Transcript Document

DOWJONES
International Newspaper Group
Pre-Press Operations….A Journey
September 2013
Pre-Press Operations Assessment…A Journey
• A common lament?
– Through acquisition and evolution, our publications have different processes
and software applications.
– This has brought challenges:
•
•
•
•
Too many different processes.
Technology and process was implemented to “do it like we used to”.
Process and technology is ever changing.
HUMAN ERROR; SYSTEM OUTAGES; PROCESS PROBLEMS
– Objectives :
• Leverage existing assets and minimize technology platforms across the
publications.
• Create the most efficient operating model of People, Process and
Technology
• Determine what if any processes should be outsourced.
2
Pre-Press Operations Assessment…A Journey
• A work in progress across three companies,
– Dow Jones/New York Post: Started with the 9 publications
– News UK: Followed with the 17 publications
– News Australia: To follow
• Utilize PROCESS ENGINEERING
– Applied Lean and Six Sigma Improvement tools
PROCESS
– We started by mapping out the current pre-press processes by publication,
to understand:
• Who does what and when.
• What technology is employed (applications).
• What are the opportunities identified throughout the process.
3
Pre-Press Operations Assessment…A Journey
COLOR IDENTIFIES THE APPLICATION USED
PUBLICATION
Alexa
PRODUCTION OPERATIONS – PAGE FLOW and PROOFING – ALEXA – AS IS /September/October 2012/Jgreer; CGalliard/ M. Bird; J. Moyer; K. Oechsner; M. Carpena; D.O’Callaghan; L. Warshawsky
PRODUCTION OPERATIONS – PAGE FLOW and PROOFING – ALEXA – AS IS /September/October 2012/Jgreer; CGalliard/ M. Bird; J. Moyer; K. Oechsner; M. Carpena; D.O’Callaghan; L. Warshawsky
PRODUCTION OPERATIONS – PAGE FLOW and PROOFING – ALEXA – AS IS /September/October 2012/Jgreer; CGalliard/ M. Bird; J. Moyer; K. Oechsner; M. Carpena; D.O’Callaghan; L. Warshawsky
Ad Booker
GCR
EVO
Black Magic
Sales Rep or
Client provides
new material
Methode
QMS
OneVision
NY proofing workflow not available in
SBK. Photo ads for high profile
customers, i.e. Tiffany’s, Ralph Lauren
not produced accurately – credits are
applied
Kraus CTP
InDesign
Ad Booker
GCR
EVO
Black Magic
Methode
QMS
OneVision
Note: Any changes
made here have
bypassed the QA
process
InDesign
Kraus CTP
Layout
placement
instructions
supplied
Sales
Sales
Desktop
Acrobat may
not be the
same and
result in
variation
Ad Booker
GCR
EVO
Black Magic
Methode
QMS
OneVision
Kraus CTP
Sales
InDesign
Is this in “Ad Booker”? (Jim Riley) Can Ad Watch or Ad Base be used here?
5-7 ads/month
Book Ad
1-2 weeks before run
Manual
All quality
checks OK?
Post PDF
to One
Vision
Server
Auto
1
Compose Page
(Advertising)
1
Advise that
layout is
complete
Y
Manual
Post PDF to
One Vision
Server
(Bldg 1211)
Create pdfs
Conduct
Preflight
Check of
pdf
Manual
process,
automated
for NY Post
Set up
NYPost
Methode
Page Plan
by Run date
Editorial
Transmit
“Methode
ready PDF”
to NYPost
Methode
Editorial
A
1-2 days before send to
print
One server no backup. Vulnerable –
potential failure
Create Ad
Layout
Post PDF
to Pub
Server
Transmit
“Methode
ready PDF”
to NYPost
Methode
Ad Ops
Compare via
visual check
Drag PDF post
GCR into EVO-3
BM3 (Kodak)
N
3
Note: Color printer produces inaccurate representation of
colors – ICC needs adjustments - 5 imaging technicians
spend 30-45 min per day adjusting ink colors (NYC)
3
PRINT SITE
N
2
Compose Page
(Editorial and Ad)
2
Generate proof
Output
Color?
