Digital Smart Factory Forum Digital Smart Factory Forum January 16-18, 2007 January 16-18, 2007

Hyatt Regency Orlando International Hyatt Regency Orlando International AirportAirport

Expand with Computer IntegratedExpand with Computer IntegratedManufacturing/Smart Factory Manufacturing/Smart Factory

ConceptsConcepts

Barry Witt, Prepress Production Manager, Seckman Barry Witt, Prepress Production Manager, Seckman

Printing, Inc.Printing, Inc.

Michael Murphy, President, Japs-Olson Co.Michael Murphy, President, Japs-Olson Co.

George Fry, Managing Director, Inter-State Studio and George Fry, Managing Director, Inter-State Studio and

PublishingPublishing

Panelists

IQ ColourIQ 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 IQ Colour vs. Conventional SeparationsSeparations

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 GCRb] 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

-20

-10

0

10

20

30

40

50

60

70

80

0% 20% 40% 60% 80% 100%

Darkness

Per

cen

t in

k sa

vin

gs 20% Saturation

40% Saturation

60% Saturation

80% Saturation

100% Saturation

Average

Press TestPress 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 TestPress Test

IQ Colour BenefitsIQ 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 CommentsTest 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 InformationContact Information

Michael J. Feldman

President, CEO

mjf@aperes.com

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

Presented by:

Michael Murphy

Japs-Olson Company

Presented by:

Michael Murphy

Japs-Olson Company

Expand with Computer Integrated Manufacturing

Digital Smart Factory Presentation – January 17th, 2007

Expand with Computer Integrated Manufacturing

Digital Smart Factory Presentation – January 17th, 2007

Japs-Olson – Who We AreJaps-Olson – Who We Are

• Full service direct mail and Full service direct mail and commercial printing companycommercial printing company

• Single facility - 800 Single facility - 800 employees – operate 24/7employees – operate 24/7

• Produce and mail 3-4 million Produce and mail 3-4 million pieces mail/daypieces mail/day

CIM at JO – OverviewCIM at JO – Overview

CIM: The complete automation of a manufacturing plant, with CIM: The complete automation of a manufacturing plant, with all processes functioning under computer control and digital all processes functioning under computer control and digital information tying them together. information tying them together.

CIP3/JDF

Scripting&

Automation

Direct Machine Interface

(DMI)

CIM at JO – CIP3/JDFCIM at JO – CIP3/JDF

• Pressroom – Ink presetsPressroom – Ink presets• Heatset (80’s)Heatset (80’s)• Sheetfed (90’s)Sheetfed (90’s)

• Pressroom - Closed loop color controlPressroom - Closed loop color control• SF presses – (late 90’s)SF presses – (late 90’s)• HS presses (2002-2003)HS presses (2002-2003)

• Bindery – Presets Bindery – Presets • Folders (2002) Folders (2002)

• 1-automated, 4-semi, no banders, 17-w/o1-automated, 4-semi, no banders, 17-w/o• Cutters (2005)Cutters (2005)

• 1-automated, 1-retrofit*, 7-w/o1-automated, 1-retrofit*, 7-w/o• Stitchers (2006)Stitchers (2006)

• 2-automated, no inkjet, 2-w/o2-automated, no inkjet, 2-w/o

……sort ofsort of

CIM at JO – CIM at JO – Scripting/AutomationScripting/Automation

• Prepress & Data ProcessingPrepress & Data Processing1.1. Prinergy – Rules Based AutomationPrinergy – Rules Based Automation

2.2. Gradual – PowerSwitchGradual – PowerSwitch

3.3. Apple – OS-X ScriptingApple – OS-X Scripting

4.4. Custom VB ScriptingCustom VB Scripting

• Quantifiable Results:Quantifiable Results: • Productivity increased 30%Productivity increased 30%

• 50% over next 3-years50% over next 3-years

CIM at JO – Our DMI StoryCIM at JO – Our DMI Story

1.1. We wanted accurate data to help us better We wanted accurate data to help us better manage our production operationsmanage our production operations

• Could not get timely informationCould not get timely information

• Either over-producing or under-producingEither over-producing or under-producing

• Consistently inaccurate counts (self reported data)Consistently inaccurate counts (self reported data)

• Could not measure or quantify performanceCould not measure or quantify performance

• Most production problems went unresolvedMost production problems went unresolved

2.2. Overall, we wanted to be proactive vs. reactiveOverall, we wanted to be proactive vs. reactive

Our DMI story…Our DMI story…

• In 2001, we decided that we needed a Direct In 2001, we decided that we needed a Direct Machine Interface (DMI) systemMachine Interface (DMI) system

• We had to create our own systemWe had to create our own system1.1. Complicated workflowComplicated workflow

Printing, Bindery, Imaging, MailingPrinting, Bindery, Imaging, Mailing

2.2. Numerous manufacturers Numerous manufacturers Heidelberg, Harris, Didde, Drent, Halm, Bobst, Stahl, Heidelberg, Harris, Didde, Drent, Halm, Bobst, Stahl, MBO, Polar, OCE, Hunkeler, Ehret, BBH, Pitney MBO, Polar, OCE, Hunkeler, Ehret, BBH, Pitney Bowes, Scitex, Buskro, Domino….Bowes, Scitex, Buskro, Domino….

