Supply and manufacture (if needed) stencil sets for screen print processes.
Check Existing Stencil sets as fit for purpose (FFP) ahead of usage
Manufacture Missing member stencil(s) if needed
Wash and file screen-sets after production usage.
Manage Screen Inventory (e.g maintain levels / reclaim / order )
Recycle / Reclaim stencils
Replace split stencils
Order new screens as needed
Order required consumables: emulsions, pastes, washes etc
From |
Details |
Art Dept |
Stencil Set requirements on Technical Specifications |
Print Department |
Notification of in usage split screen(s) - Requires priority replacement |
Stencil Departments |
Notification of Missing / Not FFP stencils in screen set(s) that are required on forthcoming processes |
Suppliers |
Repaired / Re-stretched stencils |
To |
Details |
Print Department |
Stencil Sets ready for usage |
Suppliers |
Screen Orders Consumables for stencils |
Stencil Library |
Stencil Sets for rPost-usage Filing |
Suppliers |
Purchase Orders for repair / re-stretch of split stencils |
Technical Specifications for a Screen Print Process detail the corresponding stencil set requirements.
A stencil set requirement contains the follow data attributes
The Design Identifier, artwork status, and description for the Art Work imagery that will be printed via the stencil set.
The Date the screens will be required for usage.
The total quantity of screens that comprise the stencil set.
For each member stencil within the set - its Screen Type (Size and Mesh count), and unique position identifier within the set.
The current State (existence and status) of both the Stencil set and each member stencil.
TOT working practices state that stencil set manufacture can occur only when the corresponding Artwork / Design has been fully signed off.
A specific search filter is used "Can Make" - that limits the records to : - un-started process lines that require stencil that don't exist where the corresponding Art work record
For those stencil requirements with signed off artwork, the stencil department will begin processing the requirements in date required (soonest) order.
Stencil Requirements typically fall into one of the following scenarios.
Scenario |
Details |
Stencil Set Does not exist |
This applies for brand new orders - or for repeat orders where the stencil set no longer exists |
Stencil Set Exists |
Applies for repeat orders where the stencil set is recorded as physically existing and filed within the stencil library. For this scenario see the checking existing stencils steps |
The standard flow for manufacturing stencils is shown here
Dealing with Missing / Defective Stencils
The flow for dealing with missing stencils is shown here
Managing the Stencil Set inventory involves reviewing a dashboard which provides an high level overview and status snapshot of the stencil inventory.
In broad terms, for each type of stencil (by type, read SKU or Mesh Count and Frame Size) a series of aggregate catergorisation totals are calculated as follows
Categorisation |
Business Logic |
Flagged for Reclaim |
An @sum quantity of the stencils by SKU that have been marked as flagged for reclaim By definition these are not regarded as In Use |
Expected |
An @sum quantity of the screen SKU that has been ordered
but not yet been delivered. |
Available to coat |
The quantity of this screen sku that is ready to be prepared for usage. That is, the quantity physically available to be coated with photo sensitive emulsion once prepared.
|
Coated |
The quantity of the screen's SKU that are physically coated with emulsion ready for imaging.
Note this quantity is adjusted according to the following transactions:
|
Required |
This figure is a calculated @sum of the number of screens of this size that are required on all jobs orders that have not yet begun. Specifically it is an @sum of this screen SKU where
|
Coated minus required |
Indicates the number of coated screens in excess or in shortfall of current requirements. Calculated figure of [Coated - Required] |
Total in Usage |
Total number of the screens that have been created are associated to a job order
|
Managing the inventory therefore requires that following activities
Ensuring that Coated Minus Required is a positive number - i.e. an excess of stencils vs. requirements exists
If the above metric is in danger, taking remedial actions
If there are available stencils, coat them (i.e. credit coated balance)
If there as flagged for reclaim stencils - reclaim and coat them to increment the coated balance
If there are expected stencils, prioritise their receipt and process to make coated
Failing the above measure, locate existing filed stencil sets that have not been used for a period of time and reclaim and then coat these.
