Unit 1 : Introduction
1.1 – Define: Quality, Quality assurance, Process Control, TPM, TQM and ISO.
1.2 – Quality control Process – Elements of success – Management, support , mission Statement, proper planning, bottom line, focus, measurement system, empowerment, teamwork, continuous improvement process and dedicated resources.
1.3 – Basic elements of Total Quality Management: Human resource, development and management, DMAIC Process – Define,
measure, analyse, improve and control, DMADV – Design and
validate.
1.4 – Statistical Process Control Tools: Purpose of SPC, cause and effect diagram, check sheet, flow diagram, pareto analysis, histogram, run chart and control chart.
1.5 – Basic concepts and benefits of Kaizen, LEAN, JIT, 5S and Six Sigma.
Unit 2 : Material Inspection and Testing
2.1 – Visual Inspection, Storage and Handling of Substrates and Chemicals. Maintenance of data sheets of materials – MSDS
(Material safety data sheet), TDS(Technical data sheet).
2.2 – Testing procedures for Paper and board – Grain Direction, GSM, stiffness, tensile strength, tearing resistance, folding endurance, RH, smoothness, moisture, BULK, Bursting strength and COBB.
2.3 – Dampening solution testing methods – Testing of pH and
conductivity.
2.4 – Ink testing methods – Draw down, grind gauge, Viscosity, Tack
2.5 – Introduction to light viewing booth – different light sources in light booth.
Unit 3 : Process Control
3.1 – Quality control targets – registration mark, star target, Ink Coverage target and Line Resolution target.
3.2 – Control patches – Solid patches, Halftone, Slur/Doubling, Gray Balance, Solid overprint and Plate exposure control patches.
3.3 – Wastage Management: reduction of waste from overproduction, defects, waiting time and delay, accumulation of work in process and transport – wastage disposal process.
3.4 – Process control charts – recording, monitoring and controlling procedure.
Unit 4 : Control tools, equipments & Procedure of calibration Process
4.1 – Densitometer – Basic components and its working principles.
4.2 – Spectrophotometer – Basic components and its working principles.
4.3 – Analysis of Print Attributes: Solid Ink Density (SID), Dot Gain, Print contrast, Ink Trapping and Dot Area. CIE Lab and colour difference – Delta E.
4.4 – CTP calibration and Linearization process.
Unit 5 : Implementation of ISO for Print Quality
5.1 – Introduction to ISO standards, Steps involved in ISO 9001 Certification, Common ISO standards (9001/14001/osho etc) and ISO standards for printing process.
5.2 – Press Calibration to ISO-12647-2 standard.
5.3 – Implementation Process of ISO standards in printing organisation, maintaining and renewal process of ISO certification.
5.4 – Benefits of ISO implementation, Customer Satisfaction and Case Studies of ISO certified print industry.
Text Book / Reference Book :
1. Total Quality Management, Dale H. Besterfield, Pearson Education, Delhi, 2002
2. Implementing Quality Management in the Graphic Arts, Herschel L and Michael J
Apfelberg, GATF, Pittsburgh, 1999
3. Colour control in lithography, Kelvin Tritton, Pira International Surrey UK 1995
4. What the Printer should know about Paper, 3rd ed., Lawrence A. Wilson, GATF Press,
Pittsburgh, 1998
5. What the Printer should know about Ink, Nelson R. Eldred and Terry Scarlett, GATF,
Pennsylvania, USA 1990
5. Total Quality Management, Ken Holmes, Pira International, Leatherland, 1992.