N
Unable to generate quick proofs with
current IT solution for printing.
Printing one sheet takes up to 5 min.
A
Run EVO RIP
(Kodak)
Y
Run GCR
software
Flatten
transparencies and
generate pdf X-1A
PDF GEN
Server
moves to
EVO
Run EVO RIP
(Kodak)
Legacy system no longer needed.
Potential point of failure. Slows
troubleshooting for system
problems.
Render simulation
of press quality on
actual stock
Print on BW
printer
Compare via
visual check
All quality
checks OK?
Y
Pagination
Receive Editorial
Copy (pdf)
Create
Editorial
Page
Units
Render simulation
of press quality on
actual stock (2
prints)
Pagination
Note: This is a cumbersome task as there is no
formal alert before ads are received. Sales may
contact Ad Ops or vice versa. Usually Ad Ops
will then request for a listing of other ads
running in the same issue, along with sold
status and the ATC (Ad to Come). The “Special
Section” Calendar is not issued regularly to Ad
Ops.
This is not the same BM as
NY Post
Drag PDF non
GCR into EVO-3
BM3 (Kodak)
Ad Ops
Drag PDF into
GCR software
Generate Onsite
Proof
4
4
Release Final
Pages
Setup
QMS To
Pair
Pages
Run GCR
software
Flatten
transparencies and
generate pdf X-1A
Create
“plate” in
QMS and
transmit to
Receive
Site
Using generic QMS which requires manual
setup to match Methode. 1 hr setup daily?
Does QMS Pair Pages for Alexa?
16-24 pgs @ 2-3x each page
PROOFING
Generate Output
Global Layouts
Global
Layouts
Check PDF to
WSJ
specifications
Global Layouts
Identify when ad
is to run
Pagination
Editorial
Ad Ops
Receive Ad Copy
(pdf)
“POINT OF INTEREST”
GROUP PERFORMING THE TASK
Grouped by:
•Proofing
•Manual processes
•Ad Production
•Process Performance
•Software/Technology
4
Site uses
QMA to
route
Print
Drag PDF EVO
RIP (Kodak)
Create
Plate
What Did We Find?
Process
NYC proofing workflow is not available in
SBK . This includes color proofing. REC:
8
Investigate why this is not possible and what
benefits would be gained by so doing (L,M)
PRODUCTION OPERATIONS – PAGE FLOW and PROOFING – ALEXA – AS IS /September/October 2012/Jgreer; CGalliard/ M. Bird; J. Moyer; K. Oechsner; M. Carpena; D.O’Callaghan; L. Warshawsky
PRODUCTION OPERATIONS – PAGE FLOW and PROOFING – ALEXA – AS IS /September/October 2012/Jgreer; CGalliard/ M. Bird; J. Moyer; K. Oechsner; M. Carpena; D.O’Callaghan; L. Warshawsky
PRODUCTION OPERATIONS – PAGE FLOW and PROOFING – ALEXA – AS IS /September/October 2012/Jgreer; CGalliard/ M. Bird; J. Moyer; K. Oechsner; M. Carpena; D.O’Callaghan; L. Warshawsky
Ad Booker
GCR
EVO
Black Magic
Sales Rep or
Client provides
new material
Methode
QMS
OneVision
NY proofing workflow not available in
SBK. Photo ads for high profile
customers, i.e. Tiffany’s, Ralph Lauren
not produced accurately – credits are
applied
Kraus CTP
InDesign
Ad Booker
GCR
EVO
Black Magic
Methode
QMS
OneVision
Note: Any changes
made here have
bypassed the QA
process
InDesign
Kraus CTP
Layout
placement
instructions
supplied
Sales
Sales
Desktop
Acrobat may
not be the
same and
result in
variation
Ad Booker
GCR
EVO
Black Magic
Methode
QMS
OneVision
Kraus CTP
Sales
InDesign
Is this in “Ad Booker”? (Jim Riley) Can Ad Watch or Ad Base be used here?
