Transcript Seckman Printing

Expand with Computer Integrated
Manufacturing/Smart Factory
Concepts
Digital Smart Factory Forum
January 16-18, 2007
Hyatt Regency Orlando International
Airport
Panelists
Barry Witt, Prepress Production Manager, Seckman
Printing, Inc.
Michael Murphy, President, Japs-Olson Co.
George Fry, Managing Director, Inter-State Studio and
Publishing
IQ Colour
• Color management software invented by
Dr. Ed Granger, color scientist.
– Former employers include:
• Eastman Kodak Company
• X-Rite, Inc.
• Rochester Institute of Technology
IQ Colour vs. Conventional
Separations
A comparison of PhotoShop to IQcolour for total ink savings. Photoshop used
separations with the following separation settings;
1] sRGB – Hue, Saturation and Brightness
2] Converting to CMYK for;
a] Medium GCR
b] 280% Maximum ink limit.
The IQcolour rendering engine used ;
1] sRGB to CMYK
2] a 5% K ink start
3] 280% Maximum ink limit
IQcolour Ink Savings
80
Percent ink savings
70
60
50
20% Saturation
40
40% Saturation
30
60% Saturation
80% Saturation
20
100% Saturation
10
Average
0
-10 0%
20%
40%
60%
-20
Darkness
80%
100%
Press Test
• Traditional and IQColour separations of a
series of standard GATF images were
prepared and imposed for comparison in
three trial press runs.
• In two trials the ink run rates of CMY and
K were compared between the traditional
separations and the IQColour separations
by running the press to ink exhaustion.
Press Test
IQ Colour Benefits
Ink savings of 15% to 50%
Labor Savings
Paper Savings
Quality improved
Metamarism is reduced or
eliminated
Takes the “black box” out of
printing
Lowers the minimum
economic print quantity
Minimizes the need for
expensive controls.
Test Site Comments
• “I am using about 40% less color ink.”
• “The press guys love it.’
• “It makes their mistakes less bad.”
• “Even if there was no savings the quality improvement and greater
margin for error makes it worthwhile.”
• “It is a cheap way to get the same effect as investing tons of money
in controls.”
• “You can take a press guy with spot color experience and make a
process color guy quickly and easily.”
• “There is very little waste, the start-up is efficient.”
Contact Information
Michael J. Feldman
President, CEO
[email protected]
Phone: 248-644-0446
Start Page
Company Background
Pursing Automation
CTP & Systems Evaluated
The Choosen One Heidelberg
• Heidelberg
– Suprasetter
- Printready Workflow
• Price
– Service
– Price
- Track record
• Integration
– Hardware in place
- Software in place
Achievements
• Smooth flow of data from Estimating package
to prepress workflow
• PDF workflow - complete jobs 2x as fast
• Greater organization and effectiveness
• Softproof usage maximized - quicker
turnarounds
• More plate sizes on line
• Plate production doubled
END
Expand with Computer Integrated
Manufacturing
Digital Smart Factory Presentation – January 17th, 2007
Presented by:
Michael Murphy
Japs-Olson Company
Japs-Olson – Who We Are
• Full service direct mail and
commercial printing company
• Single facility - 800
employees – operate 24/7
• Produce and mail 3-4 million
pieces mail/day
CIM at JO – Overview
CIM: The complete automation of a manufacturing plant, with
all processes functioning under computer control and digital
information tying them together.
CIP3/JDF
Scripting
&
Automation
Direct
Machine
Interface
(DMI)
CIM at JO – CIP3/JDF
• Pressroom – Ink presets
• Heatset (80’s)
• Sheetfed (90’s)
• Pressroom - Closed loop color control
• SF presses – (late 90’s)
• HS presses (2002-2003)
• Bindery – Presets …sort of
• Folders (2002)
• 1-automated, 4-semi, no banders, 17-w/o
• Cutters (2005)
• 1-automated, 1-retrofit*, 7-w/o
• Stitchers (2006)
• 2-automated, no inkjet, 2-w/o
CIM at JO – Scripting/Automation
• Prepress & Data Processing
1. Prinergy – Rules Based Automation
2. Gradual – PowerSwitch
3. Apple – OS-X Scripting
4. Custom VB Scripting
• Quantifiable Results:
• Productivity increased 30%
• 50% over next 3-years
CIM at JO – Our DMI Story
1. We wanted accurate data to help us better
manage our production operations
• Could not get timely information
• Either over-producing or under-producing
• Consistently inaccurate counts (self reported data)
• Could not measure or quantify performance
• Most production problems went unresolved
2. Overall, we wanted to be proactive vs. reactive
Our DMI story…
• In 2001, we decided that we needed a Direct
Machine Interface (DMI) system
• We had to create our own system
1. Complicated workflow
Printing, Bindery, Imaging, Mailing
2. Numerous manufacturers
Heidelberg, Harris, Didde, Drent, Halm, Bobst, Stahl,
MBO, Polar, OCE, Hunkeler, Ehret, BBH, Pitney
Bowes, Scitex, Buskro, Domino….
