Study of lifetime of digital coated plates in the rotary label sticker machine : case study sticker label factory

Abstract

The objective of this study is to predict the lifetime of digital polymer coated plates of rotary label sticker machine by measurement the tone value increase of printed colors on label sticker in 3 levels of color strength: High Light; HL (25%), Mid Tone; MT (50%) and Shadow; SH (75%). The limit of halftone color deviation is 15% from the original halftone color. Data fit in a polynomial curve to the historical data with MATLAB. The predicted lifetime of digital polymer coated plates until deviating to 15±S.D.%. At HL (25%), the result is 94,816 rounds with 15±4.3% (between 82,697 – 105,237 rounds). At MT (50%), the result is 80,134 rounds with 15±4.3% (between 71,112 – 87,924 rounds). And at SH (75%), the result is 70,208 rounds with 15±3.8% (between 62,361 – 76,988 rounds). The Mean Absolute Percentage Error (MAPE) are 3.0%, 3.1%, and 3.2%, respectively. The average lifetime of digital polymer coated plates is 81,720 rounds (between 72,057 – 90,049 rounds), much higher 31,720 rounds (63.44%) than the company's current estimation of 50,000 rounds.