quality control progress 2014

UPP- Operation Dept. – Quality Control Unit

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UPP

Quality Control Unit

Quality Control Management

Checked

Agenda

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ISO QMS documents 1

Concepts and Introduction 2

Manpower & Shifts 3

Quality Section Workflow 4

Quality Control Analysis 5

Monitoring Percentage

Rate Of Failure

Kinds of defects

Summary

Customer Complaint & Additional Cost 6

KPI’S 7

Quality Plan 2014 & 2015 8

General Topics 9

Quality Control Back ground

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Unit Till Apr 2013 Starting from June 2013 Till Date

Press Check Data only for

1st sheet Approval

Check Data and color for 1st sheet approval Monitoring No. of processes based On Achieved Production Processes Identify Printing issues with documentation for the samples (Printing / Finishing ) Monitoring products based on Standard Measurements Dampening water measurements Identify TVI Carve Variance for each machine

Binding&Final stage

Daily inspection report

Daily inspection report (last status - % of checked – office copies - flagged copies) Monitoring No. of processes based On Achieved Production Processes Final stage report (Recording for kind of error noticed) No. of process checked related to No. of Error (Error %) Quality in process Binding (New activity added in Hifelx software on July)

Quality Section analysis

Not Available Reduce Customer Complaint Reduce reprint due to quality issues Errors analysis related to Units and kind of errors Root cause analysis to identify pain area and sharing information with all

departments Achieve Monthly Rate of failure Target improve Quality Control activities

Quality Section Workflow

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Finishing

Folding

Binding

Manual Binding

Post pressPress

Ok sheet / Online checking

Measurement devices

Press / Ok sheet / Online checking

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Read Job Docket

Verify job

specifications

Make ready Decision

Start Printing

Check density

Online checking

WaitingNext Process

OK sheet

Not Ok

ok

ok

Not Ok

Press / Finishing

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Read Job Docket

Verify job

specifications

Make ready

Decision Start processing

Check for

defects

Online checking

OK sheet

Lamination FoilingUVEmbossing Die Cutting

Next Process

ok

Not Ok

Not Okok

Post press/ Folding

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Read Job Docket

Verify job

specifications

Make ready Decision

Start FoldingOnline checkingNext Process

OK sheetNot Ok

ok

Not Ok

ok

Post press / Manual Binding

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Read Job Docket

Verify job

specifications

Make ready

Decision

No

Start processing

YesCheck for

defects

Online checking

1st Copy approve

Saddle stitchManual bindingPerfect binding

Next Process

Hard case

Not Ok

ok

Final Stage

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Read Job Docket

Decision

Packing

checking

Rejected by QC

Not Ok

ok

Delivery point

Decision

Accepted copies

SortingRandom

One by One

Corrective actions

Not Ok

ok

Agenda

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Manpower & Shifts


Quality Control Analysis

Monitoring Percentage

Rate Of Failure

Kinds of defects

Summary

Customer Complaint

Additional Cost

KPI’S

Quality Plan 2014

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Quality Control Monitoring % (Printing Nov 2014)

Quality Control Monitoring % Printing ( Jan - Oct 2014 )

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 300

50

100

150

200No of processes done in printing No of processes approved by QC

No

of P

roce

sses

Jan Feb Mar April May June July August September October November0%

20%

40%

60%

80%

100%

120%

57%

33% 35% 36% 37% 39%

72%

97%

80%

96% 96%

Printing

Monitoring Percentage per M/C

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Checked by QC Not checkedChecked By PressSIGN

14198%

32%

Rotoman Monitoring 98%

3895%

25%

KBA215 Monitoring 98%

32%

9377%

2521%

KBA105 Monitoring 98% 2

3%

3255%

2441%

KBA74 Monitoring 96%

Monitoring Percentage per M/C

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Checked by QC Not checkedChecked By PressSIGN

21%

7449%

7650%

KOM 8COL1 Monitoring 98.3%

84%

2211%

16485%

KOM 8COL2 Monitoring 96%

44%

1716%

8480%

KOM 4COL Monitoring 96 % 1

2%

2657%

1941%

ROLAND 500 Monitoring 98%

Monitoring Percentage per M/C – Overall Score – Quality Evaluation per M/C

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54%

2925%

8070%

SM52 Monitoring 96%

KOM8COL2

KOM8COL1

KOM4COL

KBA105

KBA74

ROLAND500

SM52

0%

20%

40%

60%

80%

100%82% 80% 83% 88%

73%82% 77%

Overall M/C Quality Score

KOM8COL2 KOM8COL1 KOM4COL KBA105 KBA74 ROLAND500 SM520%

20%40%60%80%

100%

82%

84%

66%

90%

69% 76

%

77%91

%

93%

70%

94%

72% 81

%

77%

Primaries % (Start) Average Primaries % (End) Average

Quality Control Monitoring % Binding, (Nov 2014 )