3. Equipment age and generation
Our DMI story…
• 5-years later, every piece of production
equipment in the plant has DMI
• 194 individual pieces of equipment across 8
production departments communicating real-time
status every minute
What started out as more accurate data
through DMI has evolved into a
comprehensive digital information system
CIM at JO – Our Results
Result: Creating a culture of performance
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Total Production Control
Detailed Operator Performance
Computerized Scheduling
myjo.com
High Performance Supervision
Materials Management
Quantifiable Results:
• 3-year plant productivity up 29%
• 3-year paper waste down 20%
CIM at JO – Requirements
• Commitment to CIM
• Board/Executive Management
• Patience to build infrastructure
• Time consuming and $$
• software, hardware, communications, integration
• Large programming staff
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(1) DMI System
(1) Printflow
(3) VB / .net
(3) Legacy System
(1) Reports
CIM at JO – Lessons Learned
• Difficulty of Integration
• software, hardware, communications, training
• Software Development
• well thought out with built-in functionality
• Workforce Training and Acceptance
• HUGE cultural change
• Data Integrity & Reporting
• 300,000 status transactions/day
• Online Scheduling –
• What is really going on?
• What you can measure, you can improve!
Automated Finishing and Fulfillment
George Fry
Managing Director
USA Division
Convertible Brands
866-832-0217
Inter-State Studio & Publishing
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Largest family owned school photography and
yearbook publishing company
Founded 1933
Divisions
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Inter-State Studio
Inter-State Publishing
Campus Agendas
Inter-State Printing
Inter-State Imaging Services
Convertible Brands
Completely Digital
Portrait Product Redesigned
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Conversion to digital photography
School year printed on portraits
Choice of several graphic borders
Personalized with autographs
My Photo Adventure CD
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High resolution portrait
Copyright release
Fun software
Retouching
Major Challenge
How can we present a complex
set of personalized choices in
a simple flyer?
First the Market Test and Results
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100,000 students
8 ½ x 11 inch, 4 page flyer
Personalized with images and autograph
Pricing PDF, Scanned images
Printed on Indigo
Stapled in payment envelope
Dramatic increase in sales and response rate
Enthusiastic response from schools and parents
Confirmed basic concept
Logistic challenges
Project and Design Objectives
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Wow factor
Generate enthusiasm to buy
Sales flyer for families
Introduce and feature
personalized autograph
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Present choice of two poses
and graphic borders
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Feature many images of the child
Clear offer with
Order Form and integrated Payment Envelope
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Send to web for more information
Challenges
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High volume with Short lead times
High Quality Requirements
with Tight roll out schedule
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Highly personalized
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10 personalized portraits
Unique graphics on each portrait
Personalized autograph
Pricing unique to each school
Integrated payment envelope
No print overruns to compensate for bindery waste
RIP and printing speeds
Network traffic jams
Solutions and Implementation
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Kodak DP2 to render portraits
Quark scripts to generate pricing PDFs
Xeikon 500/5000 digital web presses
Indigo 3000 cut sheet for overflow
Lexigraph software for final RIP
Network upgrades
Fold-N-Go Pre-Press Converted stock
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Enable tear-off envelope
Eliminated bindery waste
Able to personalize envelope
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Bar coded identification
Small portrait
Pre-Press Converted Paper Stock
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Key breakthrough
20 inch roll stock
Registration marks for printing
Pre-Press perforated for
tear off envelope
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Pre-Press co-adhesive to
form envelope
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Pre-Press remoisten adhesive on flap
Post press conversion reduced to one step on traditional
folding equipment
Results
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High quality proof
Delivery reduced from 3 weeks to 3
days
Substantial increase in sales and
response rate
Decrease in labor costs
Waste reduced from 10% to .001%
New Convertible Brands division
spin-off
Impact
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Met our marketing
objective
Wow factor
Dramatic increase in sales
and response rate
Enthusiastic response
from schools and families
Learned a lot
Lessons
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Learned to manage a complex project in a
short time frame
Mastered data-driven personalized imaging
Learned to use pre-press converted paper to
personalize complex mechanical pieces
Expanded Inter-State printing to focus on
personalized jobs
Launched Convertible Brands
Send 4 terabytes to digital presses daily
Other items of interest…
30,000 – 40,000 flyers produced daily
15 – 20 yearbooks daily
40 – 48 pages each
More Results …
and the future ….
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PODi 2006 Best Practices Award
Featured in …
American Printer
The Big Picture
Print Matters
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PIA Award of Excellence
Personalization
One to one printing
Equipment
Fully Digital
Convertible Brands – Start it Up!
Speaker Presentation by:
George Fry
Managing Director
Convertible Brands
866-832-0217