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Ink Manufacturing

Ink Manufacturing . IOP Meeting 9/15/2010. Reduce Variation. 9 th type of waste - Variation Constant change – Moving target Greatly reduce the chance of finding the Root Cause What was the original reason for the ink change?. Ink T ype V ariations. Tack variances within same ink type

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Ink Manufacturing

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  1. Ink Manufacturing IOP Meeting 9/15/2010

  2. Reduce Variation • 9th type of waste - Variation • Constant change – Moving target • Greatly reducethe chance of finding the Root Cause • What was the original reason for the ink change?

  3. Ink Type Variations • Tack variances within same ink type • Pigment loadings (Toner) • Varnish Types • Oil Type • Tack variances within same ink type • Pigment loadings (Toner) • Varnish Types • Oil Type

  4. Work Content Matrix Ink

  5. Insert Series Early 2010 – 5 Insert Ink types

  6. Insert down to 3 types 2010 Current State Going to single insert formula

  7. Future Condition

  8. Conditions that Effect Ink Performance Variables that can make an ink perform poorly • Temperature • Fountain Solution • Misc. Press Variables

  9. Temperature • Fountain Solution • Blanket • Plate • Roller Settings • Ink Ball • Vibrator

  10. Fountain Solution • pH • Conductivity • Surface Tension • Bacterial Growth • Water Setting

  11. Misc Variables • Paper • Alkalinity/Acidity • Paper surface • Blanket Condition • Plate Condition • Job Coverage • Light/Heavy

  12. Door to Door VSM (high level)

  13. CRT Raw Materials Manufactured • Varnish • Pigment Dispersion • Ink • PMS • Ink Jet Purchased Bulk • Resin Solutions • Dispersion Vehicles • Dry Pigment • Oil • Wax

  14. Varnish Raw Materials Resin 5365 • #1 used Solution this year • CRT sets specs • Measure and Compare

  15. Cloud Point Testing Cloud Point temperature is measured by the • Supplier • CRT 2. Res. soln. & oil mixed via Flacktek prior to testing 1. Resin solution 35 Rail cars = 6.3 million pounds of solution 3. Test solution at 230 °C (note the clarity as the stir bar is visible) 4. Following the test: the res. soln. crashed out of the oil

  16. Dispersion Raw Materials Pigment • Carbon black – 100% 1 supplier • Yellow – 90 percent 1 supplier • Red – split between 2 supplier • Blue – split between 2 suppliers Dispersion Vehicle • 3 suppliers • Project for making our own in the future

  17. Dispersions Measurements • Bleach for strength • Viscosity of finished dispersion • Grind check • Draw down compare against STD • L^A^B values calculated for DE94 • Gloss

  18. Pigment Particle Size • Method development being designed for • Yellow • Red • Black is showing good signs of repeatability • Blue was proved out in a RCA project.

  19. PSA Problematic particle size distribution with blue Particle size distribution of Cyan after one pass milling (retain from ink made same time that Rock had piling issue) Mean size: 410nm Median size: 170nm

  20. PSA (cont) Desired particle size distribution with blue Particle size distribution of Cyan after double milling Mean size: 174 nm Median size: 161nm

  21. Overlay comparison PSA (cont) Yellow line—problematic (with tail at larger particle size) Red line------improvement made

  22. Ink Measurements • Tack • Viscosity • L^A^B • Grind • Opacity

  23. DE 94I • DK1001MD 6-1-10 through 8-5-10

  24. Tack DK1001MD 6-1-10 through 8-5-10

  25. Viscosity DK1001MD 6-1-10 through 8-5-10

  26. Variation prevention • Gauge R&R of instruments • Standard work in Manufacturing • Ink • Varnish • Dispersion • Standard work in the Lab QC process • Q4 Database

  27. Gauge R&R Type 1 Gauge R&R • Gloss Meter • Densitometer • Shell Cup • More to come… • A Type-1 GR&R (1x1x25) was conducted to validate the test since the manufacturer does not perform the test • The GR&R was successful as the %Var(Repeatability) was < 30 % (26.65 %)

  28. Standards for 59 Ink Making Steps Check do Check Each standard follows the “check do check” Total Quality Management standard.

  29. Q4 Problem Solving Q4 (A3) data base set up and trained to create a “problem solving” culture.

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