Print Process Control System Quality Level Routing
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Solution Overview
Problem
Conventional print process control systems require excessive maintenance to maintain tight tolerances, which diverts time and resources away from production, and existing inspection systems are inefficient and not adaptable to varying print job quality needs.
Innovation Solution
A print process control method that defines quality levels for print jobs based on color reproduction deviation and routes jobs to appropriate printing devices capable of achieving those levels, allowing for differential pricing and optimized resource allocation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tight tolerances are maintained to ensure high print quality, then manufacturing precision is improved, but productivity deteriorates due to excessive maintenance requirements
Solution Approach 1:
The system introduces multiple quality levels (first quality level with tighter tolerances, second quality level with looser tolerances) allowing dynamic adjustment of print quality parameters. This enables the press to operate at different precision levels depending on job requirements, reducing unnecessary maintenance while maintaining acceptable quality
Solution Approach 2:
The system dynamically assigns different quality levels to different print jobs based on their specific requirements. By making the quality level adjustable rather than fixed, the system can optimize the balance between print quality and maintenance frequency for each individual job
2Manufacturing precision
If inspection systems are used to evaluate print quality, then manufacturing precision is improved, but loss of time increases due to significant setup time required
Solution Approach 1:
The system pre-defines multiple quality levels with associated tolerance ranges before printing begins. By establishing these quality parameters in advance, the system eliminates the need for time-consuming inspection setup and configuration for each individual job
Solution Approach 2:
The quality level system serves multiple functions: it defines acceptance criteria, guides maintenance scheduling, and enables job routing decisions. This multi-functional approach replaces the need for separate inspection systems while maintaining quality control
3Manufacturing precision
If conventional inspection systems are configured for individual jobs, then manufacturing precision is improved, but device complexity increases and adaptability deteriorates
Solution Approach 1:
The system segments quality control into discrete, predefined quality levels that can be independently selected and applied to different jobs. This segmentation allows the system to adapt to varying job requirements without requiring complex individual configurations
Solution Approach 2:
By changing the quality level parameter, the system can adapt to different job requirements. Each quality level contains pre-configured tolerance ranges and criteria, allowing rapid adaptation without increasing system complexity or requiring job-specific inspection system configuration
Data Source
AI summary
A print process control system includes a plurality of printing devices and an order management system to manage print jobs to the printing devices. Each printing device has an achievable quality level corresponding to its ability to meet color printing requirements. Print jobs are assigned a quality level when received within the system. The assigned quality level is used to provide a cost value such that different quality levels result in different prices for a print job. The order management system also routes and tracks the print jobs according to the assigned quality levels and the achievable quality levels of the printing devices. The printing device also are grouped according to achievable quality levels to further manage printing operations.