The simulator is a diagnostic and

Transcription

Chinese-Egyptian Research Journal
Helwan University
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Simulation in the Printing Systems to Improve Quality of
Learning and training
Dr. Galal Ali Mohamed Sallam
Ass. Prof. in Printing, Publishing and Packaging Department, Faculty of
Applied Arts, Helwan University, Egypt.
Introduction:
The simulator is a diagnostic and training program that utilizes
custom-designed software packages to interactively practice
problem-solving techniques off-press. Included in the software is a
monitoring and cost analysis that allows the training process to
correlate effective press utilization versus the theoretical cost on a
"live" press."
Optimal productivity is significantly related to the level of press
crew competence. Investment in human capital through structured
training improves productivity, quality, and operational return on
capital investment in printing presses.
Interactive software completely simulates the running of a
printing press, reproducing a wide variety of printing condition and
problems that can be used for training, skills assessment,
performance enhancement and process analysis.
Simulation can also be used to familiarize other staff with the
printing process, improve teamwork and increase process efficiency.
France-based Sinapse Graphic International pioneered the
concept of press simulator software in 1999, when the firm meshed
its simulator into MAN Roland‘s press console.
Research problem
The problem of this research lies in the insufficient Conscious of
using simulation in the printing systems and its benefits for training
and learning.
Research aim
This research aims to make a review or a highlight on using
simulation in the printing systems to improve quality of learning
and training concerning press crew competence in order to improve
productivity, quality, continuity and operational return on capital
investment in printing presses.
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Helwan University
Research curriculum
Survey study Printing simulation systems.
The simulator is intended to help new printers acquire skills and
to help experienced personnel sharpen and extend their existing
knowledge. It plays the same sort of role as a flight simulator for
pilots. It can be used in two ways: standard or problem-solving. In
the standard mode the press is perfectly adjusted, and only the
trainee‘s actions will cause problems. This let the operators
experiment with temperature and pressure adjustments, see what
happens when the viscosity changes or the ribbons advance, etc. It
helps them understand the way the press works. In the problemsolving mode, the trainee will be confronted with unexpected
problems and will learn how to analyze them, how to check, what
the cause might be, and how to correct the problem.
Fig.(1) printing simulation system
The simulators now come with preprogrammed exercises that
correspond to the problem-solving units in the Printing Industries of
America Web and Sheetfed Curriculums. This allows you to
implement a truly interactive training program by having students
solve press problems on demand in a safe and monitored classroom
environment:
 Time after time, in country after country, the simulator has
helped us accelerate the learning curve of operators and had them
producing good impressions years earlier than any other training
method.
 Bridges the gap between being able to run a press and being
able to print with it‖
 Best thing to happen to operator training in the last 20 years
 Operators can sharpen their skills on all of the major issues.
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Helwan University
Fig (2) Printing Industries of America distributes training
simulator software to printing companies and schools, conducts a
two-day training program on how to use the simulator software, and
provides technical support for the systems.
Fig. (3) shows press console monitor in the right side and print copy
monitor in the left side.
In Fig (3) Rights controls the entire press line from paper in to
paper out. It allows all functional settings to be made and adjusted.
Icons on the press console display the printed page, its proof, and
access tools. The operator can check the press and the status of its
variable settings. An interactive diagnostic self help identifies
possible problem causes along with explanations and solution.
Lefts the operator compare differences between the printed form
and the color OK. A magnifier allows close up sheet inspection and
verification of registration. The print copy has a color control strip
which can be checked with both the magnifier and densitometer to
assess grey balance, dot gain, slurring, density, trapping, plate
exposure and other printing details.
Improving performance using simulation technology.
 Simulation based leaning effectively improves skills and is the
only way to give staff experience without interrupting
production schedules or incurring equipment risk and extra
costs in press time and materials. Simulators help answer basic
industry needs including:
 Loss of experienced staff.
 Cost effective and structured staff training .
 Demands of high speed presses needing faster operator
diagnosis and reactions to minimize waste.
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Cross- training between printing processes.
Use
of
quality
control
methods
(densitometer,
spectrophotometers, virtual proofing, standards).
