Flexible Format and Single Width Operation Tom Bernth Metro Users 2014.

Flexible Format and Single Width OperationFlexible Format and Single Width Operation

Tom Bernth

Metro Users 2014

Lifetime Support EnhancementsLifetime Support Enhancements

• Enhancements will always be available– Controls upgrades– Digital ink conversion– Digital RTP controls upgrades (CT and Static Belt)– Couple additions and press reconfigurations– Compact format conversion

• Stitched tab conversion

• Triliner conversion

– Paper Width Change with Folder enhancement packages– Press Repairs and rebuilds– Goss releasing new enhancements later this year

• Training• Spare parts

Today I will ask you to…Today I will ask you to…

• Keep an open mind and be open to change

• Be “forward thinking” to sustain and grow your business

• Review the business plan for your pressroom profit center

But first we’ll review…But first we’ll review…

SLIDES FROM THE PAST…..

Metro User Group

2007

PRESS CONSIDERATIONSPRESS CONSIDERATIONS

Waste Reduction

Increase Average Press Speed

Reduce Down Time

Former boards

Cleanliness

Registration

Folder Timing

Good plates

Vertical Drives

Set-off

Blankets

RTP performance

Web Breaks

Impression

Lubrication

Presets

Nip marking

Wrinkles

Tension

ProductivityProductivity

Color reproduction

Nice fold

Clean appearance

Former boards

Cleanliness

Registration

Folder Timing

Good plates

Vertical Drives

Set-off

Blankets

RTP performance

Web Breaks

Impression

Lubrication

Presets

Nip marking

Wrinkles

Tension

QualityQuality

48” Web width

27 lb. Paper

More color

Comic leads

Reduced staffing

Younger Staff

What next??

Productivity and “The Issues”Productivity and “The Issues”

““Like New Condition”Like New Condition”

48” Web width

27 lb. Paper

More color

Comic leads

Reduced staffing

Younger Staff

What next??

Productivity and “The Issues”Productivity and “The Issues”

““Like New Condition”Like New Condition”

AgingAging Aged??Aged??

2007 2010 2012 2007 2010 2012 2014 2014

CirculationCirculation

Page CountPage Count

ProfitsProfits

Your Questions and the Publishers…Your Questions and the Publishers…

• How can we extend the life of the press?

• How can we improve our color?

• How can we reduce our waste?

• How can we improve the delivery and speed up the press?

Make Educated DecisionsMake Educated Decisions

• Form a plan based on accurate information

– What is wrong with the press?

– How will it effect my operation?

– How do I fix it?

– How much will it cost?

– When will I need to fix it?

Press Speed CapabilitiesPress Speed Capabilities

Situation #1Situation #1

• Several Colorliner presses, Color addition on two presses for contract work

• Circulation is 250,000+

• This pressroom is printing below capacity

• 24 Color/ 88 total

• Some Contract print work to sustain pressroom as a profit center

• Circulation and page counts have dropped

• 44” web width, digital ink

Situation #1 with questions…Situation #1 with questions…

• Several Colorliner presses, Color addition on two presses for contract work

• Circulation is 250,000+• This pressroom is printing below

capacity• 24 Color/ 88 total• Some Contract print work to sustain

pressroom as a profit center• Circulation and page counts have

dropped• 44” web width, digital ink

Form a plan based on accurate information• What is wrong with the press?

– Not enough color on most presses to run straight

– Controls/ drive obsolete– Press is aging- 24 years old– Some Contract print work to sustain

pressroom as a profit center• How will it effect my operation?

• Very Expensive to print• Need ability to attract commercial

work• How do I fix it?

• Couple relocation in pressroom to add color to running presses

• How much will it cost? Expensive project• When will I need to fix it? ?

11stst Solution to Situation #1… Solution to Situation #1…

• Training • Audit and form a maintenance plan

– Keep the folders going with solid Preventive Maintenance– Check over high risk areas such as vertical drives of front

page units• Continue with long range planning• Look at Opportunities to enhance their offering for commercial

printing with a couple relocation

• But, what if you have to move your press, take on a large Newspaper or you combine operations with another printer….

Alternative Solution…Alternative Solution…

• This Newspaper has over 150,000 circulation• Requirement to Print the newspaper in one pass running straight• All Color 48-page Uniliner Press with 6-wide towers and max

speed of 85,000 IPH• Single level operation with Lean production in mind

– Efficient equipment arrangement– Every step of the process stream has value to the customer – Reduce operations cost for more profitable operation

48-page Uniliner Solution48-page Uniliner Solution

Situation #2Situation #2

• Metro with 22 ¾”, 46” web, Imperial folder

• 24 Color/32 total or 20 color/ 24 total

• Circulation has leveled at 54,000/ 81,000

• Pressroom is printing below capacity

• Have to print collect to have some contract print work but would like to have more color and run straight

• Very old page packs, Press was rebuilt in the last 10 years

3171

Situation #2Situation #2

• Metro with 22 ¾”, 46” web, Imperial folder

• 24 Color/32 total or 20 color/ 24 total• Circulation has leveled at 54,000/

81,000• Pressroom is printing below capacity• Have to print collect to have some

contract print work but would like to have more color and run straight

• Very old page packs, Press was rebuilt in the last 10 years

Form a plan based on accurate information

• What is wrong with the press?– Need 48 pages so have to run

collect– Web width, long cut-off– Old obsolete page packs– Difficult long web leads– High waste

• Why will it effect my operation?– Can’t take on additional contract

printing efficiently• How do I fix it?

