To make an analogy from the human body, if you can pay attention to preventive medicine and diligently take care of your body, you can not only get sick and stay healthy, live longer, and live a free and beautiful life all your life. The quality is stable and the mechanical life can be extended. However, the repair of general printing machines is Breakdown, and the repair work is only done when it is no longer usable. This is a matter of time-consuming and costly after-effects, and affecting production. If you do n’t know how to control your eating habits, you will soon be in poor physical condition and cause disease to your upper body. Not only your physique becomes weak, which affects your daily life and life, but also affects your lifespan. In the years of life, many people have not done planned printing machine maintenance and repair. In fact, there are planned pre-checks and monitoring of machine abnormalities, and doing precautionary work before damage is not economical. The two are very different. The human body has a natural balance and adjustment, and even recovery repair mechanism, so as long as there are regular medical consultations and ways to improve life and rest, and under the control of drugs, you will have the opportunity to recover to a good health state on your own. However, the machine does not have the automatic recovery ability of the human body. Unless replacement or adjustment and maintenance work is done, it will only get worse and worse until it is unbearable. Today's "KPM" Komori Prenent Maintennice Komori's preventive maintenance work is based on the above principles and emphasizes practical performance. The world financial tsunami from 2008 to the second half of 2009 severely hit the economy, and major printing machine manufacturers were no exception. The revival and recovery was a severe test, so If each printing business can strengthen the prevention and maintenance of the company's KPM in the medium and long-term plan, although it will not see the results tomorrow, it will be a continuous and persistent KPM to transform it into a production knowledge. It is much more efficient and safer to repair than afterwards. If the fluorescent lamps of a large hotel are not checked and there is a flashing fluorescent lamp, guests will be discounted in their management confidence.
The printing machine is an expensive and self-repairing device. If the 175 lines printed by a lithographic printing machine daily have a 1% dot diameter of less than 0.015mm, it is invisible to the naked eye, so use Zhang Ye The machine prints 5 sheets of paper per second, each with counted dots on it, and up to 15 sheets per second in commercial rotary offset printing machines, while keeping the dots transferred to the blanket and onto the paper surface. It is the axis and bearing of the printing cylinder, and the strength of the supporting structure of the axis, bearing and gear reverse wall of each transmission or re-transmission, must have good precision and stability, otherwise the two printing will not be repeated. At the location of the fine dots, printing faults cause the dots to be deformed and enlarged. To maintain the precision effect of this extremely fine and high-speed operation, how do these machine components measured in 0.001mm (micrometer) maintain the accuracy of the original manufacturing It has become the most important issue for printing machine room users, managers and maintenance personnel. If the status of the printing press is divided into four grades of A, B, C, and D, A. is still in a good range. B. I have noticed that some abnormalities should be adjusted. C. The problem has become superficial. D. The machine has obviously malfunctioned, and it must be repaired immediately, otherwise it cannot be produced. A blue line is well maintained and a printer that often performs oil replacement, cleaning, and maintenance can be kept within an accurate and usable range for 5 to 6 years. By the 9th year, it may reach the bottom of the B line, which should be damaged. Components, only entered the D line in 11 years. Another printing machine with poorly maintained red lines has seen A-line to B-line after 3 and a half years of use (the chain is not cleaned and lubricated, there are also examples of failures as long as more than a year). The line area has been unusable for 5 and a half years. This is a serious result. It not only affects the printing quality and productivity, but also the company's property loss and goodwill. Therefore, check and diagnose the status of the printing machine for abnormalities from time to time, and then make adjustments, repairs, and repairs to keep the printing machine engaged in printing in a good production state for a long time. [next]
If Heinrich's law is used for human body analysis, each time of hospitalization for pain treatment is accumulated by thousands of bad habits in daily life, about 300 of which are taken at home. 29 visits to the hospital for medical treatment to one hospitalization. A large-scale failure of the same printing machine also resulted in 300 times and 10,000 times without cleaning and lubrication, resulting in 300 times due to oil drops, water stains, air blockage, abnormal heat, vibration, abnormal sound, odor, loose parts, The wiring is slack, the filter is dirty and blocked, 29 times cannot operate normally, the bearing is damaged, the vacuum compression gas path is faulty, to one time the bearing is burnt and worn, the gas path is completely inoperable, or the electrical fault is down and other maintenance conditions, Both humans and machines accumulate small faults and form large patients that cannot be used. Therefore, treat the printing press as if it were your own body, cherish it and observe carefully and do cleaning and maintenance to ensure normal operation.
