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PRINTING QUALITY
MANAGEMENT
An overview to
in ZAMAN
Prepared by: Muharrem Yaşar
Quality and Coord. Manager
1 / 56
07.10.2013 Wan-Ifra World Publishing Expo 2013 Berlin, Germany
İstanbul, Turkey
Feza Gazetecilik A.S. known as Zaman
BS Newspaper in Turkish
daily 1 million circulation
printed in 6 printing sites
/25 3
Zaman Head Office İSTANBUL
Zaman Head Office İSTANBUL
Ankara Printing Plant
Printing Plant ANKARA
Printing sites, Distrubiton areas, % Circulation
own
contracted
% 30
% 20
% 20
% 10
% 15
% 5
6 Printing Sites
5
1
Zaman & its weekly sisters
Cuma
Cumartesi
Pazar
Todays ZAMAN & its Sunday
version Sundays Zaman
Daily English newspaper
10. 000 copies
Weekly news magazin
50. 000 copies
Separatly sold
Weekly magazin
250. 000 copies
magazin
size
What we have
Newspaper Machines
75.000 copies / h., single side-double around
40pages, 24pages colorful
+ Presetting ink keys
+ Soft proofing
- Automatic register control
- Automatic density control
- Automatic cut off register
Plate making Rooms
CTP lines ( CTP s and P&Bs)
+ Ink saving program
General
Vice General
Production
Printing Plant
Director
Quality Eng.
. Quality Eng.
. Quality Eng.
. Quality Eng.
. Quality Eng.
Quality and
Coordination
Director
Quality
Manager
Technica
Manager
Planning and
Reports M.
Purchasing
Dep. Director
Hierarchy
Quality Management
System
Environmental
Management
Systems (EMS)
14001
Occupational
Health and
Safety (OHS)
18001
(ISO) 9001 Printing Quality
Main Topics
Integrated Plant Management System
Printing QualityIntegrated Plant Management
(EMS,OHS,ISO)
3 yasar muharrem
Printing Quality Management
To get ISO 12647/3
Check printing defects
Report consumabels
A ) ISO 12647/3 :2005
Dep. Property Set values
Electronic data delivery PDF/X-1 or PDF/X-3
Press profile ISO 12647-3 (IFRA 26)
C
T
P
Ink saving
GCR
Ton value sum Max 240-260,
Black >%85
Rips
Ton values 500 lpcm
Screen frequency 40 L/ cm
FM screen 40 micron
Screen angle CMYK 15,75,0,135
Dot shape elliptical dot,
link-ups %40,%60
Purchasing Newsprint La*b* 82,0,3 ( tolerances: 3,1,1 )
Adver. , Design,
Prepress, Page
Delivery
A ) ISO 12647/3 :2005
A ) ISO 12647/3
• ISO color coordinates
• TVI dot gain curve
So;
A ) ISO 12647/3
… and technology develops
• ISO color coordinates
means decrease the ink
density ISO Lab (IFRA 26)
measuring mod :
ISO-Check
A ) ISO 12647/3
• ISO color coordinates
* With black backing
ISO (IFRA 26) values
Red 52 41 25
Yellow 78 -3 58
Green 53 -34 17
Cyan 57 -23 -27
Blue 41 7 -22
Magenta 54 44 -2
Paper 82 0 3
Black 36 1 4
only Paper and CMYK is used
M
C
Y
g
r
b
K
A ) ISO 12647/3
• ISO color coordinates
Only yellow b*
value changed
BUT ; not practical
Our referance values ? Why not?
First : determine perfect dots in ISO
Second: measure Lab with no b.backing
A ) ISO 12647/3
• ISO color coordinates
You can put your new referance values
ColorScale mod for new ref.
values
ISO-Chek mod ISO Lab values
has already loaded
A ) ISO 12647/3
• Dotgain
A ) ISO 12647/3
• Dotgain
old ….. 4,5 mm
new ….. 3 mm
A ) ISO 12647/3
Change the apparatus with a
smaller one and make tests
A ) ISO 12647/3
• Dotgain
%100
%40
A ) ISO 12647/3
• Dotgain
%40
0,78 66,8 0,81 69,5 0,82 67,8 1,14 63,6
density
% dot gain
• Dotgain
A ) ISO 12647/3
*Recordings are done by automatic measurement mode
While the Q. Engineer measures and records the dots to ERPVideo-1 :
Picture
.
Daily Printing Quality Report
Ref. densities
difference Operator succes
DG
Production Name
WEEKLY P. OPERATOR DENSITY SUCCES REPORT
Averages
DG average
The values to be
applied to CTP rips
3 yasar muharrem
/25 36
For consistence Printing DG,
plate controls is obligatory
Every week produce a test
plate which has a “plate
scale” job on it.
