Why Are Press Sheets Wet, Marking?

Highlights from “Ask a Print Expert” at graphicartsonline.com , where Ray Prince tackles challenges.

Question: We implemented color management and have done 20 jobs; 16 of them were excellent in matching between proof and press sheet. We are disturbed that four of the jobs were very bad, to say the least. What could be the problem with these?

Answer: In reviewing proofs and press sheets you sent me for those four jobs, I find two jobs printed on uncoated stock, and two were accompanied by client-supplied proofs. To address this situation, you need to have curves set up for uncoated as well at coated stock. I am a strong believer in having many curves set up based on each substrate.

In regard to supplied proofs, you are now in the area of gambling. Who says the proofs supplied are any good at all? My suggestion is to always pull a new proof (mainly do this for commercial sheetfed work, not heatset web) and compare the supplied proof to your proof. If they are different, then call the customer, before you begin the run.

Question: Scheduling in our plant is a disaster. We have a 75-employee firm, and I have had three schedulers in the last three years. None could keep up with our commercial plant operations. Where can I find the right person?

Answer: You can't. There is no human alive that can schedule your shop. But there are a number of computerized scheduling systems that can do a wonderful job. Keep in mind that most plants have seen run length go down as well as the number of jobs go up. In addition, delivery times are very, very short. There does not seem to be one scheduling program that leads the pack. Take a hard look at one that can interfaces well with your existing MIS system.

Question: I hear a lot about 'Lean Manufacturing.' Where's the best application and how to start?

Answer: Lean means different things to different people. Lean begins with a 5S program (so-called for the most common steps to effecting the efficient manufacturing process: Sort, Set In Place, Shine, Standardize, Sustain) to clean up the plant. If you are not willing to do this, don't even begin lean. To implement a 5S program is work and, like most programs, it starts at the top. The benefits of running a clean plant are great. Once you've done that, I suggest you go for where you can get the greatest return: That would be automating prepress and the front office.

Question: We have too many butt rolls, 300+, of various paper in our warehouse. The web pressmen are not using them. Should we just recycle them?

Answer: This is an issue in many plants today. Recycling should be the last thing you do and not the first. As a general rule, save all rolls over 4´´ in diameter to use as a start-up roll for another job. The best solution I have seen is to keep all butt rolls at the roll stand of the web; don't send them back to the warehouse. Once they go to the warehouse, they seem never to come back. Keep rolls at the press where they will be seen and used.