The 5S movement promoted by Japan has become a worldwide sport like karaoke, including
(1) SEIRI organizes, separates necessary and unnecessary things and arranges them in an orderly manner, and can store or remove unnecessary ones.
(2) SEITON reorganizes, puts the necessary things in the handily stipulated place, can be obtained when needed.
(3) SEISOU cleaning, do a good job of cleaning and wiping the inside and outside of machinery and tools, keep the environment clean and equipment clean, not only use it smoothly, but also "check" the equipment status during cleaning and wiping to understand what is abnormal. It is the most important item in 5S.
(4) SEIKETU is clean, keeping the body, mind and environment clean and free of dust and dirt.
(5) SITUKE literacy, abide by workplace regulations and SOP operating specifications, not only do it in accordance with the regulations themselves, but also urge colleagues' subordinates to do their jobs in accordance with the regulations.
For work, such as adding lubricating oil, lubricating grease and circulating oil replacement, oil filter core, magnet iron absorber, moisture and impurities cleaning. Clean water stains, glue, dust, and keep the printing cylinder, ink roller, water roller, bite claw, and paper discharge chain clean. Check for abnormalities, wear, heat, or unusual accidents. For abnormal ink rollers, water rollers, bite claws and machines, see adjusting and replacing parts. The main bearing of the printing machine is very precise. It is often worn and injured due to improper use of oil or the deterioration of oil. It can not be used again. The closed and opened rollers of the bite are insufficiently pressed due to smoothing, or they cannot be passed smoothly. Paper printing, etc., must be discovered through inspection and cleaning work. [next]
Air, oil, and filter are the conditions for protecting the working efficiency of the air supply and oil supply pump and not damaging them. If the filter is clogged, the air supply will be reduced, which will cause Feida to feed paper, feed, and edge regulations. The efficiency and quality of the work will be affected when the gas transmission and paper collection are not smooth. A clogged oil filter will reduce the printing machinery to the point of being unable to supply oil and wear out, causing major accidents. Therefore, it is very important to keep the filter clean and unobstructed, and maintain the filtering function. Motor cooling fan filter device plugs will also cause motor overheating and burnout. For the replacement of the motor carbon brushes, the original manufacturer suggested that it should be replaced when it wears half the length, and Mr. Chuan Ming believes that it should be replaced when it wears one-third of the length. It is safe and the electrodes on the motor rotor are not worn. In addition, the aging of the air compressor's belt, the maintenance and cleanliness of the air filter and oil-water filter are equally important, and the compressed air drum of the air compressor is likely to produce water on high-humidity days. Affect the movement and corrosion of the cylinder. The static elimination device of the printing machine itself has the effect of high voltage current. If the wire is not placed intact, it is easy to produce static sparks at the damaged parts, which may cause fire accidents.