To assist staff in managing the inventory there are some functions that can be invoked from within the dashboard
Function |
Outcome |
||||||
Adjustment: |
Ability to set / adjust specific categorisations without going through transaction debits/credits |
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Coat |
Transaction based to debit available ; credit coated |
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Split from Coated |
will debit coated ; credit split pool |
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Split from Available |
- debit available for coating ; credit split pool |
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Note: The split pool is categorised only by frame size - mesh count is not longer an attribute once the physical mesh has been punctured. thus a Std 49 can when repaired become Std 62 |
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Raise Po |
Creates a purchase order email template for any screen types selected. |
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Notes: To increase system performance, TOT's system does not at all times real time account for the categorisations of screen statuses. However, there are two functions that can be run on demand. Either function can be run at a stencil type (SKU) level or across the whole inventory
|
Scenario |
Process |
Stencils no longer required (possibly one off job) - |
Reclaim Stencil Set Users process the Stencil set as reclaimed
|
Stencils are required for likely future usage |
File Stencil Set Users process the Stencil set as Filed Accounting:-
|
Stencils are instantly required for another job / process |
Send Stencil Set to Pre-Check Users process the Stencil Set as Send to Pre-Check Accounting:-
|
Stage One Identify and tagging Potentially Reclaimable stencils
Stage Two Reclaiming the Tagged stencil sets
The flow for reclaiming stencil sets is here
Stencil splits can occur at any stage in its life cycle
The below table summarises TOT's current work practices for dealing with splits
Split stencil occurs during... |
Working Practices to remedy |
Stencil preparation |
Splits at this stage occur when the stencil is blank - i.e. no image exposed nor attached to a job order It is either in Coated state or in an Available (non coated state) The functions split from coated or split from available are used to account for the corresponding Stencil Type The qty of splits are recorded which debit the corresponding category and credit the split pool The physical stencil is then sent for re-stretching
|
Print Run |
The print run is paused The split screen is removed from the print press The stencil set detail record is opened and the corresponding stencil is processed as split (this changes the status of the stencil set to flash) Accounting wise, the in use total is debited and the split pool credit by the qty of split stencils The label for the split screen is printed out and handed to the stencil maker as a priority The process for making the stencil is outlined earlier -and is followed Once the replacement stencil is made, it is processed as complete and then out to print passed out to the print press that requires it The removed split screen is sent for repair
See here for workflow schematic
Note: TOT working practice is to pause a print run for a maximum of 20 mins. If the replacement stencil cannot be provided within this time frame, it is likely the print press will be reconfigured for the next job, and the print run that was paused re-started later. |
Pre-Print Run |
The pos identifier of the member stencil is noted This is provided to the stencil maker to draw down a coated replacement and image and make Crucially no system entries are made at this point Once the replacement stencil has been manufactured and passed back out to the print room, the split screen is accounted for by using the split from coated function in the stencil dashboard. The physical split stencil is placed in the splits ares to await repair |
washing |
Splits at this stage are on stencils that are in use - that is, they contain an image and are related to job order(s) The stencil set detail record is opened and the corresponding stencil is processed as split (this changes the status of the stencil set to part set Accounting wise, the in use total is debited and the split pool credit by the qty of split stencils The part set is physically file using the Put Away function The exception is where the whole stencil set is tagged to reclaim, so is processed as a reclaim
|
Pre check |
Splits at this stage are on stencils that are in use - that is, they contain an image and are related to job order(s) he stencil set detail record is opened and the corresponding stencil is processed as split (this changes the status of the member stencil to does not exist) The stencil set status should not update The replacement stencil will require manufacturing as outlined earlier The physical split stencil is placed in the splits ares to await repair
See here for workflow schematic |
Note: Currently split screens are denoted by a flashing status icon on the production layouts. Assessment needs to be made of the performance overhead for this, and alternate / more performant ways of achieving this.