Simulators based training is highly effective across a range of
company requirements;
New press start up
Improving productivity and quality
New technology or process change
Staff motivation and retention
Knowledge transfer
Skill assessment
Cross- training
Customers
Simulation in the web litho offset printing.
Printing simulators are winning increasing favor among
newspaper publishers looking for ways to teach old pressroom crews
new technological tricks. The arrival of multimillion-dollar press
and production facilities nationwide are compelling publishers to
purchase training products that will permit crews to become familiar
with complex press technologies - before the press is fully
commissioned. To that end, publishers with presses manufactured by
vendors such as KBA, MAN Roland and WIFAG have used
simulators to get crews up to speed. Some publishers, such as
Gannett Co. Inc. and Knight Ridder, are requiring the use of
simulators as part of their commissioning process.
Publication and commercial web printers can find answers to
many of their challenges through using simulators integrated into
structured skills enhancement programs:
High speed presses require faster operator diagnosis and reactions
to minimize waste.
Standardized and structured training is an important part of best
practice operations.
Replacement of experienced staff is necessary as the baby boom
generation retires.
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Helwan University
Fig (4) The Newspaper simulator makes it possible to train
printers on color, tension, folding,without having to do it on the
press itself. The simulator is also an excellent way to cross-train all
employees in and around the printing plant. The Newspaper
simulator takes into account the complex interaction between the
different webs and ribbons, the results of problems in the
Superstructure or Folder (slitters, angle bars, cut and collect
cylinders, delivery and conveyer sections).
The vast majority of run print jobs in the world are printed with
Websim Heatset offset: newspaper inserts, catalogues, magazines,
brochures, and even telephone directories.
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Helwan University
Fig (5) As the presses become more sophisticated, they can run
faster, print more pages, and take less time to set up. They also cost a
lot more, and this translates into a high cost for waste and for
downtime. It is neither practical nor desirable to train operators on
the press itself.
The WebSim-Heatset simulator shows operators how to recognize
and troubleshoot problems with tension, paper, ink/water balance,
dryer and folder. It can also act as a basis for refresher courses for
complex folder problems like wrinkling, dog-ears, uneven folds, etc.
The simulator covers the essential elements of commercial web
offset. It models a single-web, four-unit press with a complex folder.
Winner of the ETTE (European Training Technology) prize for best
training software, the WebSim-Heatset simulator is installed in
hundreds of locations worldwide, and in dozens of languages.
Simulators also provide more cost effective and structured staff
training; assist crew pre-training for new press installation; and help
introduce production standards and quality control tools.
Simulators can now be integrated directly into the press console.
The operator runs the virtual press in exactly the same way they run
their real press. This is dramatically effective when preparing for a
new press installation. It is also fantastic for training centers who
supply continued education to working printers.
Fig (6) The simulator puts a press (2 color - 8 color) at the user‘s
fingertips. It operates on standard PCs, using a specialized image
manipulation card and two large monitors. One of the monitors
displays the press control console, and the second monitor shows the
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Helwan University
printed result. Installations of this technology have been done for
Newspapers such as Gannett, Arlington Heights, Thomson
Newspapers, Singapore Press Holdings Omaha World Herald,
Suppliers like SUN Chemical and Training Centers like Stuttgart,
Sao Paulo, Rennes, and Press and Console Manufacturers like
MAN, KBA, ABB,EAE
Fig (7) Rights the press console monitor controls the entire line
from the paster to the folder delivery. The operator can check the
press and the status of its variable settings. An interactive diagnostic
self –help identifies possible problem along with explanations and
causes. Lefts print copy shows output from a 16 page press.
Compare print to proof, check register marks, control strip, density,
dots; manual or scanning densitometer. Magnifying the printed dots
is a good way start to problem analysis. In this example, the
doubling is caused by poor tension, not by density.
Fig (8) some of the output of simulators of web litho offset printing.
Simulation in the sheetfed litho offset printing.
Ink, dampening, additives, pH, pressure, sheet feed, spray,
powder ... hundreds of press and process parameters can be used to
teach and upgrade skills for all employees. Packaging printers can
particularly benefit from the range of simulated press configurations
of up to 6 colors and coating, with substrates ranging from label
paper to carton board. The simulator can significantly minimize
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Helwan University
wasted press time and materials by training operators to become
more efficient in handling shorter run lengths, using quality control
tools, and developing consistent quality and cost-conscious
production skills for all employees.