There are more than 300 commercial rotary machines in Japan, and there is an average of one commercial rotary machine in the drying system or the dust of the origami every year. Especially when printing, due to the accumulation of paper dust and dust, if the spark is generated, it will ignite the origami or Oven, a loss of tens of millions of yen at a time, and even scrapped to reinstall a new printing machine. There are many filters and oil filter shells are often made of transparent plastic materials or glass cups, which are easy to visit and check. However, most of the shells are too dusty and too dirty to be seen and should be replaced and cleaned. The jaws of the Zhangye offset printing machine have been changed to the cam closing method. If a single jaw is stuck, the strong closing force of the cam will not be cushioned by a spring. The pressure of more than ten kilograms will become the pressure of hundreds of kilograms. The damage of the jaw seat, which affects the safety of the printing cylinder surface, and the wear of the shaft center of the jaw and the pressed roller, shaft, and bearing is also a big accident. The electrical parts, electronics and computer fans are pumped down for cooling. If you do not pay attention to the cleanness of the inlet filter, there may be the possibility of overheated electronic and motor parts burning. The function of the fan can be confirmed by placing wires and flakes on the air supply port, as long as there is air supply, it will float without having to detect it by hand. The storage of food in the factory should also pay more attention. If you do n’t pay attention, it is easy to attract mice. Rats bite the transmission and distribution circuits and electronic circuits of the printing press for grinding teeth. It is also possible to use starch dusting. Become a rat food, so it is best not to have food in the workplace, which will save a lot of crises, and in the countryside, there will be snakes running into the factory under the rat, curled up in the distribution box and Under the machine, it was really scary. [next]
The most common pollution situations in electrical switchboards include dust, heat, burnout, dripping, dripping oil, fly ash Flyash, rats, insects, snake traces, short circuit, no power to electronic parts damage, so cleaning work Be cautious. In order to smoothly produce and produce high-quality products, and to prolong the service life and efficiency of printing presses, efforts should be made from seven aspects: environment, printing presses, printing plates, moist water, paper, ink, and rubber transfer materials.
(1) The environment has the arrangement and management of room temperature, humidity, lighting, the safety of water supply, power supply, and moving line management in the printing machine room, such as oil, solvent management, factory sanitation and personnel safety protection, and establishes SOP correct standard operating procedures To allow the staff to follow.
(2) The management of the printing press, with 5S refueling, cleaning, adjustment, replacement, inspection and abnormal observation, inspection and restoration repair, to maintain the normal operation of the printing press.
(3) Printing plate management, from CTP laser light amount, printing plate sensitivity, and stability control of developing potion, and then adjust the appropriate plate adjustment curve according to different printing machines and paper conditions to become a suitable reproduction and storage data, For output under different printing conditions, pay attention to scratches and glue stability.
(4) Ink management, fix the brand and hardness pointer, control the temperature of the printing machine room and the constant temperature of the ink supply system of the printing machine, stir thoroughly before the ink is applied to the ink tank, make the ink shake better, do not put too much ink at a time. The bottom is hardened, printed with a suitable film layer, too thick ink film is harmful to water and ink balance, prevents blowing, high heat or UV light from irradiating the ink supply system, making the ink on the ink roller sticky and fixed.
(5) The management of the ink roller and blanket must be suitable for extremely flexible hardness, the maintenance of the elasticity of the rubber surface, and the adjustment of pressure. The blanket can be properly lined according to different hardness. The printing water roller can prevent ink and oil stains. Deinking occurs when the colloid is attached. The water roller must be resistant to IPA hydrophilic rubber, and the ink roller must use lipophilic rubber.
(6) Wetting liquid management, adding suitable hydrophilic liquid and IPA replacement liquid, automatically adjusting the addition of hydrophilic liquid under the control of PH value, but it is also controlled by conductivity, which is more controlled by PH value than hydrophilic liquid with buffer accurate. Filter replacement, bad fountain solution replacement, wetting fluid circulation and temperature control.
Three Chinese printing companies and 17 Japanese printing companies have joined KPM's preventive maintenance system. After implementing KPM's maintenance activities, the maintenance cost of the first year has dropped significantly, but the most important thing is that the number of emergency repairs compared with the number of emergency repairs by the manufacturer It has dropped to less than 20%, and it is clear that the smoothness and predictability have increased! Subsequent maintenance costs in the second and third years have dropped significantly, ensuring a high level of print quality over the long term. Each manufacturer's 11 inspection items including environment, materials, wetting fluid, ink supply, water supply, rubber cylinder, plate cylinder, pressure cylinder, print data management, measuring instruments, and printing workplace 5S management increased from the earliest 51 points to 86 The high score is also due to the item-by-item inspection, so that not only mechanical equipment, environmental conditions, set parameters and material inspections are well taken care of, to achieve suitable and qualified conditions, although it takes time to do KPM in advance Inspection and adjustment and repair, but in the long run, productivity, production yield, good and bad products are greatly reduced, maintenance time and maintenance costs are greatly reduced, printing quality is stable, and the printing machine can maintain longer-term and reliable production services, with outstanding results.
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