The Role of CIJ Technology in Addressing Skilled Labor Shortages in Manufacturing

In industrial manufacturing, coding machines and printers must be set up, cleaned periodically, troubleshot when malfunctioning, and maintained with replacement parts. Companies rely heavily on technicians, engineers, and other skilled labor to keep product identification equipment running smoothly, including continuous inkjet printers.

However, with the increasing labor shortage in recent years, production and manufacturing lines must keep their human resources focused on critical areas to maintain production uptime. Due to the demands of managing printing and coding systems, the maintenance staff is losing valuable time that could be better utilized for more critical machinery and other areas that need attention or improvement.

To start the MK-G Series, simply press the Smart Startup button. The printer will automatically obtain the device status and select the necessary cleaning method. Cleaning is performed only when required and the minimum amount of solvent is used, significantly reducing running costs.

It’s been a challenge to find and retain skilled staff who can set up and maintain traditional CIJs, leading to days of production delays. Advances in CIJ technology mean fewer professionals familiar with traditional coding systems.

With many manufacturers phasing out support and training programs for older systems, waiting on parts and service may take days, resulting in downtime that impacts production completion and project delivery.

KEYENCE, a leader in automation systems, offers modern CIJ technology with automation-powered features. For example, the KEYENCE MK-G Series features a component called the MK Dock, which automates many maintenance tasks and processes that require user input in traditional CIJs, reducing the need for skilled labor.

The MK-G Series continuous inkjet printing solution has no service contracts. Users are not tied into monthly or yearly service fees nor required to depend on us for maintenance and repairs.

The MK-G Series CIJ has an intuitive, touch-screen interface for easy setup, operation, and maintenance. The user is interactively guided through every task, and the user-friendly design makes it possible for anyone to operate, maintain, and troubleshoot the system.

With the KEYENCE MK-G Series CIJ printers, the more involved maintenance tasks, including cleaning, diagnosis, and others, are automated. The auto shower function also cleans all critical areas in the print head, which is vital to print quality.

The MK Dock of the MK-G Series helps the printer self-diagnose issues and automatically resolve them. This self-diagnosis function extends to cleaning operations and notifications about important information regarding nozzles, ink viscosity, and more. The ability to detect and correct errors automatically reduces the need for skilled technicians.

Several complex steps are required to replace the nozzle in a traditional CIJ printer. First, you need to disconnect the ink supply and release the nozzle retaining mechanism. Often, 8 to 12 screws hold the printhead together, which you must unscrew to gain access to the internals of the printhead. From there, you’ll need to use needle-nose pliers to grip, twist, and remove the old nozzle and any other parts that could block access to it. Once the internals are exposed, you can proceed with replacing the costly nozzle and reassembling the printhead to return to normal operations. Even for skilled technicians, the process can take upwards of 30 minutes to complete and is quite costly.

In contrast to this lengthy, complex process, the KEYENCE One-Touch Nozzle Replacement simplifies this maintenance task. Once the MK-Dock diagnoses that the nozzle needs replacement, the illustrated touchscreen instructions will assist the user in completing the nozzle replacement with no tools required in approximately one minute. Simply remove the front cover of the printhead, take off the nozzle fastener, discard the old nozzle, and replace it with the new one.

Not only does this reduce downtime, but it is also cost-effective, with the price of KEYENCE high-grade, durable ceramic nozzles being approximately one-tenth the cost of traditional CIJ nozzles.

Traditional CIJ printers require extensive training and specialized knowledge for proper maintenance. Some CIJ manufacturers often provide training programs on how to troubleshoot and repair specific models. Training time could take weeks or extend to months.

With the KEYENCE MK-G Series automatic CIJ industrial inkjet printing machine, training time is almost non-existent. Illustrated instructions on the easy-to-use touchscreen interface walks the user through how to troubleshoot and complete maintenance operations. This process takes minutes, not hours or days.

Traditional CIJ printer maintenance involves many areas. The print head must be cleaned regularly, and the ink system and nozzles must be maintained. Monitoring ink levels, filter and pump replacement, and ink droplet calibration must also be addressed consistently.

With KEYENCE CIJ coding inkjet printers, built-in self-diagnosis and troubleshooting functions can pinpoint exactly when cleaning is required and what part needs to be replaced. Cleaning is done automatically, and the one-touch, tool-free replacement of parts has simplified maintenance procedures. This simplified troubleshooting process reduces reliance on both internal and external technicians.

Print head maintenance and cleaning prevent clogs caused by dried ink in the nozzles. A clean print head also ensures precise ink droplet formation, which enhances print quality and consistency. In traditional CIJs, print head cleaning is a manual process that exposes the individual to chemicals and uses excess solvents. This process can take up to 30 minutes, depending on the severity of the clog.

The hands-free, auto-shower cleaning function of the MK-G Series uses a high-pressure jet stream of solvent to dislodge and remove dried ink, stubborn debris, or contaminants from critical components of the print head. This helps ensure the nozzle is not blocked and remains clear. After cleaning, the built-in blower automatically dries the head to complete the procedure. This makes the MK-G Series a consistent and reliable solution that uses the proper amount of solvent each time and reduces downtime due to cleaning.

The MK-G Series continuous inkjet printing solution reduces wait times for parts or professional service. Lead times for all MKG ink and replacement parts are nonexistent. KEYENCE provides same-day shipping for all components, including new printers, with overnight delivery options available. This commitment has remained steadfast throughout the COVID-19 pandemic. In contrast, competitors often face lead times of two to three weeks or longer for parts or ink/solvents, leaving customers stranded with printers awaiting essential components.

Instructional videos and easy-to-follow onscreen instructions help all skill level employees perform maintenance and part replacement without hassles. Plus, the printer’s built-in monitoring function helps detect in real time what’s going on with every critical part of the system. There is no waiting for service, as the troubleshooting process can be initiated immediately with the press of a button. This allows for rapid recovery from any issues that may occur due to the use of quick-drying ink in CIJ printers.

For more information on the KEYENCE MK-G Series industrial inkjet printer, contact us today.