Implementation of the JDF/CIP3 Workflow at Japs-Olson Co. - CIP4

Implementation of the JDF/CIP3 Workflow at Japs-Olson Co.
Using the Hiedelberg TH Folder Series, Hiedelberg FSC-100, MBO Navigator Folders,
MBO DataManager, Polar Mohr Compucut, Polar Mohr 137 Auto Trim Cutter,
CP Microsystems Micro-cut, GMI Color Management System and
Heidelberg Color Management System Prinect and the Kodak Upfront System
Background
After a Slower year in 2002 Japs-Olson Co. decided to look at the equipment and the processes used for
production at our plant. At Japs-Olson Co. we have always had top-quality equipment but we needed an
update in our Bindery, Pressroom and Prepress areas to get maximum production from the equipment we
had and any new equipment we would need. Improvement in these systems would benefit our company
by getting our product out the door faster. Increased quality and an increase in production of jobs was a
primary focus.
At the time of observation, we had many non-automated folders. For an operator to set a job up took a
lengthy process. 3 hour setups were not uncommon on our folding system.
Providing a pattern or sample to the folder operator was sometimes a difficult task. At times these
samples were unavailable or sometimes even misplaced. An operator would have to stop production at
this point and find a folding sample. On night shifts this could be a lengthy wait.
The folder operator would look at the folded sample and make adjustments on the machine in order to
match what our customer wanted. Often times the folder operator would have to adjust the machine
numerous times to get the results the customer needed.
Objectives
The goals for Japs Olson were simple;
• Design a system that would improve change over / make ready times.
• Make the system easy to use and understand.
• Increase productivity.
• Eliminate lengthy manual steps. Such as measuring press sheets, setting pockets, knives and plates.
Methodology:
Japs-Olson’s President Michael Murphy and Operations Mangager Chris Illa each have an inherent ability
to look at a system and improve it. After looking at what systems we had in place, Michael and Chris
wanted to improve the entire Bindery, Pressroom and Prepress areas through the use of preset data.
Michael and Chris saw a need to reduce set-up times in the setup processes and decided the time was right
to improve our workflow.
Prepress
Kodak’s Upfront software package was chosen because of the flexibility the software had. The
responsiveness of the company and adaptability of the company to accept quick market changes played a
huge role in Chris Illa’s choice for the new product. Upfront’s main benefit is that we could develop
systems that would produce preset data for our cutters, folders and stitchers (all of which are currently
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unning). Upfront also gives Japs-Olson Co. the ability to generate preset data for many types of
equipment made by a variety of manufacturers.
Bindery Folding
After looking at numerous vendors, Michael acquired the first Heidelberg TH Stahlfolder in North
America. This folder was chosen over other vendors because of the ease of use to the operator, the JDF
compatibility and it had the latest technology. The folder automatically adjusts plate positions and roller
settings with the preset data.
An interface between Upfront and the TH folder would also be needed so the Heidelberg FCS-100 was
also deployed at our company. This is the system that interprets the JDF and sends the preset data to the
folder.
The MBO System chosen was just as easy to use. With the addition of the DataManager system we
improved our current Navigator series folders by alowing the operator select a job from the queue and
start production. Both systems have made solid improvements to our workflow. With the use of
automated presets our folder make ready time is seeing about 40% reduction.
Bindery Stitching
The Heidelberg Stitchmaster series was chosen because of its ability to accept either Cip3 data or JDF
data to preset the stitcher. Use of the preset data has reduced the stitcher make ready time again by about
40%.
Bindery Cutting
The CP Microsystems Microcut system was chosen. As with all other preset systems Japs-Olson
employees worked with the developers to make this system work in a functional working environment.
The Microcut system eliminates measuring of the sheet to be cut and decreases make ready time up to
50%.
The Polar Mohr Compucut System and Polar Mohr’s Auto Trim 137 was chosen for the ability to accept
a program created from a Cip3 file. The system allows the prepress operator to choose the method of
cutting right from prepress. This make ready time had been reduced by about 25%.
Pressroom Color Presets
The color management two systems we installed were both Cip3 enabled. GMI Closed Loop Color
Control and Heidelberg’s Prinect Color packages were selected. Both of the systems use a Cip3 file that is
automatically generated by Kodak’s Prinergy system. These files are loaded to the press when the press
operator begins a job.
Implementation
Bindery Folding Systems
Being the first company to have the Heidelberg folding system also meant that we would be a testing
ground for the system. The Heidelberg folder performed well out of the “box”.
When the FCS-100 was installed Heidelberg sent both their install team and a software engineer to get the
system up and running. After installation Japs Olson Co. and Heidelberg went through numerous testing
cycles and upgrades to get the product to where it is today. Today we have a system that is “stand alone”
and requires no operator intervention to send files to the folder.
For installation of the MBO System we also went through some troubleshooting and testing stages.
Custom programming was done in house to get the folding files to move from the DataManager to the
folder. MBO’s staff was more than helpful in getting the system up and running. The MBO System was a
great addition to our folding workflow.
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Bindery Stitching systems
These systems were incredibly easy to put in place. The system runs “hands off”. Anyone could get this
system running in minutes.
