Troubleshooting 6 of 6
Quality Issues
Begin quality troubleshooting by defining the defect objectively and tracing where it first appears. Do not immediately edit the PNG when the cause may be software, machine, material, production, finishing, or inspection conditions.
Isolation sequence
Define
Describe the defect, affected area, quantity, and acceptance requirement.
Contain
Stop or isolate affected work so it cannot enter fulfillment.
Compare
Compare the approved file, RIP preview, first acceptable unit, and failed unit.
Classify
Assign the likely source: file, software, machine, material, process, or inspection.
Test
Change one controlled variable and use a known reference where possible.
Correct
Apply and document the verified corrective action.
Verify
Produce and inspect a new acceptable result before resuming.
Quality symptom routing
| Symptom | Check first | Then compare |
|---|---|---|
| Blur or pixelation | Actual PNG pixels and final size | RIP scaling and physical output |
| Unexpected color | Profile and approved reference | Device state, material, ink, and inspection light |
| Halo or unwanted background | PNG alpha edge | Underbase, compositing, and substrate color |
| Incorrect placement | Template and job coordinates | Fixture, feed, registration, and handling |
| Peeling, fading, or weak durability | Material and complete process record | Cure, transfer, finishing, and care procedure |
| Variation across units | Sequence and lot records | Machine drift, preparation, environment, and operator steps |
After correction, update the applicable template, preset, work instruction, inspection rule, maintenance task, or training material so the same issue is less likely to recur.