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Quality Control Monitoring % Binding, (Jan – Nov 2014 )

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

No of pro-cesses done in Binding

53 72 92 106

152

80 58 52 62 75 63 52 42 40 62 112

85 51 66 91 49 76 73 73 81 71 32 22 52 53

No of pro-cesses ap-proved by QC

32 58 78 83 139

63 43 0 53 63 30 24 13 16 48 100

71 34 59 76 21 51 52 54 63 59 23 10 52 53

1030507090

110130150

No of processes done in Binding VS No of processes Approved by QC

No

of

Pro

cess

es

Feb Mar April May June July August September October November0%

20%

40%

60%

80%

100%

120%

75%87% 88%

96%

76% 72%87% 83%

56%

74%

Quality Control In Binding (Monitoring)

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Checked by QC Not checked by QC

ProcessNo Of proces

sCheck

edNot

checked % Remarks

Folding 804 565 239 70% Etihaad menus

Saddle

72 60 12 83%

Etihaad menus,Few jobs binding done more than one time

P.Binding91 78 13 86%

Few jobs binding done more than one time

56570%

23930%

Checked by QcNot checked by Qc

Folding Monitoring 70 %

6083%

1217%


Saddle Stitching Monitoring 83%

7886%

1314%


Perfect Binding Monitoring 86 %

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Error % 6% 0% 5% 5% 8% 6% 10%

4% 5% 3% 6% 0% 4% 0% 11%

7% 4% 4% 0% 3% 5% 5% 0% 5% 3% 8% 5% 0% 5% 5%

1%

3%

5%

7%

9%

11%

6%

0%

5%5%

8%

6%

10%

4%5%

3%

6%

0%

4%

0%

11%

7%

4% 4%

0%

3%

5% 5%

0%

5%

3%

8%

5%

0%

5% 5%

% of error VS No of processes checked - Nov, 2014Er

ror

%

Rate of failure Nov , 2014

Rate of Failure, Nov 2014

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Rate of Failure, Jan - Oct 2014

Jan Feb Mar April May June July August September October0%

5%

10%

15%

20%

25%

7%5% 4%

6%4% 4% 3% 3% 2%

5%

Rate of failure %Rate of failure 2013 was 23%

Rate of failure 2014 target is 10%

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Kind of defects and No. of repetition Jan - Oct 2014

Kind of Defects 2013

Color varia

tionse

t-off UV

scum

Cutting is

sues

Foilin

g

hickies

rolle

r marks

regist

ration m

ark

Lamination

Folding is

sues

line m

arks

powder

Uneven Jo

ints

Scra

tches

Uneven sp

ine0

10203040506070 61 63

617 18

3 8 5 6 29

194 5 9 3

Total No. of repetion related to kind of defects SEP - DEC 2013

0

50

100

150

200

250

300

125105

250

49

122

5117 8 10 28 20

4917 32

3 8 14 2 3 4 1 1 5 1 2

Summary, Jan – Oct 2014

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Summary Jan - Oct, 2014

Total No. of process checked by QC printing 10600

Total No. of process checked by QC binding 6256

Total No. of process checked by QC final check 5389

Total No. of defects noticed in final check 792

Total No of complaints 17

Total No of rejected jobs 12

Total No of risk delivery jobs 66

Risk Delivery reports, Jan – Nov 2014

Jan Feb Mar April May June July August September October November0

2

4

6

8

10

12

14

16

6

10

6 6

0

2 2

14

12

5

3

Customer complaints 2012 / 2013 / 2014

Customer Feedback Analysisand Complaints and Product Conformity (Till 24 Aug 14)

Complaints 2012 : 63Complaints 2013 : 86Complaints 2014 : 30

2012 2013 2014 % of Diff against 2012 % of Diff against 2013Materials 4 7 Prepress 3 3 1 33% 33%Printing 21 33 14 67% 42%Binding 20 10 6 30% 60%Manual Binding 2 Packing 3 1 2 67% 200%Delay in Delivery 4 2 7 175% 350%Quality 7 0%Stores 1 General 6 22 63 86 30

KPI’s 2012 - 2013 - 2014criteria Target Score Achieved Score

Sr 2012 2013 2014

1 Ensure printing start’s with Standard Measurements i.e. ˃ 85% primaries (Color Density) 15% 0% 4% 14%

2Monitoring No. of processes Achieved by Production related to No. of quality Checked processes i.e. ˃ 95% Monthly result

