The four familiarity and two controls in the quality inspection of books and periodicals are so important!

The "four familiarity and two controls" in the quality inspection of books and periodicals are so important!

The production of a book involves the coordination and cooperation of multiple links and departments such as prepress processing, printing processing and post-press binding. Post-press binding is the final process of a book or a printed product (that is, through the whole process of binding and binding of printed sheets), and it is also one of the important factors related to the overall effect of a book.

The production of a book has to go through dozens of processes from the publishing house to the printing factory. If there is a quality problem in the final process of binding, the small one will be reworked, and the large one will cause great waste and loss, and bring great harm to the society. bad influence. It is understood that in the quality inspection of books (including books, picture albums, this book, etc.) every year, the most problematic is the binding process, so the unqualified products account for more than half of the total unqualified products, which shows the seriousness of the binding quality problem.

As far as the author understands, most of the quality problems of books and periodicals are found after the finished product is completed. This problem reflects the lack of attention to process control during processing. The binding process is long and the process is cumbersome. The detection of this process is also very difficult. , According to the author's many years of experience in this work, it is crucial to achieve four familiarity and two control in quality inspection work.

four familiar

1. Familiar with standards and requirements

It is necessary to be familiar with and master the quality standards of GB/T and CY/T of various countries, as well as the requirements of various quality standards of the region and the enterprise, and be familiar with the quantitative data and qualitative requirements in the standards.

This article should be regarded as one of the basic theoretical knowledge that a quality inspection worker is most familiar with. Because these standards, especially the standards formulated at the national level, are the basis for evaluating the quality of books and periodicals. That is, those that meet these standards are qualified products, and those that do not meet these standards are unqualified products. Those that exceed the standard (higher quality requirements than the standard) can be considered for the evaluation of high-quality products. As a quality inspection worker (including quality inspection station, quality administrator and quality inspector), if you do not know or understand these standards, you will not be able to do these tasks, and you will not be able to persuade others to carry out this inspection work. Therefore, it is very important to be familiar with and master the provisions of various quality standards.

2. Familiar with the technical process, work process and technical requirements

Familiar with the technological process, work process and technical requirements of the process under the jurisdiction (such as the binding process).

The equipment for the binding process is very complicated, the commonality between the various models is very small, and the process and top-up methods are many and complicated. As a binding quality inspection worker, you are not required to be able to do it (it is also impossible), but you are in charge of the process. You must be familiar with, understand, and only have the right to speak after you have a thorough understanding of these process technologies, so as to analyze the reasons for the quality problems that arise and solve them. Convince the operator in question and deepen your understanding of the importance of quality. This requirement is the second basic theory that quality inspection workers must know.

3. Familiar with the key points where quality problems are prone to occur

This article refers to the common manifestations of quality problems that are easy to occur after books and periodicals are produced. Such as character wrinkles, wrong posts, too many posts but few posts, page drop, unqualified finished product size, etc., especially the quality problems that affect readers' use, which small process is the cause.

Whether it is a stand-alone machine or an individual, it is necessary to strictly control the standard requirements of the process, and to find and control the unqualified semi-finished products in the process as soon as possible, so as to avoid the discovery of books and periodicals after the processing is completed (and after three sides are cut). cause irreparable damage. The focus of quality inspection should be in the processing process. Only when the process control can be strictly adhered to can the product quality be guaranteed.

4. Familiar with and conscientiously do the four inspections

The four inspections refer to self-inspection, mutual inspection, random inspection and inspection of upper and lower processes. The four inspection work is the main work that the enterprise engaged in the quality inspection personnel should do. The four inspections should establish institutional constraints to control the occurrence of substandard products.

Self-inspection: The production operator conducts self-inspection of the semi-finished products produced by himself in the process of processing, and solves the problems found in the self-inspection at any time.

Mutual inspection: refers to the mutual inspection and mutual supervision and assistance between the single machines in production, between the front and back of the production line, and between the operators of the work surface. In this way, the problem can be solved by reminding each other in time.

Sampling inspection: refers to the regular or irregular random inspection of semi-finished products carried out by workshop inspectors in normal production. The number of random checks should be balanced, so that every single machine, linked production line and individual are randomly checked. Spot checks must be recorded and based on the standards set by the enterprise itself. (Because the enterprise standards are set by themselves and are higher than the national standards), spot checks should be recorded by percentage method. The spot checks should be fair and reasonable to convince the respondents Oral, and the results of random inspections are announced to the public on a monthly or quarterly basis. Those who are good should be praised or rewarded, and those who have many substandard products and failed to meet the requirements of quality standards should be criticized and punished. Rewards and punishments must be clearly defined, and the good and the bad must not be one pot and one big pot of rice. In the end, it resulted in an overall decline in quality.