3.3. Equipment age and generationEquipment age and generation

Our DMI story…Our DMI story…

• 5-years later, every piece of production 5-years later, every piece of production equipment in the plant has DMIequipment in the plant has DMI

• 194 individual pieces of equipment across 8 194 individual pieces of equipment across 8 production departments communicating real-time production departments communicating real-time status every minutestatus every minute

What started out as more accurate data What started out as more accurate data through DMI has evolved into a through DMI has evolved into a

comprehensive digital information systemcomprehensive digital information system

CIM at JO – Our ResultsCIM at JO – Our Results

Result: Creating a culture of performanceResult: Creating a culture of performance• Total Production ControlTotal Production Control• Detailed Operator PerformanceDetailed Operator Performance• Computerized SchedulingComputerized Scheduling• myjo.commyjo.com• High Performance SupervisionHigh Performance Supervision• Materials ManagementMaterials Management

Quantifiable Results: Quantifiable Results: • 3-year plant productivity up 29%3-year plant productivity up 29%• 3-year paper waste down 20%3-year paper waste down 20%

CIM at JO – RequirementsCIM at JO – Requirements

• Commitment to CIMCommitment to CIM• Board/Executive Management Board/Executive Management

• Patience to build infrastructurePatience to build infrastructure• Time consuming and $$Time consuming and $$

• software, hardware, communications, integrationsoftware, hardware, communications, integration

• Large programming staffLarge programming staff• (1) DMI System(1) DMI System• (1) Printflow(1) Printflow• (3) VB / .net(3) VB / .net• (3) Legacy System (3) Legacy System • (1) Reports(1) Reports

CIM at JO – Lessons LearnedCIM at JO – Lessons Learned

• Difficulty of IntegrationDifficulty of Integration• software, hardware, communications, trainingsoftware, hardware, communications, training

• Software DevelopmentSoftware Development • well thought out with built-in functionalitywell thought out with built-in functionality

• Workforce Training and AcceptanceWorkforce Training and Acceptance • HUGE cultural changeHUGE cultural change

• Data Integrity & ReportingData Integrity & Reporting• 300,000 status transactions/day300,000 status transactions/day

• Online Scheduling – Online Scheduling – • What is really going on?What is really going on?

• What you can measure, you can improve!What you can measure, you can improve!

Automated Finishing and Fulfillment

George FryManaging Director

USA DivisionConvertible Brands

866-832-0217

Inter-State Studio & Publishing

• Largest family owned school photography and yearbook publishing company

• Founded 1933• Divisions

• Inter-State Studio• Inter-State Publishing• Campus Agendas• Inter-State Printing• Inter-State Imaging Services• Convertible Brands

• Completely Digital

Portrait Product Redesigned

• Conversion to digital photography• School year printed on portraits• Choice of several graphic borders• Personalized with autographs• My Photo Adventure CD

• 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

• 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

• Wow factor • Generate enthusiasm to buy • Sales flyer for families• Introduce and feature

personalized autograph• Present choice of two poses

and graphic borders• Feature many images of the child• Clear offer with Order Form and integrated Payment Envelope• Send to web for more information

Project and Design Objectives

• High volume with Short lead times • High Quality Requirements with Tight roll out schedule• Highly personalized

• 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

Challenges

Solutions and Implementation

• 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

• Enable tear-off envelope• Eliminated bindery waste• Able to personalize envelope

• Bar coded identification• Small portrait

• Key breakthrough• 20 inch roll stock• Registration marks for printing• Pre-Press perforated for tear off envelope• Pre-Press co-adhesive to form envelope• Pre-Press remoisten adhesive on flap• Post press conversion reduced to one step on traditional

folding equipment

Pre-Press Converted Paper Stock

• 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

Results

Impact

• Met our marketing objective

• Wow factor• Dramatic increase in

sales and response rate• Enthusiastic response

from schools and families• Learned a lot

Lessons

• 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 ….

• PODi 2006 Best Practices Award• Featured in … American Printer The Big Picture

Print Matters • PIA Award of Excellence• Personalization• One to one printing• Equipment• Fully Digital• Convertible Brands – Start it Up!

Speaker Presentation by:

George Fry Managing DirectorConvertible Brands866-832-0217