Development of "KHS-AI", the next generation of KHS system with learning functions for web offset presses
Metamorphosis into an integrated web offset press management system with new functions and enhanced performance
- KHS :
- one-step color/register adjustment and one-step folding adjustment system.
- AI :
- Advanced Interface
KHS was jointly developed by Komori and Japan Printing Academy, in an example of cooperation between academia and industry. Our aim was to overturn conventional wisdom by creating the ultimate system for one-step register adjustment and color adjustment. At the time we had moved ahead of the rest of the industry by developing our automatic plate changing system, and the addition of one-step register adjustment delivered high print register precision with reducing working time. The development of one-step color/register adjustment completed KHS. For web offset presses, we also added one-step fold setting, and to date we have delivered 166 KHS offset presses.
We have now boosted the color/register adjustment and fold setting performance of our KHS system and added new functions to create KHS-AI, the next generation of KHS, as an integrated management system for web offset printing.
In the past, skilled operators used their perception and experience to adjust color register and folding while examining the printed patterns on print samples. Print companies needed to minimize the waste paper generated and time consumed in that process, to cut costs for ink and paper and enable shorter delivery times. The introduction of KHS yielded benefits such "drastically reduced paper wastage", "shorter job changeover times" and "promotion of standardized print management".
KHS also serves as an environmental measure, because saving on printing materials also helps to conserve forestry and fossil fuel resources, and shorter makeready time reduces press operation time, which saves electricity, and by extension, cuts CO2 emission. The reduction of makeready time that the KHS system delivers brings many benefits, and addresses the above-mentioned tasks facing printing management.
To recap, KHS is a strategic system to support the operation of printing companies by delivering these benefits:
 Reduced costs and enhanced productivity maintain profitability.
 Meeting the short delivery times clients demand helps to capture and keep new clients.
 Operators, who can be unskilled, have a reduced workload.
 Environmental load is reduced.
Komori Corporation has a share of approximately 60% of the non-newsprint commercial offset press market, and over 90% of our products are equipped with KHS. Other companies in the industry are trying to follow us in developing similar systems, which proves that the KHS concept has won the acceptance of industry.
Documented impact of installing KHS
- Drastically reduced paper wastage (Company A)
Our previous average paper loss in sample printing was 2,862 sheets, but our KHS-equipped press cut that in half to 1,255 sheets.
- Shorter job changeover times
Our job changeover time was slashed from 30 minutes to ten.
We will now explain the KHS color register adjustment functions. The most important feature of our products is the addition of self-learning functions. Previous KHS systems set the ink film on the roller in advance, based on the pattern area ratio on the plate, making it easy to set color register by ensuring ink coverage on samples. However, print companies make a wide range of fine adjustments to meet their own standards and the demands of their clients. The printed material, and environmental conditions such as temperature and humidity, can cause subtle color shifts. Our new self learning function is able to accommodate these fine adjustments and color shifts as it automatically adjusts to the optimum colors. Machines equipped with KHS-AI learn and enhance themselves through repeated correction and optimization.
Production management functions use operation records and job management for streamlined job assembly and progress monitoring, encouraging one-to-one relations with clients. Error history and maintenance management are useful for preventing print problems, and for other aspects of risk management. The volumes of printing materials used are calculated simply, which assists in cost reduction.
The shift to IT and digital systems means that web offset printing systems must be able to handle digital workflow. KHS-AI receives data from the pre-press and production management sides and prepares optimum preset data for the machine before running the print job and providing the production management side with feedback of production data.
"KHS-AI" operation menu