5-7 ads/month
Book Ad
1-2 weeks before run
Manual
All quality
checks OK?
Post PDF
to Pub
Server
Post PDF
to One
Vision
Server
Auto
Transmit
“Methode
ready PDF”
to NYPost
Methode
1
1
Compose Page
(Advertising)
Ad Ops
Compare via
visual check
Drag PDF post
GCR into EVO-3
BM3 (Kodak)
N
Advise that
layout is
complete
Y
Manual
Create pdfs
Conduct
Preflight
Check of
pdf
One server no backup. Vulnerable –
potential failure
Manual
process,
automated
for NY Post
Set up
NYPost
Methode
Page Plan
by Run date
Transmit
“Methode
ready PDF”
to NYPost
Methode
3
Note: Color printer produces inaccurate representation of
colors – ICC needs adjustments - 5 imaging technicians
spend 30-45 min per day adjusting ink colors (NYC)
3
PRINT SITE
N
2
2
Compose Page
(Editorial and Ad)
Generate proof
Output
Color?
Y
Run GCR
software
Unable to generate quick proofs with
current IT solution for printing.
Printing one sheet takes up to 5 min.
PDF GEN
Server
moves to
EVO
Run EVO RIP
(Kodak)
Legacy system no longer needed.
Potential point of failure. Slows
troubleshooting for system
problems.
N
A
Flatten
transparencies and
generate pdf X-1A
Run EVO RIP
(Kodak)
Render simulation
of press quality on
actual stock
Print on BW
printer
Compare via
visual check
All quality
checks OK?
Y
Pagination
Post PDF to
One Vision
Server
(Bldg 1211)
Editorial
A
1-2 days before send to
print
Generate Onsite
Proof
4
4
Release Final
Pages
Any changes made here, dropped
directly into Méthode, have
bypassed the QA process
REC: Investigate why changes occur past
this point (M,M)
9
PROOFING
Generate Output
Run GCR
software
Flatten
transparencies and
generate pdf X-1A
Create
“plate” in
QMS and
transmit to
Receive
Site
Site uses
QMA to
route
Unable to generate quick proofs with current IT solution for
printing. Printing one sheet takes up to 5 minutes, 16-24 pages x
2-3x each page. Note: this is between 3 .3 to 6 hours daily (16*5
min*2.5 times to 24*5 min *2.5 times) REC: Investigate replacement
of printers for proofing. (H,M)
11
“POINT OF INTEREST”
5
Print
Drag PDF EVO
RIP (Kodak)
Using generic QMS which requires manual
setup to match Methode. 1 hr setup daily?
Does QMS Pair Pages for Alexa?
16-24 pgs @ 2-3x each page
Create Ad
Layout
Setup
QMS To
Pair
Pages
Global Layouts
Receive Editorial
Copy (pdf)
Create
Editorial
Page
Units
Render simulation
of press quality on
actual stock (2
prints)
Editorial
Note: This is a cumbersome task as there is no
formal alert before ads are received. Sales may
contact Ad Ops or vice versa. Usually Ad Ops
will then request for a listing of other ads
running in the same issue, along with sold
status and the ATC (Ad to Come). The “Special
Section” Calendar is not issued regularly to Ad
Ops.
This is not the same BM as
NY Post
Drag PDF non
GCR into EVO-3
BM3 (Kodak)
Ad Ops
Drag PDF into
GCR software
Global Layouts
Global
Layouts
Check PDF to
WSJ
specifications
Pagination
Identify when ad
is to run
Pagination
Editorial
Ad Ops
Receive Ad Copy
(pdf)
Create
Plate
What Did We Find?
1
xxx
Process
1 vvv
In all, @100
for improvement
yyy
1 opportunities
were recorded
1
Combined Benefit/Effort Matrix
zzz
EFFORT
Low
BENEFIT
High
Medium
Low
Medium
2
6 11
7
7
8
9 10
1
2
1
3
4
4
6
7
1
12 14 4
2
3
3 11 2
High
8 13 12
9 10 5
3
5
10 4
13 14 15 9
6
1
8
5
6
What Did We Find?
