Print simulation
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General simulation
Print process simulation use interactive software to reproduce the operating conditions of complex multi colour printing presses that often cost several million dollars. Simulators are available for different printing process technologies (Offset Sheetfed, Heatset and Coldest Web Offset; Flexographic and Gravure Packaging), includes their consumables (like inks, plates, paper and other substrates) and where pertinent, in-line packaging operations (such as folding, cutting, label creation).
Simulation in education and training
Press operators get ‘hands-on’ experience in quality control and problem solving without the costs, dangers or unstructured training associated with learning on actual presses. A wide variety of printing conditions and problems are covered that are used for training, skills assessment, performance enhancement and process analysis. Simulation is a means of presenting infrequent problems [15] before they happen so that they can be recognized when they do occur. Exercises can evaluate specific competencies and if they are used to solve problems [7]. When possible, simulators training scenarios are linked to industry-standard curricula like PIA (Printing Industries of America), the NAA (Newspaper Association of America) and the Flexographic Technical Association.
Printing simulation
Typical systems include monitoring and cost analysis that allows the training process to correlate with versus the waste, cost and time on a ‘real’ press [8] [9]. The simulators can either be either connected to a press control console (like the 'cockpit' in a flight simulator) or run on standard micro computer hardware with single or multiple screens. Internet-based learning management systems now allow simulation exercises to be made in a one language/location and reviewed in another language by a training supervisor in a different location — what is traced is the interaction with the process, not the local name of the controls.
It is estimated that over 2000 print simulators are installed worldwide (in 2013). Users include technical schools, universities, printing companies and their suppliers, [11] [12] who find that they cut costs, accelerate training time, and give a more thorough grounding in structured problem solvin
Simulators are used alongside real presses in the EuroSkills and WorldSkills competitions to select the best printer.
References
1.Print Solutions, September 2011, The Emergence of Press Simulation Technology, Heidi Tolliver
2.http://en.wikipedia.org/wiki/Ishikawa_diagram
3.GATF World, December 2007, Heatset Simulator levels Playing Field at Quebecor World
4.PressTime (NAA) February 2006, "Pretend Press Runs savle Real-World Dollars
5.Gravure Magazine (Gravure Assoc of America) : December 2004 : pp 56-64, several articles on gravure and press simulation
6.RIND Survey, January 2012, "Simulated press problem focusses on tackling production problems"
7.Printing News, May 14, 2001, "Useful as Training Assistants, Print Simulators taking off in print shops everywhere"
8.What They Think, March 9; 2011, "Press Simulation shows wide variety of uses at Transcontinental Mexico"
9.Quebec Imprimerie, N0 211, 2011, "Au dela de la formation sur presse"
10.http://www.sinapseprint.com/IMG/pdf/Case_study_Quebecor_ST_Cloud.pdf
11.Print/Print&Paper Europe, April 2004, Confronting the skills problem, p 247
12.Wall Street Journal, http://blogs.wsj.com/informedreader/2007/03/04/training-generation-y-to-work/
13.GATF World, May/June 2003, "Using SHOTS"
14.New Heatset Simulator Generation - newsletter1
15.International Circle of Graphic School Directors, 2011 Conference, Norrkoping Sweden, "Development of knowledge and press-test based Heatset training simulator Peter Herman, Laurent Grimaldi and Gerd Carl"
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