Fig (9) Rights the sheetfed simulator models a 6-color press from
feeder to coating and delivery along with its plates, blankets, ink and
paper. Lefts the print copy monitor shows the full sheet with
zooming to any part of it. Compare print to proof using a magnifier
and densitometer. The control strip can be checked for grey balance,
dot gain, slurring, density, trapping, and other print characteristics.
Fig (10) Train Easier, Train Smarter: introducing SheetSimSHOTS, the sheetfed press simulator that is hands down the most
effective way to train your personnel. Click. It‘s just that simple.
Just ask any pressman: it takes years of hard work and traditional
on-press training to transform a new employee into a professional
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Helwan University
press operator. Trial and error is an excellent way to gain knowledge
and experience.
SheetSim-SHOTS is a complete interactive computer training
system. From prepress to press to delivery, the SheetSim-SHOTS
simulator offers your press personnel the closest thing to a real
pressroom using state-of-the-art computer technology. In this
business time is money. SheetSim-SHOTS helps you learn to run
your press efficiently and effectively, without using press time or
materials The more you use SheetSim-SHOTS, the better you‘ll get.
SheetSim-SHOTS reduces training time, increases skill level and
quickly builds confidence. It is a program that can help improve any
skill level – whether you are touching up a near-perfect technique or
starting from a blank page. From film to printed sheets, SheetSimSHOTS will have your pressmen, analyzing, correcting, and
anticipating on-press problems.
SheetSim-SHOTS offers two operational modes. For new hires
and basic training, choose the standard mode and the press simulator
is adjusted perfectly. Experiment with the variables and see what
happens. The standard mode provides an ideal setting for learning
the proper skills and special techniques necessary to run a sheetfed
press.
For experienced pressmen, choose the problem-solving mode and
see what develops. An endless number of unexpected problems can
be preprogrammed to appear. These are all real press printing defects
that require identification, cause analysis, and correction. All
exercises have three different tolerance levels to accommodate
beginners to well-practiced personnel.
Make ready. Set up. Clean up. Everything on the press takes time. At
the end of each exercise, SheetSim-SHOTS automatically calculates the
real on-press time and real on-press dollars your actions would have cost.
Costs like film, plates, blankets, roller changes, paper and valuable press
time are all taken into account. You can even enter what these procedures
cost on your own press to make the simulator better reflect your specific
press conditions. SheetSim-SHOTS makes printers at any level aware of
the costs of their actions, resulting in a more efficient and responsible
printing crew.
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Helwan University
Fig (11) some of the output of simulators of sheetfed litho offset printing.
Simulation in the flexographic printing.
The simulator allows each company to specify their own
materials and production values so that operator skills enhancement
provides optimum production cost savings. Key benefits are: Shows
operators how different jobs need different production values. Sets
reference values for inks, blades, anilox, substrates, tensions, dryers,
pressures. Saves time on changeovers and quality control.
Standardizes training and troubleshooting for all operators, crews,
presses and plants.
Fig (12)Rights wide web common-impression-cylinder press
features 8 colors, coating and lamination units; paper, film and
carton substrates; water based, solvent or UV inks; with full controls
for printing, drying and web handling. Lefts Print Copy monitor
shows the full image with zooming to any part of it.
Compare print to color OK using a magnifier, densitometer and
spectrophotometer to recognize problems, to measure and control
quality.
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Helwan University
Fig (13) some of the output of simulators of flexographic printing.
Simulation in the gravure printing.
The simulator allows each company to specify their own
materials and production values so that operator skills enhancement
provides optimum production cost savings. Key benefits are: Shows
operators how different jobs need different production values. Sets
reference values for inks, blades, print cylinder, substrates, tensions,
dryers, pressures. Saves time on changeovers and quality control.
Standardizes training and troubleshooting for all operators, crews,
presses and plants.
Fig (14) Rights press console displays printing conditions on an
8-unit press –unwind, festoon, infeed, slitter, rewinder– with all
control, unit checks and adjustments. Even lab results on tape tests
and solvent retention can be shown. Lefts the print copy view shows
print compared to color OK as a full web, with control marks and a
full set of color tools for magnification and densitometry.
