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Real User Stories: Global Color Control


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Last year I was working with a well established company in Pennsylvania that specializes in ‘museum quality’ art and photography books. They were considering several titles for their first Asia production attempt, but the company was concerned the quality that their reputation was built upon would not be upheld by the new contract facility. Additionally, they wanted to implement a color control and monitoring process at their US factory.

The company’s ultimate objective was to bring the proofing of both facilities to within 90%+ of GRACoL 2013 target values using the SpotOn! Visual Match Scorcard. At press we matched the printing color to these accurate proofs. Achieving this goal would ensure their customers continued to receive the same high quality products regardless of where these items were printed, and the company would be able to efficiently control color in two facilities nearly 8,000 miles apart.

This was a job for color experts, so we asked Bruce Bayne from Alder Technologies to spend several days in the Pennsylvania facility and calibrate their new Epson SC9900 proofer. He also installed SpotOn! Verify to bring their quality monitoring and QC assurance procedures to the next level. Moving forward, Verify would be used to control the print process by monitoring and tracking the consistency and accuracy of proofs made in the US and abroad.

Next, the highly skilled Cathay America team used SpotOn! Verify to calibrate and monitor the Epson proofers at the printer’s new facility in Shenzhen, China. Verify’s Visual Match feature guided our calibration work and helped ensure proofers on two continents would match accurately.

Finally, the US based press was calibrated, and the Cathay America team calibrated the presses in China. Both were able to achieve GRACoL2013/CGATS/CRPC6 target values. This was the last step to bring all of the proofing and production devices into alignment.

The next step was to implement a global monitoring and QC assurance system (process control) that would allow our customer to achieve the same high quality presswork over time, regardless of where their books were printed.

Thanks to the support of Bruce Bayne, our China team, and SpotOn! Verify, our customer was deeply impressed by the quality of their first prints from Asia. Both the US client/printer and the photographer whose work we reproduced were thrilled with the quality of the images in this very impressive book. Most importantly, our US client was confident that he could print his high quality museum editions at our China facility.

Since this first successful printing last year, many more titles are now being produced with excellent color. This was possible because of our process control program enabled by SpotOn! Verify.

The details of our method are below.

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Using SpotOn! Verify to monitor and control presswork.

The printer had 10 fairly new, well-maintained Komori presses, each with an Intellitrax scanning spectro. But the intellitrax software was several generations old and didn’t report anything more that solid ink densities (SID).

This limited color data was simply not enough information to tightly monitor production printing and achieve the accurate and consistent color control that we required. The printed images were quite well known, and our client needed assurance the original images could be reproduced accurately.

We decided to print on a slightly larger press sheet so that we could add a second set of colors bars at the trailing edge of the sheet. One control strip was placed in each of the four alleys of the book pages, just below the Intellitrax scanner’s control strip. These 18-patch, custom color control strips were designed to be scanned by a i1Pro2. After scanning, the measurement data was sent to SpotOn! Verify.

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Press proofing key images before the production run. Notice the SpotOn! Version 2 color control strips  that run vertically. This allowed for SpotOn! Analyse to measure and display comprehensive printing data.

 

If the press has shifted too far out of spec, the ink can be levelled accurately by scanning the press color bar with X-Rite’s Intellitrax system. The next step is to scan the custom color control strips in each of the four alleys with the i1Pro2 and SpotOn! Verify to monitor compliance with CGATS21/CRPC6 target values.

Verify clearly displays the data from each scan for the operator to evaluate compliance with the CGATS21/CRPC6 target values. If the press is out of compliance, the operator can take further corrective action to bring the press back into tolerance before running color-critical jobs.

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Great color is within reach, and it can be maintained efficiently over time. What it takes is the desire to control the process.

-  Joseph J. Pasky, Shenzhen

Test Form that Bob Signed

Patches: C, C50, M, M50, Y, Y50, Red, Green, Blue, 3/c Black, 100k, 25k, 25cmy, 50k, 50cmy, 75k, 75cmy, paper white

Click Here to try SpotOn! Verify

Real User Stories: Process Control for Seagate


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Long-time SpotOn! user and product dealer Joe Pasky at Cathay America offers insight into the value of process control…

EIGHT years ago, I was asked by Seagate Technologies (California) to help them G7 qualify the 6 printing plants that they used in China and Thailand which produced retail cartons for disk-drives. They were having difficulty with variations in the color appearance of similar product images that were printed at different factories, even though the files and proofs for these images were created by a single color-house in the States. Several runs of cartons were rejected and had to be reprinted; this caused delays in the product release schedules and extra costs.

The original strategy for press checks on new products was to ask the printer to produce a press sheet at make-ready that matched the supplied proofs as closely as possible. This best match was approved and became the master reference sheet for printing all subsequent SKUs that used those particular brand colors and product images.

The problem with this approach was that the printed product images approved at one factory were sometimes different from identical product images produced at other Seagate printers.

As we began to G7 Qualify each of the printers and train them to ‘print to the numbers’, the color differences between the master reference sheets at the multiple printing plants was greatly reduced.

When traveling to the States a few months later, I visited a Best Buy store. I took particular notice of the display of Seagate disk drives; cartons that I had approved several months earlier. Looking at the same and similar cartons side-by-side, I was disappointed to see a noticeable variation in color and balance. I took photos of the UPC codes to identify the printer and began an investigation.

As it turned out, the operators were not being vigilant in monitoring the color during the press run. We implemented a new sampling procedure where a percentage of sheets from the press run were pulled and time-stamped. These were measured by the QC department and reports from each production run were sent to the Seagate China office for review. This procedure required extra effort and attention from the press operators and supervisors, but after several months of monitoring, the printing consistency was improved and variation reduced.

Monitoring the press sheets was effective, but we also wanted to sample the individual cartons after they were formed. But once the carton was die cut from the press sheet there was nothing to measure. The press colorbars were gone. To solve this problem, we built a 7-mm, 14-patch control strip that was hidden in the glue flap and another control strip placed in the tuck-flap of the box. The patches on this strip included two brand-color patches, paper-white, CMYK, 3-color black, and the G7 tone value targets: 25k, 50k and 75k and 3-color, ¼-tone, midtone and ¾-tone tints.

We had the experience of using SpotOn! Verify software to check digital proofs. We realized that we could also use SpotOn! Verify to scan the printed control strips. We took samples of finished boxes from the production runs and used SpotOn! Verify to quickly measure and record the color data. SpotOn!’s reporting function helped us build a quality report and history for each of the production runs.

The press operators also began using SpotOn! Verify during make-ready to measure the control patches to be sure that they were hitting their G7 target values and assure that they would pass the QC department’s ‘pass/fail’ criterion. It was an excellent tool that was very easy to use in production. We no longer use proofs as a color reference; we’re printing 100% ‘to the numbers’.

Seagate was quite pleased with the results. For the past 6-years, each of the factories have been using SpotOn! Verify to monitor color on press and in the QC department, cartons from each of the factories and the images for each SKU were an excellent match to each other. All the printing plants were printing product images that were accurate and consistent from SKU to SKU and run-to-run. Color variation between boxes produced at multiple factories was practically eliminated.

Using SpotOn! Verify to measure these simple hidden color control strips that incorporate G7 data points has made it possible to monitor and improve packaging color reproduction of finished folding cartons across multiple production facilities. Any brand hoping to improve color consistency of printed packaging across a global supply chain could use this approach to improve quality and color fidelity.

Joseph J. Pasky

Cathay America

Shenzhen, China

jpasky@gmail.com