Quality Control Progress 2014

UPP- Operation Dept. – Quality Control Unit
1
UPP
Quality Control Unit
Quality Control Management

Agenda
2
UPP
 ISO QMS documents 1
 Concepts and Introduction 2
 Manpower & Shifts 3
 Quality Section Workflow 4
 Quality Control Analysis 5
 Monitoring Percentage
 Rate Of Failure
 Kinds of defects
 Summary
 Customer Complaint & Additional Cost 6
 KPI’S 7
 Quality Plan 2014 & 2015 8
 General Topics 9

Quality Control Back ground
3
UPP
Unit Till Apr 2013 Starting from June 2013 Till Date
Press  Check Data
only for
1st sheet
Approval
 Check Data and color for 1st sheet approval
 Monitoring No. of processes based On Achieved Production Processes
 Identify Printing issues with documentation for the samples (Printing / Finishing )
 Monitoring products based on Standard Measurements
 Dampening water measurements
 Identify TVI Carve Variance for each machine
Binding
&
Final stage
 Daily
inspection
report
 Daily inspection report (last status - % of checked – office copies - flagged copies)
 Monitoring No. of processes based On Achieved Production Processes
 Final stage report (Recording for kind of error noticed)
 No. of process checked related to No. of Error (Error %)
 Quality in process Binding (New activity added in Hifelx software on July)
Quality
Section
analysis
 Not Available  Reduce Customer Complaint
 Reduce reprint due to quality issues
 Errors analysis related to Units and kind of errors
 Root cause analysis to identify pain area and sharing information with all
departments
 Achieve Monthly Rate of failure Target
 improve Quality Control activities

Quality Section Workflow
4
UPP
Finishing
Folding
Binding
Manual Binding
Post pressPress
Ok sheet / Online checking
Measurement devices

Press / Ok sheet / Online checking
5
UPP
Read Job
Docket
Verify
job
specificat
ions
Make ready Decision
Start
Printing
Check
density
Online
checking
Waiting
Next Process
OK sheet
Not Ok
ok
ok
Not Ok

Press / Finishing
6
UPP
Read Job
Docket
Verify
job
specificat
ions
Make ready
Decision
Start
processing
Check
for
defects
Online
checking
OK
sheet
Lamination FoilingUVEmbossing Die Cutting
Next Process
ok
Not Ok
Not Ok
ok

Post press/ Folding
7
UPP
Read Job
Docket
Verify
job
specificat
ions
Make ready Decision
Start FoldingOnline
checking
Next Process
OK sheet
Not Ok
ok
Not Ok
ok

Post press / Manual Binding
8
UPP
Read Job
Docket
Verify
job
specificat
ions
Make ready
Decision
No
Start
processing
YesCheck
for
defects
Online
checking
1st Copy
approve
Saddle stitch
Manual
binding
Perfect binding
Next
Process
Hard case
Not Ok
ok

Final Stage
9
UPP
Read Job
Docket
Decision
Packing
checking
Rejected
by QC
Not Ok
ok
Delivery
point
Decision
Accepted
copies
SortingRandom
One by
One
Corrective
actions
Not Ok
ok

Agenda
10
UPP
 Manpower & Shifts
 Quality Section Workflow
 Quality Control Analysis
 Monitoring Percentage
 Rate Of Failure
 Kinds of defects
 Summary
 Customer Complaint
 Additional Cost
 KPI’S
 Quality Plan 2014

11
UPP
Quality Control Monitoring % (Printing Nov 2014)
Quality Control Monitoring % Printing ( Jan - Oct 2014 )
0
50
100
150
200
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
NoofProcesses
No of processes done in printing No of processes approved by QC
57%
33% 35% 36% 37% 39%
72%
97%
80%
96% 96%
0%
20%
40%
60%
80%
100%
120%
Jan Feb Mar April May June July August September October November
Printing

