operation guide

operation guide
for D-board digital workshop


purpose for this guide
1. Help operators to have a whole picture of the D-board production
2. to keep the operater under a safe working space
3. to have the jobs been well organized
4. to prevent loss on supplies and material
this guide is not a operation manual for certain machines, please refer their manual for the details.
operation guide for D-board digital workshop


Index
1. Workflow and Machine operation
2. Safety rule and Hazard subjects
3. File Management
4. Preventive maintenance of machines
5. Tips for cutting processes
6. Tips for printing processes
7. Tips for assembling and shipping packages
operation guide for D-board digital workshop


1.
Workflow and Machine operation
operation guide for D-board digital workshop
Mimaki JFX200
Print pdf
RIP PC
Rasterlink 6 RIP
i-cut Production cousole
ESKO PC
1. re-name file;
2. add registration
mark
3. save .pdf
confirmed artwork w/ die line
ESKO Kongsburg XN24
Cut pdf
reject
preflight PC


1.1 Workflow and Machine operation
operation guide for D-board digital workshop
artwork preflight
Adobe Illustrator CC and Photoshop are needed for opening the files. Older version may miss some elements during the converting.
This stage should check these details before further process, if errors does not be found in this stage, the files either be blocked by the machine or produced with wrong look. DO NOT ALTER the files in this stage.
1. the graphic and die-line content are the right version
2. the graphics match with die-line
3. no linked images missing (can not go through RIP)
4. no font missing (can not go through RIP)
5. the scale is correct
6. the artwork workspace size fit the media and machine
and you should check stock of the media availabilty
confirmed artwork w/ die line
reject


1.1 Workflow and Machine operation
operation guide for D-board digital workshop
artwork preflight
this process need a in-house data storage sever to keep the files been shared by print/cut stations.
This stage will split the artwork to printing and cutting file, the file should have a link to find and sort with each other. And the file name should help the operators to pick up right material
1. re-name file:
16mm_(DB, DL, HC...)_xxxxxxx.ai
1. re-name file;
2. add registration
mark
3. save .pdf
preflight PC
printing file
cutting file re-name with thickness
media media thickness name
orginal name
file from cleint


1.1 Workflow and Machine operation
operation guide for D-board digital workshop
artwork preflight
1. re-name file;
2. add registration
mark
3. save .pdf
preflight PC
2. add registration mark: (skip this for cut only file)
The 6.35mm diameter black round dot is the registration for cut and print, CCD camera on the cutting head will read it to identify the right location to match the cutting line with print.
That system work with all cutting table with CCD camera, but the size is different on other brand.
For i-cut system, at least 3 registration marks needed for a print to locate die-line, usually 4-5 marks are applied.
In order to make the process easier, ESKO has a free Adobe Illustrator plug-in “ ai-cut” to place the marks.


1.1 Workflow and Machine operation
operation guide for D-board digital workshop
artwork preflight
1. re-name file;
2. add registration
mark
3. save .pdf
preflight PC
2. add registration mark: (skip this for cut only file)
select the eye icon, a round dot will appear as coursor, move it on the poistion and click, the mark will be discharged.
in the meantime, a layer been genernated called “Regmark”


1.1 Workflow and Machine operation
artwork preflight
2. add registration mark: (skip this for cut only file)
the register mark should be placed OUT of the die line
operation guide for D-board digital workshop
1. re-name file;
2. add registration
mark
3. save .pdf
preflight PC
for back (V-cut) or double side cut, a retangle cut frame added on another layer


1.1 Workflow and Machine operation
G_xxxmmxxxx
operation guide for D-board digital workshop
artwork preflight
3. save .pdf- PRINT
Delete all layer except Regmark and graphic layers. *add file name on the edge
save it as G_xxmmxxxxx.pdf
DO NOT OVERWRITE original artwork.
1. re-name file;
2. add registration
mark
3. save .pdf
preflight PC


