ELEMENT 5: Running Targets for Quality Control

Quality Control targets enable you to measure key variables such as density, trapping, dot gain, contrast and gray balance with a densitometer. These measurements can then be compared to the original SHarper System Snapshot™ created for each flexo printing system to determine if results are within agreed-upon tolerances or if adjustments need to be made.

By defining verifiable measurements and tolerance ranges, running targets also provide the print buyer and converter with a clear and accurate frame of reference for determining desired results. This can save all concerned a great deal of time and effort and avoid costly errors.

Running targets also provide a way to document and ensure that each flexo press is producing the desired results over time.

Running Targets
With the SHARPER System" you get two different layouts of running process control images. These can be included on either side of the web. The long single row is usually run on the edge of webs that will be trimmed after printing.

The rectangular shape can be fitted into waste areas or hidden flaps of die cut materials. Often, larger print buying companies require control targets to ensure quality. In this case, if there is no area to hide them in, the running
targets are usually incorporated into a back panel of the package.

Including this image on both sides of the press will assist the operator in evaluating the parallelism of each printing unit.

Each single color image segment consists of an impression hexagon and input dot area percentages of 3%, 10%, 30%, 70% and 100% or solid. Each segment is separated by a registration mark for precise alignment. The overprint segment begins with a black tint, a three color neutral and another black tint to assist in visually monitoring color balance on web rewind presses during the running time of the roll. This is followed by the solid   overprints in magenta/yellow, cyan/yellow, cyan/magenta, three color solid and four color solid. These areas are used to evaluate the trapping efficiency of the ink system.

By comparing the running process control targets on production jobs to the target established by the running targets on the printing snapshot, we can determine if we are printing consistently. By constantly measuring and graphing this information we can use statistical process control methods to monitor and report the quality of production runs.

ELEMENT 6 - Printing by the Numbers

In the SHarper System™, element six shows proof of your science on press. The proof is a control device produced by the prepress tradehouse to communicate to the flexo printer and buyer the expected graphic results on press. Each proof includes control targets for checking specific measurable variables to ensure all are within tolerance, as planned.

As shown here, running targets on your actual print can be checked against the proof targets to prove your color match. This confidence provides "peace of mind" predictability for each press run. If and when your targets don’t match, you can quickly determine the problem and correct it.

ELEMENT 7 - Continuous Improvement Plan

This is perhaps the most important element of the SHarper System™. Without continuous improvement "thinking" and follow-through, the system will loose its print optimization benefits. This process improvement thinking comes in two forms:

A.  Anilox Roll Inventory Management

Anilox inventory management involved systematically auditing your current anilox surfaces and projecting their upgrades in relationship to future needs.

By pre-planning your inventories, the decisions of volume and screens can be addressed systematically, insuring maximum use of you anilox budget dollars. Additionally, properly planned inventories reduce roll change over(s) needed while eliminating odd, seldom used rolls. By taking a "big picture" view of your anilox tooling, we can find and fill gaps where quality is a struggle.

Your cost benefits of an optimum anilox inventory:

• Reduced anilox inventory through standardization of line screen and volume selection.
• Reduced anilox changes thus less downtime and less risk of damage.
• Reduced number of anilox rolls purchased due to planned inventory management.
• Maximum quality for every print order and greater print buyer loyalty.

B. Graphic Team Meetings (GTM's)

To best manage anilox inventories in relationship to other operating inputs, clear communication between your overall graphic team is vital. Annual Graphic Team Meetings (GTMs) are recommended when the SHarper System™ is up and running. These meetings aid everyone in clearly understanding your quality needs going into the future. They also provide a communication forum in which suppliers can introduce new technologies.

At each GTM, the team can be given direction on what is needed to improve both quality and productivity. Plate, anilox and ink suppliers should all be present, along with the key personnel responsible for your daily print quality and productivity. Agendas can cover anything from press crew training to developing a plan for achieving new quality levels. In either case, the aim is for everyone to collectively understand your goals and to improve your profits and your competitive position in the marketplace.

Get the SHarper System™ Advantage

With The SHarper System™ you will:

• Predict color match on press before anilox rolls are installed or made
• Reduce set up time because you’ll run "by the numbers"
• Produce consistent, predictable, profitable flexo

The Sharper System™ has been created specifically to allow flexo printers and converters to achieve unprecedented levels of consistency, quality and profitability. The SHarper System™ is available exclusively from Harper Corporation of America. Call us now to begin experiencing the benefits of the SHarper System™ in your operation. 800-438-3111 (704-588-3371 outside the U.S. and Canada).