Monitoring Percentage per M/C
12
UPP
Checked by QC Not checkedChecked By PressSIGN
141
98%
3
2%
Rotoman Monitoring 98%
38
95%
2
5%
KBA215 Monitoring 98%
3
2%
93
77%
25
21%
2
4%
32
55%
24
41%

Monitoring Percentage per M/C
13
UPP
Checked by QC Not checkedChecked By PressSIGN
2
1%
74
49%
76
50%
KOM 8COL1 Monitoring 98.3%
8
4%
22
11%
164
85%
KOM 8COL2 Monitoring 96%
4
4%
17
16%
84
80%
KOM 4COL Monitoring 96 %
1
2%
26
57%
19
41%
ROLAND 500 Monitoring 98%

Monitoring Percentage per M/C – Overall Score – Quality Evaluation per M/C
14
UPP
5
4%
29
26%
80
70%
SM52 Monitoring 96%
82% 80% 83% 88%
73%
82% 77%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Overall M/C Quality Score
82%
84%
66%
90%
69%
76%
77%
91%
93%
70%
94%
72%
81%
77%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
KOM8COL2 KOM8COL1 KOM4COL KBA105 KBA74 ROLAND500 SM52
Primaries % (Start) Average Primaries % (End) Average

Quality Control Monitoring % Binding, (Nov 2014 )
15
UPP
Quality Control Monitoring % Binding, (Jan – Nov 2014 )
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
No of processes done in Binding 53 72 92 106 152 80 58 52 62 75 63 52 42 40 62 112 85 51 66 91 49 76 73 73 81 71 32 22 52 53
No of processes approved by QC 32 58 78 83 139 63 43 0 53 63 30 24 13 16 48 100 71 34 59 76 21 51 52 54 63 59 23 10 52 53
0
20
40
60
80
100
120
140
160
NoofProcesses
No of processes done in Binding VS No of processes Approved by QC
75%
87% 88%
96%
76% 72%
87% 83%
56%
74%
0%
20%
40%
60%
80%
100%
120%
Feb Mar April May June July August September October November

Quality Control In Binding (Monitoring)
16
UPP
Checked by QC Not checked by QC
Process
No Of
proces
s
Check
ed
Not
checked
% Remarks
Folding 804 565 239 70% Etihaad menus
Saddle
72 60 12 83%
Etihaad menus,Few jobs
binding done more than
one time
P.Binding
91 78 13 86%
Few jobs binding done
more than one time
565
70%
239
30%
Checked by Qc
Not checked by Qc
Folding Monitoring 70 %
60
83%
12
17%
Checked by Qc
Not checked by Qc
Saddle Stitching Monitoring 83%
78
86%
13
14%
Checked by Qc
Not checked by Qc
Perfect Binding Monitoring 86 %

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Error % 6% 0% 5% 5% 8% 6% 10% 4% 5% 3% 6% 0% 4% 0% 11% 7% 4% 4% 0% 3% 5% 5% 0% 5% 3% 8% 5% 0% 5% 5%
6%
0%
5%
5%
8%
6%
10%
4%
5%
3%
6%
0%
4%
0%
11%
7%
4% 4%
0%
3%
5%
5%
0%
5%
3%
8%
5%
0%
5%5%
0%
2%
4%
6%
8%
10%
12%
Error% % of error VS No of processes checked - Nov, 2014
Rate of
failure Nov
Rate of Failure, Nov 2014
17
UPP
Rate of Failure, Jan - Oct 2014
7%
5% 4%
6%
4% 4% 3% 3% 2%
5%
0%
5%
10%
15%
20%
25%
Jan Feb Mar April May June July August September October
Rate of failure %
Rate of failure 2013 was 23%
Rate of failure 2014 target is 10%

18
UPP
Kind of defects and No. of repetition Jan - Oct 2014
Kind of Defects 2013
61 63
6
17 18
3
8 5 6 2
9
19
4 5 9
3
0
10
20
30
40
50
60
70
Total No. of repetion related to kind of defects SEP - DEC 2013
125
105
250
49
122
51
17 8 10
28 20
49
17
32
3 8 14 2 3 4 1 1 5 1 2
0
50
100
150
200
250
300

