There are three main reasons for wasting time on the binding line: equipment failure, pre-startup preparation and machine adjustment, and abnormal materials. To improve the production efficiency of the binding line, we need to start from the following aspects.
maintenance
Maintenance is a cultural quality. Evaluating the quality of the operator based only on the amount of production will cause the habit of not paying attention to maintenance. If you have a strong sense of quality, you will turn off the machine and adjust the machine when you encounter a problem. Although it is tiring to remove the old knife from the machine, this time is worth the time.
In order to extend the tool change cycle, some bookbinding factories use a low-temperature tempering method, using liquid nitrogen to cool the knife to below 300 degrees Fahrenheit for a period of time. According to reports, if handled properly, the low temperature tempering method can change the microstructure of the knife and increase the strength of the knife. -The cost of secondary low temperature tempering treatment is based on the weight of the knife and the number of knives to be treated.
Reduce preparation time before starting
In order to reduce the preparation time before starting the machine, some people advocate a one-minute die change method. This method was originally developed from the automotive industry. It divides all tasks into internal and external categories. Internal tasks can only be performed during shutdown, external tasks can be performed while the machine is running. Preparatory work is a way to reduce internal tasks. For example, check whether all the tools and materials required for the preparation work before starting the machine are correct and applicable? If yes, are they layered and easy to get? Are all tools and materials working normally? Recording the adjustments and operating conditions of the equipment helps to identify areas that need improvement.
The adjustment of the new generation of bookbinding machines is simpler, and most of them use programmable logic controllers (PLC) to control the preparation before starting, display the production status and perform fault diagnosis.
Miller Martini's Prima saddle stitcher has an automatic, computer-controlled pre-start-up preparation system, which can directly adjust the machine and timing adjustment. The automatic adjustment is performed by a PC controller. Repeatable settings allow work data to be stored on disk for later recall and reuse. While the current job is still in progress, you can program the next job. According to statistics, the entire preparatory work before starting up, including data input, can be completed in 10 to 15 minutes.
Smooth paper
Some experts believe that folding and transporting the folded paper to the collating table accounts for 80% of the saddle stitching process. Some problems that may occur when loading the signature bucket, such as: the paper is skewed, curled, torn, the signature is not compacted when folded, is not crisp, and the signature is uneven, etc. These problems will cause paper It becomes very difficult, so that the speed of the stapler is greatly reduced.
The signature recognition device helps to feed paper smoothly. This device has a sensor inside the feeder that can optically scan the signature. It can measure the prescribed signature section, and compare the measured value with the preset value that has been automatically stored in the device at the beginning of production. Deviation signatures will be detected and detected Removed from the production line.
The BestOsakoSystem368, a medium-volume booklet launched by Best Graphics, features a central console for monitoring speed, counters, fault displays, and paper jam alarms.
Rosback Company launched Lynx line 724 saddle stitching stapler, the design and production capacity is 500 ～ 32000 copies per day. Its characteristic is that it has a 4-bucket vertical paper feeding device, each station can hold 9in (22.86cm) paper stock and can load paper when it is turned on.
Heidelberg's Stitchmaster 270 medium-capacity saddle stitching machine, the signature bucket can be set up or horizontal. The vertical structure can hold more signatures, thus reducing the number of paper loading. This feature can also reduce the operator's fatigue, they can determine whether to make it into a standing or horizontal type according to the specific conditions of each batch of work.
Full service Mailers installed a Fenimore-Vijuk 920 Sidewinder with 9 signature buckets, which can be used for the production of booklets in short batches. Sidewinder uses a vertical rotary paper feed device. Its signature bucket system allows users to change the signature bucket stations according to the live batch size, and can adjust each signature bucket to accommodate paper of various thicknesses. Materials or signatures. The rated speed of Sidewinder is 5000 books / hour, and it is still good if it is opened to 25,000 books / hour.
Add supporting equipment
The increase in the efficiency of the printing shop will inevitably put pressure on the binding. In order to speed up business turnover, it is better to meet the various needs of customers by configuring suitable new and efficient binding machines or adding supporting equipment such as inkjet devices or mailing tables behind the binding machines.
Time-saving auxiliary equipment
People now install automatic counting and stacking machines behind the binding machines. Many people have installed a continuous paper feeder and signature hopper feeder, but the binding of book blocks should be done in the printing workshop. For the side of the waste paper next to the three-sided cutter, an automatic system can be designed to suck them into the hut where the waste paper is piled by continuous air flow, and then pack and transport away from there. The binding workshop often has a large number of calendars to be bound. If you can complete the saddle stitching and punching on one line, you will save a lot of time. Auxiliary devices that can save time include strapping machines, shrink packaging machines, and various counting and weighing equipment.
Willing to spend time on training
Operators should be trained in a planned manner, especially when installing new machines, as much time as possible must be arranged for training. During the training, please ask the maintenance personnel to participate, because the machine can only be repaired if you are familiar with the operation of the machine.
Finally, remember that "fast" is not necessarily good. Only by handing over the neat and clean products will we be able to recover the payment. The customer doesn't care how fast your machine is turning.
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