Bindery Cutting Systems
We worked hard with the developers of the CP Microsystems Microcut Program. They were very
responsive and helped us develop a system that was very easy to use. Within a month the system was
installed and tailored to our workflow. Incredibly easy to use, this system took older cutting machines and
made them perform as well as many new models.
The CompuCut system was installed on an older cutter. We installed a computer at this cutter with the
CompuCut software loaded on it, which allow the operator to “browse” for the file to be loaded from the
network. The development was our first attempt at providing preset data so initial startup setup was
longer than normal. However the system has not been modified since installation. Looking back, the
system would be very easy to install and get working in a day or two.
Pressroom Color Presets
A primary initiative for the pressroom was to improve quality and reduce make ready times. CLC
Packages From Heidelberg and GMI where selected because of their ease of use and their ability to
produce the highest quality product. Another great benefit of these applications was we now have happier
press operators who don’t have to work as hard to make a superior product.
Resulting Workflow/Processes
The folding workflow is illustrated below;
Upfront
Workstation
A folding pattern is selected for the layout.
A JDF file is exported for folding to a hot
folder on the FCS-100.
A folding layout is created in cip3 format for
the MBO system. This file is exported to a
folder on the network and picked up at
MBO’s Datamanger terminal.
MBO
DataManager
Interprets Cip3 files for folding and stores
them in database.
The Stitching workflow is illustrated below;
Upfront
Workstation
A Stitching file (Cip3 or JDF) is created,
giving stitch type,
Number of stitch, trims and pocket settings.
FCS-100
Workstation
Interprets JDF files for folding and
sends the information to the job
queue located on the folder.
Japs Olson
Shopterm
Once an operator punches into a job,
the shopterm program completes a
command in the database and the file
is released to the folding queue on
the MBO Folder.
Heidelberg
Stitchmaster
The operator selects the job from the
network folder and transfers the
presets into that machine.
Heidelberg TH
Folder
The job presets are loaded from the
job queue. Plates and rollers are
moved into position automatically
and the job is started.
MBO
Navigator Folder
The operator selects the job from the
queue and begins to fold.
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The Cutting workflow is illustrated below;
Upfront
Workstation
A Cutting Cip3 File is generated from
Upfront
The Closed Loop Color Control workflow is illustrated below;
Kodak Prinergy
Workstation
A color management Cip3 File is generated
from Prinergy at the time of plating. This
files contains Ink key preset data.
Microcut
System
The operator selects the job from the
network folder, select the style of cut
and transfers the presets into that
machine. Cutting is started.
CompuCut
System
The prepress operator opens the
upfront Cip3 file. The operator then
sets the cutting style and saves the
job to the network.
GMI Color System
The press operator selects the cip3
file when starting a job. The operator
loads the file from the network. Ink
keys are set and printing is started.
Heidelberg
Prinect Color
System
The press operator selects the job to
be run from the list in the Prinect
program and loads the settings into
the press console. Printing is started.
Heidelberg
137 AutoTrim Cutter
The cutter operator selects the job , then
transfers the file to the cutter.
The job is cut without any measurements
taken manually by the operator.
Section VI. Details for most innovative use of process automation technology in an
implementation
Many companies even today are using manual systems. Japs-Olson Co. wanted to stay ahead of
the crowd in an already fiercely competitive market. We saw a need to improve systems with a
combination of workflow, equipment, and custom programming. We have made the largest
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gains with Kodak’s Upfront. This software package supplies files for our Cutters, Stitchers,
Folders, Press layouts and Layouts for our Data Processing Department. Kodak’s World Wide
Product Manager Eliza Leung has been responsive in tailoring the software to fit many of the
dynamics of making all these different systems work all at once.
How Kodak’s Upfront drives many different
systems at Japs-Olson Co.
Kodak’s Prinergy
Software
A press layout is automatically
loaded from the template and job file
produced from Upfront.
CP Microsystems’
Micro-cut
Interprets the Cip3 files. The
operator chooses a basic cutting style
and the system generates the
program in seconds.
Polar Mohr’s
CompuCut
The Cip3 file is opened here and the
style of cut is chosen. The file is
saved on the network and will be
loaded by the Cutter operator.
Upfront
Workstation
A folding pattern is selected for the layout.
A JDF file is exported for folding to a hot
folder on the FCS-100.
A folding layout is created in cip3 format for
the MBO system. This file is exported to a
folder on the network and picked up at
MBO’s Datamanger terminal.
A CIP3/JDF stitching file is made.
This file is sent to a folder on the network
and picked up directly by the stitcher
operator.
A Press layout in generated and placed into
Kodaks Prinergy Software
A Cip 3 Cutting file is generated and picked
up by and operator at our Cip3 Microsystems
Cutter.
A Cip3 Cutting is generated and is written to
the network to be picked up and modified by
Polar Mohr’s Compucut Program.
A PDF Diagram is produced showing layout
for the personalization process
PDF for Data
Processing
The PDf File from Upfront is
available to show the operator the
Form layout
Heidelberg’s
FCS-100
Workstation
Interprets JDF files for folding and
sends the information to the job
queue located on the folder.
MBO’s
DataManager
Interprets Cip3 files for folding and
stores them in database.
Heidelberg
Stitchmaster
Takes either Cip3 or Jdf Data and
adjusts pockets and trims.
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