Plate Scale
Measurements are done and recorded by a plate measurement
device. Then the program calculates the dot gain of the plate
/25 38
Plate Quality Report
3 yasar muharrem
%2, %98 and % 50 tone values are measured with plate
densitometer by the prepress man to understand if there is
an abnormality or not. If the values are seem to be changed,
he produce a test plate for exact measurement and
calibration
Daily Plate Checking
A tone scale stays on the bended side of the plates is checked daily.
Plate is taken before P&B machine for measurement.
only Plate
Plate + Press
Applied dot gains
While the Q. Engineer evaluates and records the print defects to ERPVideo-2 :
B Printing Defects Checking
Printing Quality Report
Solve mains
Notice news
Main target:
DEFECTS INCQC points PAGES
B Printing Defects Checking
INCQC defects table is used
B Printing Defects Checking
So ; we are checking ourselves like we are in competition INCQC
everyday
B Printing Defects Checking
First run or restart - following a stop copies:
Customers complains mostly :
from the “startup “ newspapers or “restart - following a stop ” newspapers.
Because mechanically they are the worst.
salable , low quality, not salable,
B Printing Defects Checking
C Consumabels Reporting
a) are being used (Current)
Ex: Newsprint Evaluation Report
b) Test metarials
Target is;
To prepare a list to our purchasing department.
Show preferred and not preferred
So we ask:
not to bought unwanted,
instead, the preferred if possible much
every month automatically produced by ERP
Printing plant / Type of newspaper -IFRA reel code- / Newsprint making machine number
Weight is for weighted average
forms to the chief of printers
Point are given as ;
5 Better
4 Good
3 Normal
2 Bad
1Worse
QE records to ERP
Described by our
personals;
criterions , weights
4 different working
areas
Ex:
Ex:
Register and tension
control
Cleaning
Reel Stand
Ink and water
adjustments
Ex: 45gr. Std Newsprint
Newsprints from top to bottom
they are in 3 groups
GOOD, BAD, WORSE
GOOD
BAD
Printing Quality Management
Try to get ISO
Newspaper standart
check printing defects
Report newsprint
AS a SUMMARY
Thanks for listening
56 /56
any questions?
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
_
Muharrem YAŞAR
ZAMAN Newspaper
Quality & Coord. Manager
Ahmet Taner Kışlalı Cad. No:6
Yenibosna / İstanbul / Türkiye
+90 (0)212 454 87 03
m.yasar@zaman.com.tr
for contact:

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3 yasar muharrem

  • 1. PRINTING QUALITY MANAGEMENT An overview to in ZAMAN Prepared by: Muharrem Yaşar Quality and Coord. Manager 1 / 56 07.10.2013 Wan-Ifra World Publishing Expo 2013 Berlin, Germany
  • 2. İstanbul, Turkey Feza Gazetecilik A.S. known as Zaman BS Newspaper in Turkish daily 1 million circulation printed in 6 printing sites
  • 4. Zaman Head Office İSTANBUL
  • 5. Zaman Head Office İSTANBUL
  • 7. Printing sites, Distrubiton areas, % Circulation own contracted % 30 % 20 % 20 % 10 % 15 % 5 6 Printing Sites 5 1
  • 8. Zaman & its weekly sisters Cuma Cumartesi Pazar
  • 9. Todays ZAMAN & its Sunday version Sundays Zaman Daily English newspaper 10. 000 copies
  • 10. Weekly news magazin 50. 000 copies Separatly sold Weekly magazin 250. 000 copies magazin size
  • 11. What we have Newspaper Machines 75.000 copies / h., single side-double around 40pages, 24pages colorful + Presetting ink keys + Soft proofing - Automatic register control - Automatic density control - Automatic cut off register Plate making Rooms CTP lines ( CTP s and P&Bs) + Ink saving program
  • 12. General Vice General Production Printing Plant Director Quality Eng. . Quality Eng. . Quality Eng. . Quality Eng. . Quality Eng. Quality and Coordination Director Quality Manager Technica Manager Planning and Reports M. Purchasing Dep. Director Hierarchy
  • 13. Quality Management System Environmental Management Systems (EMS) 14001 Occupational Health and Safety (OHS) 18001 (ISO) 9001 Printing Quality Main Topics Integrated Plant Management System
  • 14. Printing QualityIntegrated Plant Management (EMS,OHS,ISO)
  • 16. Printing Quality Management To get ISO 12647/3 Check printing defects Report consumabels
  • 17. A ) ISO 12647/3 :2005
