The production of a book involves the coordination and cooperation of pre-press processing, printing processing and post-press binding. Post-press binding is one of the final processes of a book or a finished product (that is, through the whole process of binding and finishing of the printed sheet), and is also one of the important factors related to the overall effect of a book.
The production of a book, from the publishing house to the printing factory, has to go through dozens of processes. If the quality of the final process is bound due to binding, the small rework will result in great waste and loss, and will bring great benefits to the society. bad influence. It is understood that the most frequently problematic in the book (including books, albums, books, etc.) is the binding process, so that the non-conforming products account for more than half of the total non-conforming products, showing the serious problem of the quality of the binding.
According to the author's understanding, most of the current quality problems of books and periodicals appear after the finished products are finished. This problem reflects the lack of attention to process control in processing. The binding process is long and the process is cumbersome. It is also difficult to perform this process. According to the author's years of experience in this work, it is essential that the quality inspection work achieves four familiarities and two controls.
Four familiar
1. Familiar with standards and requirements
Be familiar with and master the national GB/T, CY/T quality standards and the quality standards of the region and the company, and be familiar with the quantitative data and qualitative requirements in the standard.
This provision should be one of the basic theoretical knowledge that is most familiar to quality inspection workers. Because these standards, especially the standards set by the national level, are the basis for the quality of the books. That is, these standards are met as qualified products, and those that are not reached are non-conforming products. Exceeding the standard (higher than the quality requirements of the standard) can consider the quality of the product. As a quality inspection worker (including quality inspection station, quality manager and quality inspector), if you don't know or understand these standards, you can't do it. You can't convince others and carry out this test. Therefore, it is very important to be familiar with and master the various provisions of various quality standards.
2. Familiar with art process, work process and technical requirements
Familiar with the process and work processes and technical requirements of the processes under the jurisdiction (such as the binding process).
The equipment in the binding process is very messy, the commonality between the various models is very small, and the process is complicated and complicated. As a binding quality inspection worker, you are not required to do it (and impossible) but the process of your management. It is necessary to be familiar with, understand, and only have a thorough understanding of these process technologies before they have the right to manage, in order to analyze the causes of the quality problems that arise, and to solve them. Make the operator of the problem convinced and deepen, and deepen the understanding of the importance of quality. This requirement is the second basic theory that the quality inspection work knows.
3. Familiar with the key points of quality problems
This section refers to the probable form of quality problems that are common after the book is made. Such as eight-character wrinkles, wrong posts, more posts, fewer posts, dropped pages, unqualified finished products, etc., especially affecting the quality problems of the readers, which is the reason for the small process.
Whether it is a single machine or an individual, it is necessary to strictly control the standard requirements of the process. It is necessary to control the unqualified semi-finished products in the process and prevent them from being detected early, so as to avoid the late completion of the book processing (and after three sides). Cause irreparable damage. The focus of quality inspection work should be in the processing process, only the process control can be strictly maintained, and the product quality can be guaranteed.
4. Familiar and conscientiously do the four inspections
The four inspections refer to the self-inspection, mutual inspection, sampling inspection and the upper and lower process layer inspection. The four inspections are the main tasks that the company should do for quality inspection personnel. Four inspections should establish institutional constraints to control the emergence of non-conforming products.
Self-inspection: The production operator conducts self-inspection of the semi-finished products produced by the manufacturer during the processing, and solves the problems at any time in time.
Mutual inspection: refers to the mutual inspection and mutual supervision and assistance between the front and back of the 7 production lines between the single machines in production and between the operators of the work surfaces. In this way, the problem can be solved in time and promptly.
Sampling: Refers to the regular or irregular inspection of semi-finished products by workshop inspectors during normal production. The number of random checks should be balanced so that each single machine, linked production line and individuals are spotted. The spot check shall be recorded, based on the standards set by the enterprise itself (because the enterprise standard is self-developed and higher than the national standard). The spot check shall be carried out by means of a percentage method. The spot check shall be fair and reasonable, so that the respondent is convinced. Oral, the results of spot checks are published on a monthly or quarterly basis. Good to be praised or rewarded, and there are many unqualified products and criticisms and penalties for failing to meet the quality standards. The rewards and punishments must be clearly defined, and must not be a good one, and eat a big pot of rice. In the end, the quality has declined.
Upper and lower process layer inspection: Refers to the non-conforming product in the next process that always gets stuck in the upper process. If there is no non-conforming product that is stuck in the process, it should be criticized and punished (to be punished). This kind of management is also called a layer-by-layer system. In this way, in the process of multi-process processing, the non-conforming product is stuck from every link of the first process (process).