Summary, Jan – Oct 2014
19
UPP
Summary Jan - Oct, 2014
Total No. of process checked by QC printing 10600
Total No. of process checked by QC binding 6256
Total No. of process checked by QC final check 5389
Total No. of defects noticed in final check 792
Total No of complaints 17
Total No of rejected jobs 12
Total No of risk delivery jobs 66
Risk Delivery reports, Jan – Nov 2014
6
10
6 6
0
2 2
14
12
5
3
0
2
4
6
8
10
12
14
16
Jan Feb Mar April May June July August September October November

Customer complaints 2012 / 2013 / 2014
Customer Feedback Analysis
and Complaints and Product
Conformity (Till 24 Aug 14)
Complaints 2012 : 63
2012 2013 2014 % of Diff against 2012 % of Diff against 2013
Materials 4 7
Prepress 3 3 1 33% 33%
Printing 21 33 14 67% 42%
Binding 20 10 6 30% 60%
Manual Binding 2
Packing 3 1 2 67% 200%
Delay in Delivery 4 2 7 175% 350%
Quality 7 0%
Stores 1
General 6 22
63 86 30

KPI’s 2012 - 2013 - 2014
criteria Target Score Achieved Score
Sr 2012 2013 2014
1
Ensure printing start’s with Standard Measurements
i.e. ˃ 85% primaries (Color Density)
15% 0% 4% 14%
2
Monitoring No. of processes Achieved by Production
related to No. of quality Checked processes i.e. ˃ 95%
Monthly result
15% 0% 8% 12%
3 Identify and adjust TVI Carve for each machine 15% 0% 0% 10%
4 Devices Calibrations Plan 5% 2% 3% 5%
5 Quality Control Team Possibilities 5% 1% 3% 5%
6 Reduce Customer Complaint 10% 5% 5% 10%
7 Reduce reprint due to quality issues 10% 5% 5% 10%
8 AchieveMonthly Rate of failure Target 10% 0% 2% 9%
9 improve Quality Control activities 10% 0% 5% 8%
10 improve Team communication and Technical skills 5% 2% 4% 5%
Total 100% 15% 39% 88%
Y2012 Y2013 Y2014
Achieved Score 15% 39% 88%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
AchievedScore
KPI's

 Manpower & Shifts
 Quality Section Workflow
 Quality Control Analysis
 Quality Plan 2014 & 2015
Agenda

Quality Plan 2014 - Color Management Improvement
23
UPP
pressSIGN Software & TECKON measurement devices
‫عن‬ ‫تقل‬ ‫ال‬ ‫بنسبة‬ ‫الجودة‬ ‫مستوى‬ ‫رفع‬30%‫العالمية‬ ‫القياسية‬ ‫المواصفات‬ ‫من‬
‫االستدامة‬ ‫حيث‬ ‫من‬ ، ‫المال‬ ‫رأس‬ ‫وأصحاب‬ ‫والعاملين‬ ‫العمالء‬ ‫رضا‬ ‫مستوى‬ ‫رفع‬.
‫الـ‬ ‫على‬ ‫للحصول‬ ‫الماكينة‬ ‫وضبط‬ ‫إعداد‬ ‫وقت‬ ‫توفير‬OK Sheet‫بواقع‬50%
‫للـ‬ ‫الالزمة‬ ‫الطبع‬ ‫أفرخ‬ ‫عدد‬ ‫توفير‬Make-ready‫عن‬ ‫تقل‬ ‫ال‬ ‫بنسبة‬30%
‫الـ‬ ‫تدريب‬Operator‫بالنفس‬ ‫الثقة‬ ‫وارتفاع‬ ‫االنتماء‬ ‫زيادة‬ ‫على‬ ‫يساعد‬ ‫مما‬ ‫عالمية‬ ‫تكنولوجيا‬ ‫أحدث‬ ‫استخدام‬ ‫على‬
‫للعمالء‬ ‫قيمة‬ ‫وإضافة‬ ، ‫والمرتقبين‬ ‫الحاليين‬ ‫العمالء‬ ‫لدى‬ ‫الثقة‬ ‫زيادة‬.
‫للمطبعة‬ ‫للتسويق‬ ‫كأداة‬ ‫استخدامها‬ ‫يمكن‬ ‫كما‬.
o Raising of quality level by not less than 30% of the international standard specifications
o Raising of satisfaction level for Customers, workers and stockholders , in terms of sustainability.
o Saving the time of adjusting the machine to get the OK Sheet by 50%
o Saving number of sheets of Make-ready by at least 30%
o Operator training on the use of the latest global technology, which helps to increase the sense
of belonging and high self-esteem
o Increase the confidence of existing and prospective customers, and add value for customers.
o It also can be used as a marketing tool for the Press.