– Consider all possibilities– Business plan for pressroom

profit center with ROI calculation including operation savings.

• How much will it cost? Expensive• When will I need to fix it?

A Solution to Situation #2A Solution to Situation #2

• Training • Audit and form a maintenance plan

– Keep the folders going with solid Preventive Maintenance– Check over high risk areas such as vertical drives of front

page units• Continue with long range planning Conversion to Digital page

packs– Probably consider used page packs– Controls upgrade to modernize equipment

• Reduce risk

– Consider 44” PWC if or when paper price increases

Another Solution to Situation #2Another Solution to Situation #2

• Right size press- 16-page tabloid Magnum compact (24 pages if using ribbon decks)

– All Color with two sections each run (two formers)

– Improved quality

– Additional Micro zones available with 2- minute plate changes

– Additional printing opportunities through speed and increased color

• Single level operation with Lean efficient production

Situation #3Situation #3

• The pressroom is printing at well below capacity– HO press with Imperial folder 16/48 when running collect– Only runs two sections. Balloon not used

• The press needs more color capability even when running collect and waste is very high

• Very little contract print work to sustain the pressroom as a profit center• Circulation has leveled off to 24,000/ 35,000• The press has not been updated. Still has old Single piston Injector, no pre-

setting controls and 48” web

Situation #3Situation #3

• The pressroom is printing at well below capacity

– HO press with Imperial folder 16/48 when running collect

– Only runs two sections• The press needs more color

capability even when running collect and waste is very high

• Very little contract print work to sustain the pressroom as a profit center

• Circulation has leveled off to 24,000/ 35,000

• The press has not been updated. Still has old Single piston Injector, no pre-setting controls and 48” web

• Form a plan based on accurate information– What is wrong with the press?

• Not enough color, too large press• Press is very old- 1983• Too expensive to upgrade

– Need press controls and digital ink

– Why will it effect my operation?• Too expensive to operate• No future with the existing equip• No benefit with high cost.

– How do I fix it?• Consider small new press• Low cost operation

– How much will it cost? • Calculate cost of equipment plus

operation cost. Careful ROI calculation.

– When will I need to fix it? Soon

Solution to Situation #3Solution to Situation #3

• SSC Press with two runs for daily Edition. Each run has 2 sections

• 16 page All color per run

– Option to run tabloid format which is quarter folded to Compact broadsheet format for 32 pages in one run

– Product inserted midway through the 2nd run

• Single level operation with Lean production in mind

SummarySummary

• Which situation do you fit into?• Can situations change year to year?• What is your focus?

– To do it like we have always done it? Break even business

– Be innovative and lean in your Pressroom profit center business plan with a keen focus on profit?

Auto Plate LoaderAuto Plate Loader

• Visit our booth and try the Auto Plate Loader demo• Proven Technology- Simple and Reliable

Pressroom Profit Center Business plan…Pressroom Profit Center Business plan…

• Starts with a blank sheet of paper

Discussion or Questions…Discussion or Questions…

Thank you!!!Thank you!!!

[email protected]

Lifetime Support

Situation #1Situation #1

• This pressroom is printing at or near volume capacity

• 4 presses, Color update on one press

• Acceptable color capability but would like more

• Contract print work to sustain my pressroom as a profit center

• Circulation and page counts have leveled off

• The press has been updated but needs some repair and enhancements for commercial printing and improved efficiency

• 28 Color/ 56 Total

Situation #1 with questions…Situation #1 with questions…

• My pressroom is printing at or near volume capacity

• 4 presses, Color update on one press

• Acceptable color capability but would like more

• Contract print work to sustain my pressroom as a profit center

• Circulation and page counts have leveled off

• The press has been updated but needs some repair and enhancements for commercial printing and improved efficiency

• 28 Color/ 56 Total

• Form a plan based on accurate information

– What is wrong with the

press?

– Why will it effect my

operation?

– How do I fix it?

– How much will it cost?

– When will I need to fix it?

A Solution to Situation #1…A Solution to Situation #1…

• This Newspaper has already enhanced their RTPs and have purchased motorized auto registration.

• Training• Audit and form a maintenance plan

– Keep the folders going with solid Preventive Maintenance– Check over high risk areas such as vertical drives of front

page units• Continue with long range planning• Look at Opportunities to enhance their offering for commercial

printing

• But, what if you have to move your press, take on a large Newspaper or you combine operations with another printer….

Alternative Solution…Alternative Solution…

• This Newspaper has over 150,000 circulation• Wants to print the newspaper in one pass running straight• Single level 6-wide towers with max speed of 85,000 IPH• Single level production facility with Pre-press, press and mailroom

on a single floor level– Efficient equipment arrangement– Lean Manufacturing– Reduce operations cost for more profitable operation

Uniliner diagram hereUniliner diagram here……