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Accuracy is essential for the coding and marking industry. However, printing errors still occur, especially in high-volume industrial printing where frequent data changes and complex workflows are involved.
When such issues happen, it will significantly slow down the production processes and increase downtime expenses. Therefore, manufacturers must overcome them with an effective strategy. Explore the following to discover a complete strategy and optimize your printing process.
Common Printing Errors in High-Volume Production
Errors in the printing process can arise and cause delays, inefficiencies, and quality issues. To better understand them, let’s examine the most frequent errors and their impact on the production process.
Misprints and Smudging
Misprints and smudging typically occur in high-volume printing production. For misprints, it may happen when printed content does not align properly. It can also arise when you are using incorrect fonts, designs, and colors.
Conversely, smudging occurs when inks fail to dry properly or quickly enough. The result often looks blurry or incomplete, which reduces the overall quality and professionalism of the printed product.
Unreadable Barcodes and QR Codes
Aside from misprints and smudging, unreadable barcodes also become printing errors that may happen in high-volume production.
Barcodes are essential for inventory management and tracking and any issues in their readability can cause serious impact. Unreadable barcodes, even with a small error, can result in delays in processing and product tracking. In industries such as pharmaceuticals or food, even minor barcode errors can compromise compliance, disrupt supply chains, and increase the risk of costly recalls.
Incorrect Date Codes and Batch Numbers
Similar to barcodes, batch numbers and date codes are essential for ensuring traceability and products’ safety. Errors may occur because of incorrect system data or printer malfunctions.
Incorrect or inaccurate codes can trigger regulatory non-compliance, erode customer trust, and even cause large-scale product recalls. In some sectors like food products, it may cause confusion regarding the product’s authenticity and freshness.
Ink Spillage and Overspray
Printing errors, such as ink spillage and overspray, happen when the printing head is clogged or when settings are incorrect. It can cause wastage and create dirty marks which leads to unprofessional-looking products. In serious cases, it could also result in maintenance downtime.
Printer Downtime and Maintenance Issues
It is undeniable that high-volume production printers are prone to breakdown and maintenance issues. Frequently, printer downtime can be caused by software issues, mechanical problems, or delays in obtaining replacement parts.
Downtime and maintenance issues, both can have significant impact on production schedules and lead to missed deadlines. Once it happens, it will also affect the increased operational costs and reduced overall productivity.
Effective Strategies to Reduce Printing Errors
To maintain consistency and optimize workflow, manufacturers need to utilize effective strategies to reduce errors in high-volume production. Here are key approaches that can help you mitigate errors.
Regular Maintenance
Conducting regular maintenance is highly recommended to ensure the printer is running at its best. This process entails replacing worn-out components, cleaning print heads, and updating software.
When this regular maintenance is done properly, the likelihood of mechanical failures can be prevented. It can also lower the downtime frequency and reduce the risk of print quality degradation.
Implementation of Automation Tools
Implementing automation tools, like sensors and quality control software, can help you detect printing errors in real-time. If potential issues arise, they can automatically alert operators, adjust the settings, or even halt the printing process.
By their ability to identify problems early, automation ultimately can reduce human errors and ensure consistent print quality. Automation also enables predictive adjustments, helping manufacturers optimize printer performance and reduce unplanned downtime.
Standardizing Print Specifications
One of the most effective ways to reduce the chance of errors and inconsistent results is by standardizing the print settings. It includes regularizing the font size, color profiles, and so on, to streamline the production process.
Employing Advanced Printing Technology
Modern and advanced printer technology come with accentuated features, such as automated alignment, error detection, and better resolution outputs. Employing this type of technology, like thermal inkjet printers, can reduce errors due to outdated equipment.
In the long run, investing in newer technology can improve print quality, ensure faster turnaround times, and have the potential to reduce some environmental problems related to industrial printing.
Read About: Environmental Problems in Industrial Printing
Optimize Your Printing Process for Maximum Efficiency
In order to optimize the printing process for maximum efficiency, it is crucial for any manufacturer to focus on several important factors. Start by organizing the production steps, ensuring printers are adequately maintained, and assessing for consistent quality regularly.
Upgrading to high-performance and modern printers can also be a perfect help to improve speed and reduce printing errors in high-volume production. Moreover, regularizing and standardizing materials like inks and papers make possible consistent results and minimize the chances of waste.
By combining all of these strategies, you can significantly improve print quality and speed up the production process. Ultimately, these improvements not only minimize waste and downtime but also enhance compliance, sustainability, and long-term cost efficiency. Discover and choose high-quality yet cost-effective thermal inkjet printers for your high-volume printing needs at Markcom Global!
References:
https://www.domino-printing.com/en-us/blog/2021/8-wastes-lean-manufacturing-for-printing-and-coding
https://www.minosha.in/blog/common-challenges-in-production-printing-and-how-to-overcome-them/
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