1.1 Workflow and Machine operation
operation guide for D-board digital workshop
artwork preflight
3. save .pdf- CUT
Delete the graphic layer and
save it as C_xxmmxxxxx. pdf
As the cutting tools will be defined by layers, any actions in different speed, depth, order, side or tool should be placed on different layers respectively.
reg frame: CUT OUT, front partial cut, back
V-Cut on, back
CUT OUT, back or front
1. re-name file;
2. add registration
mark
3. save .pdf
preflight PC


1.2.1 Workflow and Machine operation
RIP(Rasterlize Image Processor)
operation guide for D-board digital workshop
RIP PC
Rasterlink 6 RIP
RIP:
This stage is convert the print pdf to a job for Mimaki printer. the workflow as:
1. Load the print pdf into the Rasterlink 6
2. define its printing resolution.
3. define print orientation (should be same as the media)
4. submit it for RIP
5. create job log and send to printer


1.2.1 Workflow and Machine operation
Print
operation guide for D-board digital workshop
Mimaki JFX200
Print:
this page have to wait till the printer’s training.


1.2.2 Workflow and Machine operation
Cut
i-cut Production cousole
ESKO PC
Cut:
XN24 equipped with a PC control the machine, the interface call “i-cut Production cousole”
the workflow:
1. Load the cut pdf
2. Define tool (with speed, depth) for evey layer
3. Load the media
4. Define the cut order
5. Run the production
6. save cut file*
operation guide for D-board digital workshop


1.2.2 Workflow and Machine operation
Cut
Cut:
XN24 is a easy-handeling cutting table, you do not need to measure the media thickness or size, the operate interface is easy to learn. Before run the production, you should make sure:
1. The right media been loaded.
2. The right tool/knife have mounted on the chasis.
3. No foreign objects in the machine working path
then you can click the “Run” key on the i-cut priduction, the cutting will start.
The machine may stop for broken knife or media debris and V-cut slots clean up, if the media has not been moved, the job can be continued in the same point before the stop.
ESKO Kongsburg XN24
operation guide for D-board digital workshop


2.1 Safety rule and Hazard subjects
safety rule
● Both printing and cutting machines has auto-stop safety sensors to suspend the printing/ cutting heads if foreign subjects pass their sensors. No injuries been reported for hitten by the machine. However, there are a lot damage reported on the cutting/printing head, axis, bearings and platform caused by unexpect run-in objects. So do not allow anyone pass the warnning line while the machine operating. Be sure to stop the machine before you take any action.
● The cuttting table’s vacumm run at 380Volt with working temperature around 50 C, Do not touch it with wet hands.
● The operators often burned by melting gule than cut by the kinfe, wear gloves for using the glue gun. DO NOT Leave a plugged glue gun without attendsion. Athough it may not cause fire, but someone may get hurt by the hot temperature.
operation guide for D-board digital workshop


2.1 Safety rule and Hazard subjects
Hazard subjects
● The UV- cured inks are solvent based mixtures, though they had been certifited as non-toxic chemicals. Keep ventitation as possible. The bottled waste ink should be collected by a profession recycle agent.
● The broken knifves can be recycled as steel, DO not mix with waste paper.
● There is no flammable medias or supplies in the workshop, but everthing is burnable.
NO fire or smoking allowed in the working space.
operation guide for D-board digital workshop


3.1.1 File Management
File Naming rule
pick the right graphic and cut file is the foundation to get the job done right. So the files should be
1. easy to find
2. no confusion with different versions and storage locations
3. no missing parts
Please refer The rule for naming the working files on 1.1, for the job intake from client, follow this
1. create a folder with client’s name for new client, skip this for existing clients
2. create a project folder in the client’s folder
3. name the file with project and item discription
4. add date for revision files.
operation guide for D-board digital workshop


3.1.2 File Management
File Archive
The working files (cut and print .pdf) should be deleted if the artwork been revised after the production. Only different version artwork files may be kept for record purpose.
Archive the artwork every season by the chronological order
operation guide for D-board digital workshop