Layer-by-layer inspection of upper and lower processes: Refers to the unqualified products that will always be stuck in the previous process in the next process. If there is no unqualified product stuck in the previous process, it will be criticized and punished (a series of penalties will be imposed). This management is also called the layer-by-layer gatekeeping system. In this way, in the process of multi-process processing, every link from the first process (process) will be stuck with non-conforming products.

Only by strictly implementing the four inspections, the final product quality will be guaranteed.

two controls

The two controls refer to the two inspection tasks and contents of process control and product control. When carrying out "process control" and "product control" work, the basis is the enterprise standard (at least GB/T and CY/T in national standards), so as a quality inspection staff (including quality inspection station, enterprise quality First of all, it is necessary to understand and master the basic theoretical knowledge (four familiar contents) of scientific management of the quality of books and periodicals. Guarantee the qualified product quality.

1. What is process control?

Process control in the binding workshop refers to the detection and control of each link between the first process (over-counting, page collision, and material opening) to the last process (cutting into books and packaging) after printing semi-finished sheets into binding. In the process control, the "four inspections" mentioned earlier should be done.

The basis of process control is enterprise standards, which are generally higher than national standards, in order to ensure the qualified quality of the finished products of the enterprise. Without strict process control, the reliability of qualified product quality cannot be guaranteed.

2. What is product control?

How to test the quality of books and periodicals? Product control refers to the quality inspection and control before the binding workshop processes the printed products into books and periodicals that can be read and used. The product control range is the inspection of the appearance and the book block according to the different installation methods.

(1) Detection of paperback glue binding

Appearance: Indicates that the paperback is free of oil and dirt, and the back of the book is flush without wrinkles, blistering, holes, ridges and broken heads; the layout and the back of the book have accurate specifications; the thickness of the adhesive layer is correct, no glue overflows, and the indentation line is accurate; after cutting The four corners of the finished booklet are vertical, without skew, curling, and the incision is smooth without knife flowers and upper and lower knives. The finished product size is consistent with the standard requirements. The cover matches the book block.

Inside the book block: the sticky mouth is correct and firm without skew, the sticky mouth size meets the standard requirements, the page number layout is arranged in the correct order, the page number tolerance meets the requirements, no more or less posts (pages), no wrong posts (pages), no white version, Torn pages, dirty pages, folded corners; groove depth and spacing are correct. The whole book is bonded smoothly and firmly without falling pages, loose pages, front and rear tearing pages and book block breakage. Book block and cover match.

(2) Detection of hardcover books

Appearance: The hot stamping graphic position is accurate, there is no skew, no hot stamping, hot paste, and it is firm and does not fall off; the flap is consistent on three sides and the size is correct; the incision of the book block is smooth, no knife flower, no curling: the round shape and ridge of the round back book The height meets the requirements, the front incision of the square back is straight, and there is no rounding phenomenon; The bookcase and the book block are in the correct and consistent shape. The fitted hardcover book has a flat and clean appearance, the four corners are vertical without distortion and skew, the book slot is firmly bonded and flat without wrinkles and breaks, and the surface of the bookcase is not warped or uneven.

In the book block, in addition to the content of the paperback glued binding [that is, "inside the book block" in (1)], the monitoring content of the hardcover book block also includes: the ring lining has a flat and correct width, and the lining is flat and firm after gluing. , There are no wrinkles and wavy lines on three sides and falling off; the book block and the middle seam of the bookcase are firmly bonded. The needle position, number of needles, and needle distance of the locking thread are correct, and there is no broken needle hole, missing lock, broken thread, skewed roll and post, and lock interlayer phenomenon. After the book is locked, the sequence is correct, the tightness is appropriate, and the thickness is consistent.

(3) Detection of saddle-stitched books

Due to the simpler process of saddle stitching and less content during detection, the main points are as follows:

a. The book blocks are arranged in the correct order, and the page number tolerance meets the requirements. Not many posts, no dirt, oil, torn pages, folded corners. The wire diameter is appropriate, the booklet is firm and the inner pages will not fall off, the position of the saw is accurate, and the spacing meets the requirements.

b. After cutting, the booklet has no broken head, knife, curling or distortion, the appearance is smooth and wrinkle-free, and the size meets the standard requirements.

The test content and basis of the above three commonly used installation methods are all subject to the national standard GB /T and CY /T (the enterprise standard is higher than the national standard, it can be used, and the lower one cannot be used and recognized).

The items and contents of the above inspections all have quantitative data, and there are qualitative requirements for those that cannot be quantitative. It is hoped that workers engaged in book quality inspection must learn and master the relevant national standards and the process technology of the processes they contact and govern. The leaders of quality management should often go to the factory to have a deep understanding, study carefully, discover problems, assist the front-line workers to improve their skills, and contribute to the production of good books and good books.

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