Quality Management
We maintain quality by acting as described below.
Operation Flow
Upon receiving an order from a customer, the production office creates a work order under the supervision of the chief. Based on this work order, we arrange for the raw paper, plate making, and die cutting. Once the materials are ready, they are handed over to the factory manager, who distributes them to each printing operator for printing, inspection, packaging, and shipment preparation.
A work order is an A4-sized form that includes the following information: order date, delivery date, name, raw paper, quantity, number of processes, total number of sheets, number of colors, color details, special processing, dimensions, raw paper order meter, finished state, plate information, die information, delivery method, and management number. The work orders are stored in transparent files and used for operation. Each work order is filed and stored for each order.
Files are stored for three years from the date of the last order. In addition to the work order, the file contains a work communication sheet (ink mixing ratio, raw paper flow direction, processing precautions, i.e., operator warnings), plates, films, and color samples. The work order is managed and operated with the number issued at the time of the quotation.
Sales Staff
We handle inquiries, free samples, and quotations. We may also arrange meetings as necessary. Sales representatives handle orders as a general rule. They can also operate printing machines and Adobe Illustrator. In case of any issues, the sales representative will be the point of contact.
Production Staff
We create work orders from purchase orders. After creating the work order, we enter the order date, delivery date, customer name, product name, number of colors, quantity, number of faces, total number of sheets, delivery method, special processing, and remarks into an Excel sheet called a reception form. We also handle ordering raw paper and materials, responding to delivery dates, and operating Illustrator data.
Printing Operator Staff
They set and adjust materials (raw paper, plates, dies) on the printing machine. Products are manufactured when the following check items are cleared. At the end of the day's work, they update the order system status to complete and update the weekly schedule on the whiteboard to complete their tasks. Please refer to the following for check items.
Check Items During Printing
Printing Color
We constantly check the printing materials and the colors specified (actual sample, PANTONE, DIC). In the case of reprints, we match the color to the previous print.
Plate Misalignment
A plate misalignment of 0.3mm or more is unacceptable. We check constantly.
Die Misalignment
A die misalignment of 0.3mm or more is unacceptable. We check constantly.
Half Cut
We check regularly every 2000 sheets to ensure the blade is not cutting too deeply.
Packaging
We wrap products in kraft paper. We attach the enclosed product to the outer surface and indicate the quantity. We package up to about 8kg in cardboard boxes. We fill gaps in the cardboard with cushioning material. If there are packaging instructions, we will comply.
Print Color Quality Management
Printing Rollers
When switching projects, each unit's printing rollers are automatically cleaned with a cleaning solution for over 10 minutes. After automatic cleaning, they are disassembled and wiped with a cloth to remove any residue. Cleaning is repeated until ink no longer adheres to the cloth. After cleaning with the cloth, impurities are removed from the surface of each roller using adhesive tape. Finally, automatic cleaning is performed again to complete the process.
Ink Pots
When switching projects, the ink pots in each unit are cleaned with a cleaning solution and brush. The cleaning solution is wiped off with a cloth. Cleaning is complete when no color remains on the cloth.
About Prototypes (Proofs)
To ensure satisfaction with our products, we recommend confirming the finished product before mass production. It is important to verify colors and specifications. We do not accept complaints about the finished product if a prototype has not been made.
Quality Management of Printing Materials
Plates
・The manufacturer's warranty period for plates is one year from the date of manufacture. We purchase plates on a cycle of once every two months.
・We select the hardness type of the plate according to the printing design.
・In the event of a revision, the old plates are checked and then disposed of to prevent mistakes.
・If a plate is damaged during printing, it is immediately remade to maintain quality.
Die
・Stored for up to three years.
・In the case of deterioration due to the use of rectangular or circular dies, we replace them free of charge (deformed shapes require a fee).
Ink
・We purchase ink from the manufacturer with the date of manufacture indicated. Ink that has passed its expiration date is discarded.
・Ink purchase history is also managed.
・We can provide documents such as RoHS, SDS, and REACH.
Raw Paper
・Raw paper is ordered only as needed at the time of order. For customers who wish, we manage and share the lot number of the raw paper used. Please inform your contact person.
・The stock is kept for three years (manufacturer's recommended adhesive standard value is over 9800; even after three years, it was 10018).
・Raw paper that has been in stock for more than one year from the manufacturer's shipment date is used for adjustments (color matching, plate matching, die matching).
・For inclusions, we use those that meet the manufacturer's standards (not by the number of inclusions but by the total area per 1 square meter. Inclusions larger than 0.05mm are considered, and if the total area per 1 square meter is within 13mm, it is considered a good product).
・We can provide documents such as chemSHERPA, REACH, RoHS, UL/CUL standards, etc.
Cleaning Oil (Ink Cleaning Solution)
The manufacturer does not set an expiration date for cleaning oil. Contaminated cleaning oil generated during the cleaning of printing machine parts is regularly disposed of by industrial waste disposal companies.
Printing Machine Maintenance
UV Lamps
We replace UV lamps based on the manufacturer's recommended 1500 hours.
Various Printing Rollers
We always stock various printing rollers and replace them immediately in case of any defects.
Grease Injection
We perform this once a month.
Printing Machine Cutters
When the sharpness deteriorates, we sharpen them.
All the above maintenance and management records are kept.
Printing Data
・We do not modify the printing data unless requested (for a fee).
・If there is a defect caused by errors in the data provided during printing, we will stop printing immediately and contact you. However, it may not always be possible to detect all errors.
・We store the AI data for printing of the ordered products for 10 years.
Information Security
We have implemented Norton 360 Deluxe on all PCs for protection against spyware, viruses, malware, and ransomware. Some PCs use Norton AntiTrack to prevent tracking. Additionally, we have adopted the WatchGuard UTM to prevent virus intrusion from external sources.
Error Report
If an error is discovered before shipment, printing will be stopped immediately. When an error occurs, an error report (quotation number, product name, quantity, customer, responsible person, discovery date, resolution date, damage amount, error rank, discovery route, error details, customer handling request, cause investigation, recurrence prevention measures, confirmation stamp) is created to prevent recurrence.
The created error report is reviewed by each individual and stored in Evernote with tags (date, error details, error rank, responsible person). There are no penalties for the person responsible for the error.
Complaint Report
If there is any complaint, please inform your sales representative. We will respond immediately. When a complaint occurs, a complaint report (quotation number, product name, quantity, customer, responsible person, discovery date, resolution date, damage amount, complaint rank, discovery route, complaint details, customer handling request, cause investigation, recurrence prevention measures, confirmation stamp) is created to prevent recurrence.
The created complaint report is reviewed by each individual and stored in Evernote with tags (date, complaint details, complaint rank, responsible person). Please refer to the terms of use for complaints.
Accident Report
If, in the unlikely event, a significant loss occurs to the customer, an accident report will be issued to prevent recurrence.
All the above reports are stored in Evernote.
For more information, please see below
