Printing Tips: Using the 20/80 Principle in the Printing Workshop

"80% of revenue comes from 20% of customers." This is the Pareto law that everyone is very familiar with, also known as the 20/80 rule "Most, they can only cause a little impact. A few, they cause major, major Impact". Pareto's law is usually used to explain the distribution of wealth in society. Here we analyze the relationship between the quality of the printing shop and the famous theorem.

First, identify the defective products and waste products and their causes. After enough analysis, the causes of quality problems will be sorted according to their importance. The most important factor is the first one. Everyone may find that the top 20% of them cause 80% of quality problems. As shown in Tables I and II.

Table 1: Analysis of Quality Problems in Printing Workshops with Pareto Law

Quality defects î ‹ Printing machine 1 î ‹ Printing machine 2 î ‹ Printing machine 3 î ‹ Printing machine 4 î ‹ Total defective quantity
Color cast 550 î ‹430 î ‹234 î ‹476 î ‹1690
Imprinting is not allowed î ‹150 î ‹27 î ‹31 î ‹265 î ‹473
White spot 50 î ‹ 45 î ‹ 80 î ‹ 10 î ‹ 185
Printed product scratches î ‹10 î ‹14 î ‹3 î ‹60 î ‹87
Excessive dusting î ‹16 î ‹21 î ‹30 î ‹5 î ‹72
Others 30 î ‹ 37 î ‹ 21 î ‹ 30 î ‹ 118

Table 2: Analysis of Quality Problems in Photographic Workshops Using Pareto Law

The cause of the error î ‹ Camera 1 î ‹ Camera 2 î ‹ Camera 3 î ‹ Total defective quantity
The size is not right î ‹2 î ‹5 î ‹3 î ‹10
Exposure î ‹20 î ‹40 î ‹12 î ‹72
Developer î ‹ 30 î ‹ 40 î ‹ 25 î ‹ 95
Contrast î ‹5 î ‹10 î ‹0 î ‹15
Film error î ‹10 î ‹5 î ‹0 î ‹15

According to Pareto law, we can avoid 80% of the waste by solving the 20% most important reason. Table 1 shows the most frequently occurring problems, and which device is the most prone to problems. The data in the table shows how many times the device has experienced some kind of problem. From this we can see that color shift is the most important issue, and image registration ranks second, but careful analysis, image registration problems mainly appear on the two printing presses (machines 1 and 4), and so on. Through this analysis, you can roughly find out the root cause of the problem and then seek solutions.

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