Print simulation

Print process simulation uses interactive simulation 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 Coldset 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 before they happen so that they can be recognized when they do occur.[1] Exercises can evaluate specific competencies and if they are used to solve problems.[2] When possible, simulators training scenarios are linked to industry-standard curricula like PIA, the NAA (Newspaper Association of America) and the Flexographic Technical Association.[3]

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.[4] 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.[5]

a print simulator integrated into a real press control console, the different screens show (from left to right)
1. the pressroom (access to the machine and environment)
2. the printed copy : high contrast, small display
3. the printed copy: lower contract, large display
4. a real operator interface to a process control system

As of 2013 it is estimated that over 2000 print simulators are installed worldwide (in 2013). Users include technical schools, universities, printing companies and their suppliers,[6][7] who find that they cut costs, accelerate training time, and give a more thorough grounding in structured problem solving

Simulators from Sinapse are used alongside real presses in the EuroSkills and WorldSkills competitions to select the best printer.[5][8] Simulation based training is well adapted for the learning habits of today's world [7]

In 2013 the print simulation cloud-based learning system (DLMS) won a PIA (Printing Industries of America) Intertech Award:[9]
Language-independent, it automatically analysed and compares training results from different countries, in different languages.
This DLMS was used at worldskillsLeipzig 2013[10] to analyze and compare results from contestants using simulators in 10+ languages.

References
  • RIND Survey, January 2012, "Simulated press problem focusses on tackling production problems"
  • Printing News, May 14, 2001, "Useful as Training Assistants, Print Simulators taking off in print shops everywhere"
  1. Herman, Peter; Grimaldi, Laurent; Carl, Gerd (September 19–23, 2011). Development of knowledge and press-test based Heatset training simulator (abstract). 43rd annual conference of the International Circle of Educational Institutes for Graphic Arts, Technology and Management. Norrköping Sweden: International Circle of Teaching Institute for Polygraphic industry. Retrieved March 8, 2013. External link in |publisher= (help)
  2. "Useful as Training Assistants, Print Simulators taking off in print shops everywhere".
  3. Flexographic Technical Association
  4. "Press simulation shows wide variety of uses at Transcontinental Mexico". 9 Mar 2011. Retrieved 8 Mar 2013.
  5. WorldSkills International
  6. "Confronting the skills problem". Print & Paper Online Magazine. Apr 2004. p. 247. External link in |publisher= (help); Missing or empty |url= (help)
  7. "Training Generation Y to Work". Wall Street Journal. 4 Mar 2007. Retrieved 8 Mar 2013.
  8. Sinapse Print – Training Simulators & Software
  9. "Innovative Technologies Earn 2013 InterTech™ Award". www.printing.org. Archived from the original on 2013-08-18.
  10. Sinapse Print Simulators (23 July 2013). "WSL 2013 Print Media Technology" – via YouTube.
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