4.1.1 Preventive
manataince of
machines clean
keep the workspace clean is the best way to keep the machine in good condition. Do not leave anything than the working media on the sucking platform. All rails should be cleaned daily to remove the debris and dust.
operation guide for D-board digital workshop


4.1 Preventive
maintenance of
machines clean
to clean the platform and rail, you need blower (connect to air compressor)
vacumm cleaner
brush rag
operation guide for D-board digital workshop


4.2 Preventive
maintenance of
machines Lubrication
for cutting table, the lubrication for the oscillating rod and rails are necessary maintenance for every two weeks.
operation guide for D-board digital workshop


4.3 Preventive
maintenance of
machines replace the supplies
1. the cutting mat of Kongsburg lasts for three to four years, it should be replaced while distored or broke to keep the media fixture.
2. replace the knife when dull or notches on the cutting edge
operation guide for D-board digital workshop


5.1 Tips for cutting
processes order for cutting
the basic rule for arrange the cutting order
1. Cut the line on the top for overlaping cut (V-cut / P-Cut/ D-cut)
2. Cut the register squares first for back cutting
3. Cut the small elements prior than the shape outline
operation guide for D-board digital workshop


5.1.1 Tips for cutting
processes
1. Cut the line on the top for overlaping cut (V-cut / P-Cut/ D-cut)
cut the register square and reverse them
turn the back up, mirror the cutting file, perform V-cut and clean the slots after V-Cut
the double side registration method is a patent of Dayeh
die cut
partial cut
operation guide for D-board digital workshop


5.1.2 Tips for cutting
processes
2. Cut the register squares first for back cutting
cut the register square and reverse them
turn the back up, mirror the cutting file, perform V-cut, partial cut, die-cut at one run (for non-overlaping job)
operation guide for D-board digital workshop


5.1.3 Tips for cutting
processes
3. Cut the small elements prior than the shape outline
the reason to arrange the small elements been cut first is the media will be more stable while less cut been made. The oscillating kinfe may move the media while it is too small to hold by the table vacumm.
operation guide for D-board digital workshop


5.1.4 Tips for cutting
processes
cost for blade and supply
blade for boards thicker than blade for boards up to 10mm V-Cut blade 10mm 38.5 EURO /pc 31.5 EURO /pc 0.79 EURO /pc
the blades for oscillating and static around 38.5 -29EURO per piece , kiss cut at 13.5 EURO and Vcut blade at 0.79 EURO, PVC underlay costs 500 EURO -https://www.esko.com/en/store/kongsberg-bits-blades/knife-blades/kiss-cut-blades/
operation guide for D-board digital workshop


5.2.1 Tips printing
processes
RIP preview looks the same
complicated file create error while ripping
simplyfy file can be ripped
operation guide for D-board digital workshop


5.2.2 Tips printing
processes Print
The Mimaki is a real platform UV inkjet which can perform same spot make-up job if the registration fixed. The alignment rod is a good tool to help the aliment.
For the small size media, the zone vacumm and mask for exposive areas will help the media fixture.
operation guide for D-board digital workshop


6.Tips for assembling and shipping packages
There are many tools and supplies for D-board assembling, the function can be divided by
1. media remove hand tools
2. joint (gule, screw, rivet, tape...)
flat screw driver
staple remover
short Philip screw driver
pipe clamp
punch drill
operation guide for D-board digital workshop


6.Tips for assembling and shipping packages
Only two power tool may use in D-board assembling: Power screw driver and heat glue gun
operation guide for D-board digital workshop


6.Tips for assembling and shipping packages
Basic steps for assembling
1.Remove the notches, V-cut slots and medium inside the mortise before the assembling.
2. Assembling parts with upward notches prior than those with downward.
3. Apply heat melt glue on the V-notch surface for those fully assembled products.
operation guide for D-board digital workshop


6.Tips for assembling and shipping packages
The best parts to protect the D-board from crushed edge are the frame around the cut-out shape. Keep those frame for those knock-down products.
operation guide for D-board digital workshop