Quality Plan 2014 - Color Management Improvement
24
UPP
 pressSIGN takes you quickly and easily to your own or international printing standards.
 pressSIGN’s five easy steps reduce make-ready times and improve your color.
‫العمل‬ ‫بمكان‬ ‫الخاصة‬ ‫المقاييس‬ ‫أو‬ ‫العالمية‬ ‫المقاييس‬ ‫على‬ ‫الجودة‬ ‫اعتماد‬ ‫إمكانية‬.
‫ال‬ ‫على‬ ‫والحصول‬ ‫الماكينة‬ ‫لضبط‬ ‫الالزم‬ ‫الوقت‬ ‫تقليل‬ ‫النظام‬ ‫هذا‬ ‫باستخدام‬ ‫يمكن‬ ‫محددة‬ ‫خطوات‬ ‫خمس‬ ‫فى‬‫ـ‬OK
Sheet
40% 73%

• implement FOGRA - ISO 12647- 2 for certificate :
Process Standard Offset (PSO) Audit
Quality Plan 2015
Benefits are as follows:
1. Material specification is clear
The optical parameters of both ink and paper are specifically described in their respective standard. Incoming materials can easily be verified
when materials are inspected.
2. Cost of Quality is lower
Since quality is built inside each process the chances of problems from reaching the print buyer is very minimal, if not, totally avoided since
these are detected early on and are prevented from being passed on to the next work center.
3. Uniformity & Consistency
Regardless of shift, the same aim points remain. Whether we have a new employee in either prepress or press, the same output will be met
every time. The same quality level will be delivered to the customer tomorrow and several months from now.
4. For print buyers
A clear set of requirement is communicated to them (ie. bleed allowance, resolution, ICC profiles, etc.) ensuring the files are prepared
according to our press requirements. But even if the customer's files are not conforming to our color requirements we can feed this into a
color server that will remap the colors to the colors of our press without any problems. Some form of automation is involved in this process.
5. For print provider
Customer demands will be met especially international buyers
A more efficient operation in the printing complex's supply chain
A reduction of make ready waste, time and cost
Special cause variation is avoided
6. PSO Certificate
To successfully get a PSO certificate is a validation that the entire process in the organization is world class. It is an indication that we are
doing the right things right. It tells us that in each process that we do is adding value for the customer.
7. Higher revenue
This depends on the company's marketing and sales strategy and also on the day to day operation in production where post calculation is
regularly monitored as one of the KPIs. But this is another story.
By the way, once certification is achieved, customer's expectation will be higher, the shareholder's expectation in terms of investment return
will be greater. These are just some of the realities and the challenges that I have faced once a company is certified. How to make it
sustainable...that is the greater challenge.

7 Months 17 New reports Done in 2013

27
UPP
Thanks For your reading
Thanks for MY Team for
their HARD effort
Arunoday
Essam Hemadh
Vinod Kumar
Bickash
Harri
Suman
Thirta
Ichchha
Gopal
Roy
Jino
&
Ahmed Gado

Quality Control Progress 2014

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