Process
In all, @100 opportunities for improvement
were recorded
•
Some Common Trends:
– Several different groups were doing common tasks, distinct by publication.
– Some of the tasks were very time-consuming as a result of the technology
limitations.
– Applications, even by the same vendor, were not used consistently across the
publications or companies.
– Some changes to ad copy made later in the process were not re-checked by an
upstream Quality Control check.
– Pre-flight checks of received ads for some publications failed quite often.
– Unfamiliarity with editorial copy tools causes delays and rework.
•
Many of these are already being corrected.
7
What Did We Find?
•
Technology
Companies used different applications to get the same work done.
– One company is using three times the number of applications than another.
– One publication alone has eighteen applications strung together, just to perform
pre-press.
– A majority of the overall applications are unique to a single publication.
•
Why is this important?
– Production is being affected by technology breakdowns.
– Significant cost and effort to maintain applications.
We need a common solution to handle a common process
8
What Did We Find?
Technology
The systems/applications used are in a constant state of change, mostly
dictated by the needs of business.
Summary for Elapsed Time (Hours)
A nderson-Darling N ormality Test
QMS
Merlin
External FTP
File & Print
NYP-CNG MAC
NYP-CNG File & Print
Median Elapsed Time –
1.6 Hours
0
100
200
300
400
500
600
A -S quared
P -V alue <
33.75
0.005
M ean
S tDev
V ariance
S kew ness
Kurtosis
N
16.403
58.358
3405.637
7.7717
72.1280
141
M inimum
1st Q uartile
M edian
3rd Q uartile
M aximum
-10.889
0.659
1.636
7.694
597.392
95% C onfidence Interv al for M ean
6.687
26.120
95% C onfidence Interv al for M edian
1.144
2.657
95% C onfidence Interv al for S tDev
9 5 % C onfidence Inter vals
52.249
66.096
Mean
Median
0
Which applications affect print
production the most
5
10
15
20
25
Median Elapsed time that the
application is down
This volatility requires that we simplify and standardize processes and
supporting applications to prevent increases in cost to maintain and operate.
9
What Did We Find?
People
•
The review noted that “tribal knowledge” (the practice of subject matter
experts fully knowledgeable in their areas but largely undocumented) was
commonplace.
•
An overall lack of reference materials, consistent training and support
supplied to the process participants that should be addressed.
•
The non-standardized processes (each publication performs similar
tasks differently) adds to the general inability to leverage resources in
times of need across publications.
10
Pre-Press Operations Assessment…Our Next Steps
Common Pre-Press Tasks across all publications
Manage
Ads
Create
Pages
Content
Create
Classified
Ad Copy
Typeset
and Preflight
Plan
Book
Assemble
Pages
Proof
Transmit
MINIMIZE VARIATION of the tasks, they should be consistent
SIMPLIFY THE TASKS to reduce complexities and reduce cycle-time
STANDARDIZE THE APPLICATIONS to reduce complexities and cost
CONSIDER CONSOLIDATING IN A SHARED SERVICE OR
OUTSOURCING
11
AS IS
Define, Measure
Pre-Press Operations Assessment…Our Next Steps
DJ
Broadsheet;
Tabloid;
Magazine
NI
NL
AS IS – TO BE
Analyze, Improve
Broadsheet;
Tabloid;
Magazine
“Strawman”
Common
NewsCorp
TO BE
Analyze, Improve
Review
proposed plan
(DJ;NI;NL; tech
and pre-press)
TO BE
Implement, Control
Broadsheet;
Tabloid;
Magazine
12
Common
NewsCorp
Pre-Press Operations Assessment…Our Next Steps
•
Objective:
– A standardized process and technology solution to address each type
of publication that can be leveraged for like products across News
Corporation.
– Use the least amount of company resources while maintaining or
improving product quality and customer service.
– Our PROCESS ENGINEERING approach helped us get here…
13