Pressroom Management System
Presentation Outline
1) Introduction/Background to Costs in the Pressroom
3) Saving Opportunity Areas
2) The CYPRO Pressroom Management Approach
5) Summary
4) Review “Live” CYPRO Application http://demo.monroegraphic.com
Pressroom CostsPress Throughput isreduced by hundredsof factors!
Goal of CYPRO is to provide tools to increase pressroom efficiency so you can produce a better product at a lower cost!
Monroe Graphic Service
Web Offset Printing Press Remanufacturer for over 20 yrs
Services include complete remanufactured printing presses, refurbished print units, press installations and electrical control upgrades Customer list includes small privately owned companies as well as many of the major printers worldwide
The CYPRO Solution
CYPRO securely leverages the power of the Internet, allowing all users to review data from anywhere.
CYPRO is electronically tied to the press to capture all impressions and time associated with press events. This includes press stops and starts, web breaks, splices and more.
CYPRO helps printers to substantially reduce costs associated with waste, press speed, downtime and paper consumption.
CYPRO automatically captures production data, paper consumption, pallets, maintenance and much more.
CYPRO Capabilities
Production Analysis
Paper Consumption
Finished Goods
Job Forecasting
Preventative MaintenancePressroom
Review
Savings Opportunities
Integration into Front Office System—Pallets, Paper, Estimate Info, etc.
Use of CYPRO Reporting Tools--Micro & Macro
Document System—Troubleshoot, Operations, etc.
Ability to react to other ideas to impact operations
Paper Savings—Running Waste Reduction, BW Monitoring, Slab Waste Analysis Maintenance System—PM, WO, etc.
Focus on Beating Estimate
Use “Pressroom” screen to discover jobs with potential issues
Cause of Issues If an issue exists, use “Forecasting” screen
to understandcause of issue (slow speed, excessive
waste, excessivedowntime, a combination of issues,
invalid estimate, etc.) and begin to formulate a plan to
address issue
Sources of Waste/DT Use “Job Report” screen to understand
sources of waste and downtime, etc. and use to
resolveissues while the job is still “On
Press”
Estimate vs Actual
Production Reporting
Improve Systemic ProblemsWhich has a bigger impact on productivity? Major Breakdown that happens 4 times a year for 4 hours of downtime vs. Minor issue that happens every third shift for 10 minutes 16 hours/year vs. 60 hours/year—The Minor
issue actually reduces total Press Throughput by 1% per year!
Running Waste easily identified and quantified!
Paper module allows for the entry of roll based consumption data.
Paper Consumption
CYPRO automatically calculates the “true” basis weight for each consumed roll of paper This value often exceeds the "Mill Basis Weight" and is a hidden source of waste. In fact, excessive basis weight can result in 2 to 5% of additional waste which is often an overlooked cause for running out of paper on a job.
Paper Roll Tag Info
6.3% Difference in weight and linear feet between Rolls 1 &
3
Roll 1
Roll 2
Roll 3
Can you trust the paper suppliers?
Same Weight, Width and Basis Weight…Yet a 766 linear foot
difference!
Basis Weight Variation
Paper lots exhibiting excessive basis weight variation may warrant a Mill claim; CYPRO Paper Reports detail and quantify the problem to make justification easy
Changes in paper lots often lead to basis weight variation. This can result in tension problems on the press affecting register, color and converting as well as inaccuracies in scale based counting systems which rely on a specified basis weight as part of its calculation.
Comparing Paper Suppliers
CYPRO Paper Reporting allows for analysis of all rolls of paper consumed over a defined time period (BW, Slab & Core Weight)
Excessive Slab Weight
Maintenance SystemPreventative Maintenance Task Approach
Work Order Approach
Use of Maintenance System
PM results in Reduced Downtime due to reduction in
breakdowns due to premature wear Longer Lifetime of Equipment—M110B
in Green Bayhas not needed a replacement roller
or cylinder inthe machine in 7 years while running
430 millionimpressions
Work Order system promotes communication about
malfunctioning equipment in the pressroom and
gets it restored to proper operating order quicker;
this results in productivity gains and a safer work
environment
Documents
Document System available to provide Pressroom withneeded information on demand—Documents can include scans of user manuals, operating procedures, photos, etc.
Integration to Front Office Integrate CYPRO into Front
Office System using web services
Estimate Job & Form Data electronically can be uploaded to CYPRO
Actual Production Data electronically can be downloaded to Front Office System
Eliminates Duplicate efforts and Errors example—Finished Pallet Information available for Shipping System automatically
http://demo.monroegraphic.com/cypro/JobData.asmx
Additional CYPRO Uses
Scale Integration for Verifying Finished Good Counts
Makeready Reduction Project--Measure and reduce time and waste
Using Pallet Log to Verify Shipments to Binderies
Automatic Upload of Link Tech Ink Meters consumption data
Load Tickets for Roll to Roll Process incorporate Original Roll data
Using Preventative Maintenance System to track Press Operator Functions
In-line Finishing front end setup photos and documentation
Result—Elimination of Overruns and Underruns
Result—Savings of over $200,000 per year per press
Result—Complete and Reliable Audit Trail
Result—Job And Period Ink Cost data
Result—Improved Converting Process
Result—Reduced Downtime
Result---Reduced Makeready Times on similar jobs
Printstream Run Speed
0
5,000
10,000
15,000
20,000
25,000
30,000
5/1/20
08 to
5/31
/2008
7/1/20
08 to
7/31
/2008
9/1/20
08 to
9/30
/2008
11/1/
2008
to 11
/30/20
08
1/1/20
09 to
1/31
/2009
3/1/20
09 to
3/31
/2009
5/1/20
09 to
5/31
/2009
Time Period (Monthly)
Pres
s Sp
eed
Imps
/Hr
Run SpeedLinear (Run Speed)
Printstream Waste Percentage
0.0%2.0%4.0%6.0%8.0%
10.0%12.0%14.0%16.0%18.0%
5/1/20
08 to
5/31
/2008
7/1/20
08to
7/31/2
008
9/1/20
08 to
9/30
/2008
11/1/
2008
to 11
/30/20
08
1/1/20
09 to
1/31
/2009
3/1/20
09 to
3/31
/2009
5/1/20
09 to
5/31
/2009
Time Period (Monthly)
Was
te %
Run Waste %Total Waste %Linear (Run Waste %)Linear (Total Waste %) Printstream Unproductive Time
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
5/1/20
08 to
5/31
/2008
7/1/20
08to
7/31/2
008
9/1/20
08 to
9/30
/2008
11/1/
2008
to 11
/30/20
08
1/1/20
09 to
1/31
/2009
3/1/20
09 to
3/31
/2009
5/1/20
09 to
5/31
/2009
Time Period (Monthly)
Dow
ntim
e
DT %Linear (DT %)
Graphs of UsersRun Speed has increased from 25,500 to 29,000 imps per hour
Run Waste has decreased from 8.5 % to 5 %
Downtime has decreased from 20 % to 18 %
Summary of Savings
Total Operating improvement of over $280,000 annually!
The PossibilitiesEncompasses your entire pressroom
Provides the opportunity to improve on various press functions Small improvements in many areas realize large productivity gains
Allows evaluation of measurable press activities
Increase your Net Output!