15% 0% 8% 12%

3 Identify and adjust TVI Carve for each machine 15% 0% 0% 10%4 Devices Calibrations Plan 5% 2% 3% 5%5 Quality Control Team Possibilities 5% 1% 3% 5%6 Reduce Customer Complaint 10% 5% 5% 10%7 Reduce reprint due to quality issues 10% 5% 5% 10%8 Achieve Monthly Rate of failure Target 10% 0% 2% 9%9 improve Quality Control activities 10% 0% 5% 8%

10 improve Team communication and Technical skills 5% 2% 4% 5%Total 100% 15% 39% 88%

Y2012 Y2013 Y2014

Achieved Score 0.15 0.39 0.88

5%15%25%35%45%55%65%75%85%95%

KPI's

Achi

eved

Sco

re

Manpower & Shifts


Quality Control Analysis

Quality Plan 2014 & 2015

Agenda

Quality Plan 2014 - Color Management Improvement

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pressSIGN Software & TECKON measurement devices

عن تقل ال بنسبة الجودة مستوى العالمية % 30رفع القياسية المواصفات من . االستدامة حيث من ، المال رأس وأصحاب والعاملين العمالء رضا مستوى رفع الـ على للحصول الماكينة وضبط إعداد وقت % 50بواقع OK Sheetتوفير للـ الالزمة الطبع أفرخ عدد عن Make-readyتوفير تقل ال % 30بنسبة الـ وارتفاع Operatorتدريب االنتماء زيادة على يساعد مما عالمية تكنولوجيا أحدث استخدام على

بالنفس الثقة. للعمالء قيمة وإضافة ، والمرتقبين الحاليين العمالء لدى الثقة زيادة . للمطبعة للتسويق كأداة استخدامها يمكن كما

o Raising of quality level by not less than 30% of the international standard specifications o Raising of satisfaction level for Customers, workers and stockholders , in terms of sustainability. o Saving the time of adjusting the machine to get the OK Sheet by 50% o Saving number of sheets of Make-ready by at least 30% o Operator training on the use of the latest global technology, which helps to increase the sense

of belonging and high self-esteem o Increase the confidence of existing and prospective customers, and add value for customers. o It also can be used as a marketing tool for the Press.

Quality Plan 2014 - Color Management Improvement

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pressSIGN takes you quickly and easily to your own or international printing standards. pressSIGN’s five easy steps reduce make-ready times and improve your color.

بمكان الخاصة المقاييس أو العالمية المقاييس على الجودة اعتماد إمكانيةالعمل.

الالزم الوقت تقليل النظام هذا باستخدام يمكن محددة خطوات خمس فىالـ على والحصول الماكينة OK Sheetلضبط

pressSIGN Software

40% 73%

• implement FOGRA - ISO 12647- 2 for certificate : Process Standard Offset (PSO) Audit

Quality Plan 2015

Benefits are as follows:1. Material specification is clearThe optical parameters of both ink and paper are specifically described in their respective standard. Incoming materials can easily be verified when materials are inspected.2. Cost of Quality is lowerSince quality is built inside each process the chances of problems from reaching the print buyer is very minimal, if not, totally avoided since these are detected early on and are prevented from being passed on to the next work center. 3. Uniformity & ConsistencyRegardless of shift, the same aim points remain. Whether we have a new employee in either prepress or press, the same output will be met every time. The same quality level will be delivered to the customer tomorrow and several months from now. 4. For print buyersA clear set of requirement is communicated to them (ie. bleed allowance, resolution, ICC profiles, etc.) ensuring the files are prepared according to our press requirements. But even if the customer's files are not conforming to our color requirements we can feed this into a color server that will remap the colors to the colors of our press without any problems. Some form of automation is involved in this process. 5. For print providerCustomer demands will be met especially international buyersA more efficient operation in the printing complex's supply chainA reduction of make ready waste, time and costSpecial cause variation is avoided6. PSO CertificateTo successfully get a PSO certificate is a validation that the entire process in the organization is world class. It is an indication that we are doing the right things right. It tells us that in each process that we do is adding value for the customer. 7. Higher revenue This depends on the company's marketing and sales strategy and also on the day to day operation in production where post calculation is regularly monitored as one of the KPIs. But this is another story.

By the way, once certification is achieved, customer's expectation will be higher, the shareholder's expectation in terms of investment return will be greater. These are just some of the realities and the challenges that I have faced once a company is certified. How to make it sustainable...that is the greater challenge.

Total result

7 Months 17 New reports Done in 2013


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Thanks For your readingThanks for MY Team

for their HARD effort

ArunodayEssam HemadhVinod Kumar

BickashHarriSumanThirtaIchchhaGopalRoyJino

&

Ahmed Gado

quality control progress 2014

Documents

upp quality control

quality control activities

quality section analysis

process ok sheet

quality issues errors

upp operation

job specificat ions

sheet approval monitoring