Digital Printing Press Finishing Machine Adjustment
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Solution Overview
Problem
In digital printing systems with multiple processing machines, the changeover between production orders often results in inefficiencies such as material waste and extended production times due to the need for idle cycles during machine adjustments, which cannot be continuously varied and result in production delays and material loss.
Innovation Solution
Determine the longest adjustment time for the further processing machine and initiate its adjustment as soon as the last printed product of the previous order is completed, allowing upstream components to process the next order during this time, ensuring seamless material flow and minimizing waste and production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If idle cycles are inserted during machine adjustment, then the further processing machine can be adjusted to different formats, but material waste occurs and production time increases
Solution Approach 1:
The further processing machine begins adjustment operations in advance while the printing machine is still printing the transition run. By determining the required adjustment time beforehand and starting the adjustment as soon as the last printed product leaves the machine, the system prepares for the next format change without waiting for idle cycles, thus eliminating material waste associated with idle cycles.
Solution Approach 2:
The printing machine maintains continuous operation by printing a transition run during the adjustment period of the further processing machine. This ensures that the printing material web keeps moving through the system without interruption, and the further processing machine resumes processing immediately after adjustment, maintaining continuous useful action throughout the production line.
2Adaptability or versatility
If idle cycles are inserted during machine adjustment, then the further processing machine can be adjusted to different formats, but production time increases
Solution Approach 1:
The system determines the adjustment time required for the further processing machine in advance and initiates the adjustment process as soon as the last printed product of the previous order leaves the machine. This preliminary planning allows the adjustment to occur during the transition run printing, eliminating the need for separate idle cycle time and reducing total production time for format changes.
Solution Approach 2:
By maintaining continuous printing of the transition run while the further processing machine adjusts, the system eliminates idle cycles and keeps both machines productive throughout the changeover process. The printing machine operates continuously while the further processing machine performs its adjustment, and then both resume processing the new format without interruption.
3Ease of repair
If the printing material web is stopped during adjustment, then the further processing machine can be adjusted, but material flow interruption occurs causing production delays
Solution Approach 1:
The further processing machine starts its adjustment as soon as the last printed product leaves the machine, which is determined in advance. This timing allows the adjustment to be completed before the transition run ends, ensuring seamless material flow without interruptions or stops in the printing material web throughout the adjustment process.
Data Source
Figure 1
Figure 2~3
AI summary
The present invention relates to a method for producing printed products (1) on a production plant (5) equipped with a digital printing press (2) and at least one finishing machine (3) arranged downstream of the digital printing press (2). The printed products (1) are produced according to production orders, for which the digital printing press (2) prints a substrate web (7). The finishing machine (3) further processes the substrate web into printed products (1), with the production plant (5) being reconfigured when different printed products (1) are to be produced with a subsequent production order compared to a preceding production order. First, a time period for adjusting the finishing machine (3) is determined, which requires the longest adjustment time.The finishing machine (3) to be adjusted begins adjusting as soon as the last printed product (1) of the preceding production order (51) leaves this finishing machine (3). The finishing machine (3) to be adjusted begins processing the subsequent production order (52) as soon as the determined adjustment time for the finishing machine (3) has elapsed after the adjustment has begun.