Connected Automation: The Concept

Labor and work saving technologies for prepress processes have evolved in recent years, bringing significant changes. With the introduction of DTP and CTP, the creation of printing plates, which used to involve large numbers of skilled workers toiling in darkrooms, has been completely revolutionized. In printing processes, new automation systems have been introduced for steps such as press cleaning and changing of plates.

New print quality control devices are also being introduced that use equipment such as cameras and scanners. However, production and postpress processes continue to be handled largely by hand.
In postpress, although many finishing processes involve simple and repetitive actions, they still require large numbers of workers, which hinders productivity. Furthermore, as these processes are the final steps before shipping, delivery can often be tight, sometimes forcing departments to throw their entire workforce at the problem in order to meet deadlines.
Time management is integral to saving work and labor during these processes. Printing companies need to grasp the numbers of workers and amount of time they are spending on current tasks, and calculate how efficiency can be improved through steps such as introduction of new equipment and improvements to workflow. Efficiency can be improved by introducing unmanned operation, labor-saving designs and then work saving designs (eliminating the need for special skills), in that order.Re-evaluating postpress productivity can create labor surpluses that can further improve plant productivity.

When analyzing visualized data and introducing labor and work saving designs, it is essential that quality management be preserved. The level of print quality management in Japan is among the most stringent in the world, and is supported by highly experienced technicians. However, the number of veteran print operators is dwindling, as is the number of clients with in-depth knowledge in printing. In order to achieve a Smart Factory while maintaining the same levels of quality, it is absolutely vital that processes be standardized so that the same end-product can be achieved, every time, regardless of the operator.
For instance, while the majority of presses are currently equipped with colorimeters, it appears that in many cases they are not being used correctly. One of the leading causes of this is related to proofing. When proofing is done by hand and pages printed under differing conditions are pasted together, standardization becomes difficult to achieve. The first step is to standardize proofing methods.
In recent years it has become popular to use inkjet printers for proofing, because of the ease of color management. If proofing quality were standardized, however, printing would likewise become easier to standardize. In fact, the majority of work can be standardized and sped up, through use of CTP for highly accurate plate creation, and use of press color compensation features in conjunction with CIP4 data.
Additionally, there are a number of features that use tools such as colorimeters and cameras to monitor, control and record quality, even after final printing begins, and these features are steadily growing in popularity. Cameras equipped on presses and bookbinding machines for inspection of individual sheets have grown more accurate, offering better quality control. Additionally, equipment has recently become available to ensure traceability for defective and removed sheets, such as devices that create PDF images from platemaking data for comparison with printed items, or numbering systems that use inkjets to print a unique number on every sheet. Adopting the best equipment currently available allows printers to reduce the number of inspectors and better visualize quality, while still maintaining the same quality standards.