Job Setting Ink duct setting & Cleaning & Zero Setting Water Emulcification (80 %) Ink water

balance All settings Non Standard proof Roller glazing & Roller condition

Priority Number

Dependent

3 6 4 1 2 5

Operator skill Operator skill Customer usage of machine

frequency Once in a day(ink duct) & once in 15 days(zero setting) For every new job For every new job For every new job For every new job Once in three months

Running

Dependent

Priority Number

Mis registration Gripper registration Speed variation Water Emulcification (20%) Ink contamination Blanket piling Feeder Stoppages Operator skill Plate weak

Machine & Material Usage & GSM variation Operation Ink Property Source of contamination Source of contamination Multiple reason Education & training Usage for long period

5 6 7 9 4 3 1 2 8

PRINTING 5 WHY ANALYSIS & ACTION PLAN FOR COLOR VARIATION S.No. Reasons Why1 Why2 Why3 Why4 Operator unskilled Machine not capable for low GSM Why5 Why6 1) OPL to be made Improper alignment of paper Pile turner operation not done properly 2) Training to be given to operator 3) Manpower not to be changed very frequently 1) OPL to be made for Manual pile making 1) Spares to be arranged & parts replaced. Double Paper Difference in paper sizes Improper cutting operation Size variation in Sheeted paper from Store 1) Paper sheeting Machine brakes & Shaft guide worn out & Chain loose 2) AM to be started 3) OPL to be made for Sheeting Cutting standards not available in Paper cell Operator unskilled Standards not displayed Distarging not adequate Accumulation of dust on discharging rod Not included in check point 1) Standards for qty & margin to be made for GSM : 70-100, 130-170, 220-300 & > 300. 1) SOP to be made Frequency set for 15 days in 1) M/c daily checklist to be made as per revised format PM 1) It will be include in check point. 2) Cleaning schedule for damper cleaning to be made Replace not done / life cycle not established Air / vacuum filter got chocked Poor material of blade Cleaning not proper Cleaning not proper COUNTER MEASURE

Feeder setting not Ok

Pressure foot (Panja), Air nozzles, Lifting suckers, brushes, pile heights, Static charge

Paper sticking

Condense water due to removal of insulation Water droplet from Dampening system Ink accumlation on damper from water droplet Carbon blade worn out Inconsistency in the vaccum Carbon blade brocken Filter chocking

Feeder Stoppages

1) Life cycle to be established.Check list to be revised. Done once a week Done when problem comes 1) Life cycle to be established.Check list to be revised. 1) Standards to be made 2) Training to be made

Feeder setting not Ok Cross Paper Paper lifting sucker worn out Runner setting not Ok Paper waviness Paper upside down Paper problem Paper damage Paper bent at corners (Dog ear) Improper functioning of feeder because of low GSM paper Over run problem 2 Operator Skill Compatibility of this paper with printing machine is not there.

Air pipe choke Replace not done / life cycle not established Standards not set Operator unskilled Due to excess Moisture Sheeted paper not Ok Raw matl not Ok

Water dropping from AC & from Cooler in Sheeting Store Not kept for 48hrs after converting from Roll to Sheet under Weight

1) AC & Cooler to be re located 1) Sheeted paper should be keep atleast for 12 hrs. before sending it on shop floor. 1) Audit to be done for every lot.

Raw matl not Ok

1) Speed target to be set for different GSM of paper. Operator use excess powder to prevent sheets from setoff.

Powder dust / fluff accumulation Excess powder used in 1st side on sensor printing

Blanket piling

Powder accumlation Operator skill Paper Fluff Blunt cutting blade Quality of paper Ink quality

1) Operator to be trained.SOP to be made. 2) Frequency of changing blade to be standerdized.

Ink contaminationSkin formation Paper Fluff Improper griper setting

Oxidation

Duct open

Covers not proper & not used

1) Feasibility of cover to be studied & provided

Mis registration

Deposition of ink / paper fluff on Cleaning / Setting frequency once in a grippers year Variable GSM paper Couneter measure to decide

1) Cleaning to be done once in 3 months.

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