are pieces of adhesive tape sticking to the plate or pressure roller.
(12) Each order must be completed with both quality and quantity. If any item fails to meet the standard, the site foreman or supervisor must be asked to communicate with the quality control and technical department to determine the treatment opinions, and then the order can be considered as successfully completed.
9. End stage
(1) After the end of production, the captain will turn off the computer automatic positioning system and turn off all electrical switches except the main motor. Fill in daily production report, shift record and process feedback. The specific requirements for filling in daily production report and shift handover record are as follows:
① (production daily report) includes: order number, product and customer name, material name and specification, quantity of each volume input, quantity of each output volume, ratio and amount of ink name, solvent ratio and dosage, number of printing plate, several flavors, color change, plate change, new or old version, preparation, production stages, abnormal situation statement, proofing waste, correction Often change the volume of waste, abnormal waste, the name of each post personnel.
② (shift handover record) includes: order completion, equipment, all abnormal conditions in production, special processes and requirements, auxiliary tool usage, site 6S implementation, and personnel arrival.
③ (process feedback) content: all normal feedback content should be fed back truthfully, and feedback should be given to the special process of production control and abnormal handling methods. In order to avoid the recurrence of the same quality abnormality and waste of raw materials in the next production.
(2) The first aid is to unload the ink, arrange the remaining ink, scrape the sample, fill in the ink information identification sheet, attach the sample and paste it on the residual ink bucket, and timely inform the ink team to seal and pull it back to the ink room. At the same time, the ink on the floor of the color deck should be cleaned.
(3) The second assistant and the third assistant jointly wash the plate, wipe the scraper, clean up the waste, dump the garbage, empty the barrel, and clean up the surrounding sanitation of the machine.
(4) The captain shall carry out the final comprehensive inspection according to 6S standard, and thoroughly sort out the unqualified items.
(5) Finally, the staff of each post should hand over all the work point-to-point with the staff who take over the post, and the successor should also fully, carefully and patiently inquire about it. The staff of the two classes should strengthen communication and exchange, so as to encourage each other to learn, make common progress, enhance friendship, and create a good atmosphere of a harmonious team.
Dongguan Beite packaging materials Co., Ltd. - located in Dongguan City, the world's manufacturing city, is a subsidiary of Beite packaging (China) Co., Ltd., with a plant area of 6000 square meters. It is a flexible packaging enterprise integrating R & D, production and sales. It has a complete set of domestic advanced production equipment, a scientific and humanized management system and a group of experienced technical personnel For backing, to provide customers with quality products and first-class service.