Packaging is the fastest growing segment of the print market
today. As other segments fight against competing media, packaging
becomes increasingly important. Whether you order it over the
Internet, or buy it at your local supermarket, your product comes in a
package: candy bar wrappers, food cartons, yogurt tops . . . you
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Helwan University
name it, it‘s probably printed with gravure. Reputed for its reliability
and print quality, packaging gravure is often the process of choice
for long run, repeated run packaging.
Packaging gravure is certainly the best friend of long runs.
However, packaging gravure printers can be very profitable in a
short run environment. We have examples of printers in gravure
(with 50‘ wide presses) whose average run lengths are between
3,000 and 5,000 yards! They have found that getting to this level
actually can reduce scrap, best satisfies customer needs, and makes
them competitive with flexo printers.
Operating in a short run environment requires operators who have
been trained in a consistent method, who have developed
troubleshooting skills that are the most efficient, and who really
understand the interrelationships of press operating systems.
The challenges in Packaging gravure therefore include training
operators to understand the process (there are almost no schools that
teach "hands on" gravure), making sure they see how different
materials will need different press settings, helping them to learn
troubleshooting to reduce make-ready and improve uptime, and
letting them see the "costs" and consequences of their actions.
Obviously all of these are easier with a simulation-based training
tool.
Fig (15) As other segments fight against competing media,
packaging becomes increasingly important. Whether you order it
over the Internet, or buy it at your local supermarket, your product
comes in a package: candy bar wrappers, food cartons, yogurt tops .
. . you name it, it‘s probably printed with gravure. Reputed for its
reliability and print quality, packaging gravure is often the process of
choice for long run, repeated run packaging
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Helwan University
Fig (16) some of the output of simulators of gravure printing.
Fig (17) Over hundreds of schools and training centers use
Sinapse print simulators all over the world. The HdM Stuttgart, one
of the major German Graphic Arts Schools currently has 4 sheetfed
and 2 web heatset simulators in its curriculum.
Results and recommendation
1. It‫׳‬s better to practice on the simulator than to pay for press time.
2. Employers need to adapt their recruiting and training methods
to new staff who are often characterized by short attention
spans, high tech literacy and a high self focus . Many companies
succeed by using computer game like training simulation.
someone who plays will rapidly acquire problem solving skills
3. The objective for printers is to improve the overall utilization of
equipment, improve quality of the printed product and increase
profitability through the enhanced skills of employees.
Suppliers will benefit by the training of personnel who will
interact in the pressrooms of their customers"
4. Simulators can now be integrated directly into the press
console. The operator runs the virtual press in exactly the same
way they run their real press. This is dramatically effective
when preparing for a new press installation. It is also fantastic
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Helwan University
5.
6.
7.
8.
for training centers who supply continued education to working
printers.
Simulator training is a tool to help press operators make an
easier transition to new press equipment, particularly if they are
not used to central press console operation. Pre-installation
training can be made at any time or place because no press is
required.
Pressmen, technical and other staff (in groups of three to five)
run through a variety of simulated printing problems (register,
ink/water balance, web tension, folder, color setting,
densitometer use) to ascertain any special training needs prior to
live production.
Exercises are programmed for the needs of each group (such as
start-up or mechanical problems) and each trainee‘s knowledge
and problem-solving approach is objectively assessed.
Simulator allows the creation of print defects in exercises that
require operators to make the right decision at the right time to
acquire better and faster problem solving skills.
In the end of this research we can say there is not any simulator
system of printing training in the Egyptian schools and universities
and we must use this system to improve quality of learning and
training concerning press crew competence in order to improve
productivity, quality, continuity and operational return on capital
investment in printing presses.
References:
1. http://librarey.966.com
2. Sinapse print simulator catalogue, simulator training real results,
France.
3. www.ercim.org
4. www. labelsandlabling.com
5. www.newsandtech.com/index.htm
6. www.printing.org/page/3855
7. www.printingtalk.com
8. www. Sinapseprint.com/ commercial – printing –and - publishing
9. www. Sinapseprint.com/ newspaper
10. www. Sinapseprint.com/ packaging
11. www.sinapseprint.com/spip.php
12. www.stsintl.com
13. www.syros.aegean.gr
14. www.usink.com
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The simulator is a diagnostic and

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