Forum 2016 Attendees Prepare for the Future with FQC Session

 

James and Michaud
James and Michaud

FORT WORTH, TX—With one question—Are you ready for the future?—RR Donnelley’s Jean Engelke and 3M’s Pam Dorrough began the second Monday session at Forum 2016, with FQC: Preparing for the Future.

Alexander James, Kodak’s indirect channel manager and Ann Michaud, 3M’s senior technical service specialist, took the stage first to give an update on the Flexo Quality Consortium’s (FQC)’s High Resolution Printing – Part B, Print Performance Comparison project. “The goal of the project was to clarify the meaning of ‘high resolution,’” Michaud said. Part A developed a test target, while Part B uses the test target to compare various technical approaches and measure the output print results, record the data and present it to the industry.

In order to get that data, James and Michaud asked for printers to make use of the single color target. The pair outlined a print trial packet, which will contain necessary files, written documentation, and data collection guidelines and spreadsheets. The trials are currently seeking assistance from narrow web; following the completion of those, they intend to move to wide web.

Three trials have been completed so far, at Smyth Companies, WS Packaging Group and Nilpeter. The data collection and analysis for those runs is now underway. Michaud expressed gratitude on behalf of the FQC for those printers, as well as a number of volunteers and participants.

Rich
Rich

Dr. Danny Rich spoke next, offering updates from the Standards Working Group (SWG). Since Forum 2015, two ISO meetings have taken place. Rich gave an update on advancements in the last year to:

  • Technical specifications
    • ISO TS 15311-1
    • ISO TS 15311-2
    • NWIP
  • ISO 13655
  • ISO 20616
    • PQX
  • ISO 20654
  • NWIP ECG (7-color)
Forum 2016 Jason Cagle
Cagle

Following Rich’s SWG update, Jason Cagle came to the podium to give a look at his research project. Cagle was the first place winner of the Rossini Scholarship in 2015 and is a senior at Clemson University; he also worked on the 2014 FLEXO Magazine cover project.

Cagle’s project asked if high resolution imaging techniques, combined with flat top features, provide stochastic screening with high resolution images appropriate for flexographic printing. Recognizing issues with stochastic screening in the past as well as advantages, Cagle pointed to new technology that prompted a reevaluation. “What if we could print all seven colors stochastic?” he asked the audience. “What about process work with spot colors?”

Cagle presented his findings in depth before finally rejecting his initial hypothesis. “Just because you can, doesn’t mean you should,” he said, recalling a former teacher’s suggestion. But he added that the research was not for nothing—using a hybrid stochastic technique, Cagle said he came away with impressive prints.

Also offering a presentation on a research project, Bilge Altay, the second place winner of the 2015 Rossini Scholarship, spoke about smart inks for flexo printing. She defined these inks as those that:

  • Can serve a purpose greater than coloring
  • Contain pigments/polymers with electrical properties
  • Are used in the fabrication of electronic devices

Printed electronics, Altay said, are thin, lightweight and flexible. They reduce production time and cost. The are bendable, rollable—even washable. And they are environmentally friendly. Because silver and gold are prohibitively expensive, she chose nickel pigment, for its lower cost and high conductivity, as well as oxidation reduction and magnetic properties.

Altay
Altay

Through four phases, Altay experimented with different ink compositions:

  • Phase 1: Rheological analysis of commercial inks (graphic and conductive)
  • Phase 2: Study of nickel screen printing ink
  • Phase 3: Synthesis of nickel nanoparticles
  • Phase 4: Formulation with purchased nickel nanoparticles

She went through the results and finding from each phase, illustrating measurements like particle size, a temperature ramp and other data. Summarizing her work to this point, Altay said that low viscosity binders are needed to achieve high solids loading, surface tension and anilox parameters should be compatible both with plate and surface energy of the substrate, nanoparticles require less sintering, and calendaring has a high impact on reducing resistivity. “Printed electronics are unavoidable,” she concluded.

Finishing the FQC session, Tracinda Yaw, a master black belt at 3M, discussed her company’s Lean Six Sigma journey. She began with a look at what Lean Six Sigma is and how 3M was introduced to it by its CEO. In less than a year, Yaw recalled, 3M went from a “standing start to full deployment.” Training was given to all salaried employees as well as some hourly workers. The journey began in 2001 and has grown to include lean awareness, customer collaboration, Hoshin Kanri and a lean value stream implementation.

Yaw depicted a continuous improvement roadmap, following steps that begin at defining business opportunity and success measures and carries through visualizing the current process, finding root causes, developing improvement plans and finally, sustaining gains that have been earned.

Yaw
Yaw

The combination of lean and six sigma, Yaw explained, yields strength in process. Individually, however, they still provide useful skills:

  • Lean
    • Speed
    • Continuous improvement
    • Removes waste
    • Improves productivity
    • Decreases lead time
    • Focuses on customers
  • Six Sigma
    • Accuracy
    • Improves quality
    • Reduces defects
    • Reduces cycle time
    • Reduces variation
    • Focuses on customers