Only when the four inspections are strictly carried out, the final product quality will be guaranteed.
Two controls
Two controls refer to the two inspections and content of process control and product control. In the process of "process control" and "product control", the basis is the enterprise standard (minimum GB/T and CY/T in the national standard), so as a quality inspection staff (including quality inspection station, enterprise quality) In addition to the management and management of the basic theoretical knowledge of scientific management books and periodicals (four familiar content), we must always go deep into practice to understand all aspects of process control, and do a good job in quality testing. Guarantee the quality of the product.
1. What is process control?
Process control in the binding shop refers to the detection and control of each link between the printing of the semi-finished printed sheets and the binding from the first process (over-numbering, page-breaking, cutting) to the last process (cutting into books and packaging). In the process control, we must do the "four inspections" mentioned before.
The basis of process control is the enterprise standard. The enterprise standard is generally higher than the national standard. It is to ensure the quality of the finished product of the enterprise. Without strict process control, the reliability of the product quality cannot be guaranteed.
2. What is product control?
How to test the quality of books? Product control means that the binding shop processes the printed products into books and magazines and becomes quality inspection and control before reading and using. The range of product control is detected by the appearance and the book block according to the different loading methods.
(1) Flat-mounted adhesive binding detection
Appearance: It shows that the paperwork is oil-free and dirty, the back of the book is flush and wrinkle-free, foaming, eyelet, ridge and broken head; the layout of the back and the back of the book is accurate; the thickness of the glue layer is correct without overflow, and the indentation line is accurate; The finished book has four corners perpendicular, no skew, curling, smooth cut without knife and upper and lower knives, and the finished product size conforms to the standard requirements. The cover is consistent with the book block.
Inside the book block: the adhesive mouth is correct and firm without skew, the size of the adhesive mouth meets the standard requirements, the page layout is in the correct order, the page number tolerance meets the requirements, no more, less posts (pages), no wrong posts (pages), no white version, Tear pages, dirty pages, chamfers; the groove depth and spacing are correct. The book is flat and firm, without any droppage, loose pages, no tearing pages before and after, and booklet breakage. The book block and the cover match.
(2) Inspection of hardcover books
Appearance: hot stamping position is accurate, no skew, no hot flowers, hot paste, firm and not falling off; the three sides of the floating mouth are consistent, the size is correct; the book core is smooth without knife flowers, no curling: the roundness and ridge of the round endorsement The height meets the requirements, the front cut is straight, and there is no rounding phenomenon; the square corner book has sharp edges and corners, and the rounded smooth pleats are flat and correct. The book case and the book block are in the same correct and consistent manner. The assembled hardcover book has a flat and clean appearance, the four corners are vertical without distortion and skew, and the book slot is firmly bonded and has no wrinkles and breaks, and the surface of the book case has no warping unevenness.
In the book block, in addition to the contents of the flat-loaded adhesive [ie, "in the book block" in (1)], the hardcover book core monitoring content also includes: the ring lining is smooth and the width is correct, and the lining is bonded and flattened. The three sides have no wrinkles and wavy lines and fall off; the book core and the book case are firmly bonded to the middle seam. The needle position, the number of needles and the stitch length of the lock line are correct, and there is no pinhole breakage, leakage lock, broken wire, skewed skew, and lock interlayer phenomenon. The order of the books is correct, the tightness is appropriate, and the thickness is consistent.
(3) Detection of saddle stitching books
The saddle-stitching is simple because of the simple process, and the content is less when testing. The main points are as follows:
a. The book cores are arranged in the correct order and the page tolerances meet the requirements. There are not many posts, no dirt, oil, tearing pages, and chamfers. The wire diameter of the iron wire is appropriate, and the booklet in the booklet is firm and the inner sheet does not fall off, the position of the binding saw is accurate, and the distance is in accordance with the requirements.
b. After cutting, the book has no broken head, knives, curling, and twisting. The appearance is smooth and wrinkle-free, and the size meets the standard requirements.
The test contents and basis of the above three commonly used methods are based on the national standard GB / T and CY / T (the enterprise standard is higher than the national standard available, lower than the non-use and recognition).
The above items and contents of each test have quantitative data. It is impossible to quantify and have qualitative requirements. It is hoped that workers engaged in book quality inspection must learn and master the relevant national standards and the processes and technologies involved in the process. Leaders of quality management should often go to the factory to practice in-depth understanding, seriously study, find problems, assist front-line workers to improve their skills, and contribute to a good book and a good book.
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