  • 18. Dep. Property Set values Electronic data delivery PDF/X-1 or PDF/X-3 Press profile ISO 12647-3 (IFRA 26) C T P Ink saving GCR Ton value sum Max 240-260, Black >%85 Rips Ton values 500 lpcm Screen frequency 40 L/ cm FM screen 40 micron Screen angle CMYK 15,75,0,135 Dot shape elliptical dot, link-ups %40,%60 Purchasing Newsprint La*b* 82,0,3 ( tolerances: 3,1,1 ) Adver. , Design, Prepress, Page Delivery
  • 19. A ) ISO 12647/3 :2005
  • 20. A ) ISO 12647/3 • ISO color coordinates • TVI dot gain curve So;
  • 21. A ) ISO 12647/3 … and technology develops • ISO color coordinates means decrease the ink density ISO Lab (IFRA 26) measuring mod : ISO-Check
  • 22. A ) ISO 12647/3 • ISO color coordinates * With black backing ISO (IFRA 26) values Red 52 41 25 Yellow 78 -3 58 Green 53 -34 17 Cyan 57 -23 -27 Blue 41 7 -22 Magenta 54 44 -2 Paper 82 0 3 Black 36 1 4 only Paper and CMYK is used M C Y g r b K
  • 23. A ) ISO 12647/3 • ISO color coordinates Only yellow b* value changed BUT ; not practical Our referance values ? Why not? First : determine perfect dots in ISO Second: measure Lab with no b.backing
  • 24. A ) ISO 12647/3 • ISO color coordinates You can put your new referance values ColorScale mod for new ref. values ISO-Chek mod ISO Lab values has already loaded
  • 25. A ) ISO 12647/3 • Dotgain
  • 26. A ) ISO 12647/3 • Dotgain old ….. 4,5 mm new ….. 3 mm
  • 27. A ) ISO 12647/3 Change the apparatus with a smaller one and make tests
  • 28. A ) ISO 12647/3 • Dotgain %100 %40
  • 29. A ) ISO 12647/3 • Dotgain %40
  • 30. 0,78 66,8 0,81 69,5 0,82 67,8 1,14 63,6 density % dot gain • Dotgain A ) ISO 12647/3 *Recordings are done by automatic measurement mode
  • 31. While the Q. Engineer measures and records the dots to ERPVideo-1 : Picture .
  • 32. Daily Printing Quality Report Ref. densities difference Operator succes DG Production Name
  • 33. WEEKLY P. OPERATOR DENSITY SUCCES REPORT
  • 34. Averages DG average The values to be applied to CTP rips
  • 36. /25 36 For consistence Printing DG, plate controls is obligatory Every week produce a test plate which has a “plate scale” job on it. Plate Scale
  • 37. Measurements are done and recorded by a plate measurement device. Then the program calculates the dot gain of the plate
  • 40. %2, %98 and % 50 tone values are measured with plate densitometer by the prepress man to understand if there is an abnormality or not. If the values are seem to be changed, he produce a test plate for exact measurement and calibration Daily Plate Checking A tone scale stays on the bended side of the plates is checked daily. Plate is taken before P&B machine for measurement. only Plate Plate + Press Applied dot gains
  • 41. While the Q. Engineer evaluates and records the print defects to ERPVideo-2 : B Printing Defects Checking
  • 42. Printing Quality Report Solve mains Notice news Main target:
  • 43. DEFECTS INCQC points PAGES B Printing Defects Checking
  • 44. INCQC defects table is used B Printing Defects Checking
  • 45. So ; we are checking ourselves like we are in competition INCQC everyday B Printing Defects Checking
  • 46. First run or restart - following a stop copies: Customers complains mostly : from the “startup “ newspapers or “restart - following a stop ” newspapers. Because mechanically they are the worst. salable , low quality, not salable, B Printing Defects Checking
  • 47. C Consumabels Reporting a) are being used (Current) Ex: Newsprint Evaluation Report b) Test metarials Target is; To prepare a list to our purchasing department. Show preferred and not preferred So we ask: not to bought unwanted, instead, the preferred if possible much
  • 48. every month automatically produced by ERP
  • 49. Printing plant / Type of newspaper -IFRA reel code- / Newsprint making machine number Weight is for weighted average
  • 50. forms to the chief of printers Point are given as ; 5 Better 4 Good 3 Normal 2 Bad 1Worse
  • 52. Described by our personals; criterions , weights 4 different working areas Ex: Ex: Register and tension control Cleaning Reel Stand Ink and water adjustments
  • 53. Ex: 45gr. Std Newsprint Newsprints from top to bottom they are in 3 groups GOOD, BAD, WORSE GOOD BAD
  • 54. Printing Quality Management Try to get ISO Newspaper standart check printing defects Report newsprint AS a SUMMARY
  • 56. 56 /56 any questions? _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Muharrem YAŞAR ZAMAN Newspaper Quality & Coord. Manager Ahmet Taner Kışlalı Cad. No:6 Yenibosna / İstanbul / Türkiye +90 (0)212 454 87 03 m.yasar@zaman.com.tr for contact: