Bonding with the Bindery

The bindery often has been viewed as the last frontier in which to employ computer-integrated manufacturing into its workflow. Unfortunately, while many pieces of bindery equipment are indeed JDF- and CIP4-compatible, few printers have yet to realize the faster makeready, throughput, and productivity gains that come from the utilization of these systems.

But for those businesses that have taken the steps to integrate their binderies and pressrooms, more often than not a systems approach has been employed—and with much success. Here, either several different finishing stations have been networked together to make the bindery more efficient, or several pieces of equipment have been replaced with one that produces all of the work in a single unit.

One such company that has successfully applied the efficiencies of JDF to the real-world production of saddle stitched books is RR Donnelley, which implemented a pilot program at The Nielsen Company, one of its key commercial printing facilities located in Cincinnati, Ohio.

Partner companies in the pilot include Creo with its Prinergy workflow and UpFront job planning software, MAN Roland and Komori with their JDF-ready web presses, and Müller Martini with its PrimaPlus SB saddle stitching system. The stitcher's Amrys (automated makeready) feature extends the JDF workflow to the bindery by automating the dozens of settings a stitcher line requires through a network of digitally controlled servo motors.

The Donnelley JDF workflow pilot at Nielsen is built around five objectives:

• reduce overall cost of manufacturing, beginning with the reduction of print errors caused by poor information getting into the process due to manual inputting errors;
• reduce cycle times by turning around every job in 48 hours or less;
• being able to achieve more throughput with less staff;
• develop an overall production process that is integrated for repeatable and predictable results; and
• optimize equipment utilization so that Nielsen can feed more work to its presses to improve its return on investment.

After only two months in operation, the pilot workflow is scoring high marks on each of the objectives, according to Ray Hartman, senior vice president of manufacturing technology for RR Donnelley, who is responsible for equipping the company's facilities with state-of-the-art systems worldwide.

"We call it 'print-on-command,' " he says of the Nielsen pilot program. "And we intend on modeling it over our commercial platform throughout the Donnelley network."

The bindery is a particular area of concern when it comes to fully integrating a commercial facility's workflow, because of the precise physical functions—like folding, gathering, stitching, and trimming—that it needs to perform.

At Nielsen, five saddle stitching systems of various vintages were at the heart of the postpress process. For its new JDF workflow, the company replaced its two oldest systems with one Müller Martini PrimaPlus.

Each stitcher had been delivering 6,500 copies per hour. As anticipated, PrimaPlus has raised the bar on that performance considerably.

"We are now producing in the range of 12,000 to 13,000 copies per hour on the PrimaPlus, so we've got 100% coverage in terms of net speed," Hartman states. "In terms of ROI, we expect payback in less than three years just on the production savings that PrimaPlus provides."

But it is in the area of postpress makeready that Prima-Plus's connection to the JDF workflow really pays off. Nielsen utilizes Creo's JDF-based UpFront job planning software as its entry point for job specifications. Version 3.0 of UpFront, the latest iteration of the software, hands down all of the job's specifications, such as the overall size of the book, trim dimensions, and quantity of the job to PrimaPlus's Amrys connection.

"Before we instituted this JDF workflow with PrimaPlus, the operators would have to look everything up on a job ticket and set all of the adjustments throughout the machine by hand," Hartman says. "Now we can have the JDF workflow presetting PrimaPlus automatically as the signatures are coming off the press. That gives us predictable and repeatable results from information that's organized within the workflow."

As a result, Nielsen is now able to turn around most jobs in 30 to 60 minutes on its PrimaPlus. "And we've only been running it for two months," Hartman notes. "That kind of turnaround in such a short amount of time is amazing."

John Lestingi, vice president of manufacturing for Nielsen, agrees.

"This is the first significant technology we've seen come down to the bindery in a long time," he asserts. "Müller Martini has really stepped up to the plate with Amrys. We run 11 presses altogether, so it doesn't take long to bury our bindery. PrimaPlus has helped us with our efficiency, and enables us to keep up with the pressroom curve."

The Nielsen Company expects to notch up its stitcher throughput even higher by investing in log stream feeders, which are available from Müller Martini for the PrimaPlus. The upgrade would result in a more automated and integrated flow of printed signatures from the pressroom to the bindery.

At the heart of the JDF workflow at Nielsen are two 16-page web offset presses: a Komori machine with Microcolor closed-loop inking system from Graphics Microsystems, and a MAN Roland Rotoman with its own Pecom operating and automation system. "We reduced our four-man crew to three in the pressroom as a result of this pilot program," Hartman notes. "Over three shifts, that really adds up."

Producing consistent results and achieving consistent performance from shift to shift is implicit in Donnelley's objectives for the JDF pilot.

"As is the case in most plants, our third shift is the least experienced," Hartman explains. "Thanks to Amrys and JDF, we can have a 24/7 system that we can depend on from shift to shift."

The Nielsen Company is taking advantage of what Hartman classifies as a "predictable" makeready on its PrimaPlus. "We don't need tribal knowledge to get it going," Hartman says. "We don't need air hoses to push the book down on the chain, or have to figure out where to blow the air. On the PrimaPlus, the air blast comes right through to the pocket on the timed cycle. Thus, everybody sets it up the same way, and we get consistent results."

The PrimaPlus and JDF workflow are proving their worth on repeat jobs as well, Hartman states. In the pressroom, the Komori and MAN Roland web presses are virtually setting their own color profiles for reruns, using data from the original job.

Similarly, in the bindery, PrimaPlus recalls job parameters on its own, including any on-the-fly tweaks that might have been necessary, to accelerate the set-up of repeat runs. "We want to start up as close as possible to what we need to turn around the job as quickly as possible," Hartman explains. "Amrys helps us do that."

Donnelley also finds that JDF's electronic job ticket functionality reduces process errors. "People aren't guessing," Hartman declares. "In JDF, a text file tells you the specifications on how that job needs to be run correctly."

The next phase of the pilot is connecting Nielsen's EFI Logic management information system to its new JDF workflow. "We want to get machine data downloaded from the Prima into the Logic MIS so we can do cost variance reporting of actual production times versus our estimates," Hartman says. "Eventually, we want to benchmark our equipment and standardize the process across the platform of the entire commercial printing plant. That involves hooking into every machine with MIS to know what our costs are."

Hartman began looking at PrimaPlus as his JDF-driven finishing solution in 2002, when the system received an InterTech Technology Award from the Graphic Arts Technical Foundation (GATF). "My confidence level was initially built around the award," he says. "That brought me to GATF, which runs a PrimaPlus Amrys in its research facility near Pittsburgh, for my first demo on the machine. I wanted proof that it not only received the award for JDF integration, but that it actually worked. And it certainly did."

Smaller-size shops are reaping the benefits of an integrated bindery as well.

For instance, AJ Images, a 23-employee commercial print shop located in Roselle, N.J., is serving as the field-test site for MBO's Data Manager and Creo's UpFront software running on an MBO Perfection folder.

AJ Images's Perfection folder is equipped with Touch Screen and Navigator control, a digital microprocessor controlled technology that automates the folding process, reduces errors in the production process, and integrates the bindery into the digital workflow. Data Manager, an optional software system for Perfection folders, integrates the MBO folding machine into a CIP3/CIP4- and JDF-compliant digital workflow.

"The system works very well," says Arnold Greebel, vice president of AJ Images, which utilizes a six-color MAN Roland 706 40" perfector press, a five-color MAN Roland RFK 3B Series 643 40" perfector, and a two-color MAN Roland 40TC Series 636 40" sheetfed press. "The operator no longer has to set up the folder manually for each job. With Data Manager, the bindery manager can preset the jobs remotely from anywhere in the plant to anywhere outside the plant. The only job the operator might need to do is tweak the set-up."

AJ Images took this system further and added Creo's UpFront software to set up job impositions. "Presently, we're working on getting UpFront to understand all of the folds we do," explains Greebel. "That's the beta portion that we are working on."

In the meantime, AJ Images has significantly reduced its turnaround time and increased productivity in its bindery. Greebel says that what used to take an hour to make ready, especially for gatefolds, now only takes 10 to 15 minutes or less with the Perfection folding machines. Further, repetitive jobs, which AJ Images counts on for much of its work, are stored within the system, further aiding productivity.

"Having MBO's DataManager has helped tremendously to alleviate bottlenecks in the bindery," he states. "It's given us the ability to produce a huge volume of work. For example, we print train schedules. The job needs to be delivered in a certain time frame, and we have a short time to print and deliver the thousands that are needed. The train company trusts us because of our technology, and they know we will deliver the job in timely manner and with high quality.

"We were looking for a folder control system that was as automated as possible for higher efficiency, more accuracy, and less operator intervention," he continues, citing that where the company used to need two or three operators, it now needs just one.

"Ultimately, the goal was to have the desktop department be able to set up folding impositions on the folder electronically through the computer network, thus requiring fewer operators. The MBO Perfection with Touch Screen and Navigator was the only machine on the market that was CIP3/CIP4-compliant. It's fast and easy to set up. The folder itself is extremely accurate, and the computer is easy to navigate," he adds.

Some printers look to upgrade their binderies primarily to help keep up with the speed of their high-speed presses.

In April 2004, Litho Inc., located in St. Paul, Minn., completely upgraded its bindery with brand-new postpress systems to match pace with the company's two six-color Heidelberg Speedmaster SM 105 40" sheetfed presses and six-color Komori System 38 web press.

The 115-employee web and sheetfed printer—which specializes in catalogs, marketing materials, publication inserts, and annual reports—replaced a standalone cutter, three folders, and two stitchers with a variety of new computerized bindery equipment from Heidelberg. Litho Inc. installed a custom-designed system with a 12-pocket Heidelberg ST 400 Stitchmaster automated gatherer/stitcher/trimmer line, a Polar Cutting System 6 automated cutting line, and two Heidelberg TD Topline Series Stahlfolders with perforating and in-line paper banding.

"There were two main reasons that we upgraded our bindery equipment," says Litho Inc. operations manager John Warner. "First, we found that our older equipment was becoming unreliable. By installing the automated stitcher with its video recognition system, we can ensure a quality product. Second, we bought the equipment for workflow purposes. For example, a lot of our products need to be shrink-wrapped. We can send our product straight from the stacker to the shrink-wrapper and move it more efficiently. We used to have to handle it twice."

Warner relates that Litho Inc.'s ST 400 Stitchmaster—which features nine pockets and three cover feeders with in-line punching, scoring, loop stitch, and folding capabilities—offers state-of-the-art camera recognition, electronic programming, and in-line shrink-wrapping. The video recognition system ensures that the proper signature is placed in the correct pocket so as to avoid any inaccurate versioning or incomplete stitched components.

Says Warner, this unit runs at nearly double the speed and output of Litho's previous equipment, and will cut makeready times by more than 50%.

"The stitcher's makeready times are very short, usually less than 30 minutes," Warner states, "and we can store them in memory. Even short-run jobs can be produced efficiently."

The Polar Cutting System 6, one of only a few in the U.S., allows cut materials to automatically traverse and stack themselves onto pallets. This equipment represents a 40% improvement in efficiency compared to Litho's previous cutting system, says Warner.

The two new Heidelberg TD Topline Series Stahlfolders complement and enhance Litho's existing folding capabilities.

"We feel that this equipment will allow our prepress department to send files via CIP4 and automate our stitching and folding areas," says Warner. "Having the ability to set up job parameters in prepress allows us to have a more efficient workflow that is far less labor-intensive and costly in terms of lead times.

"We also feel that this equipment will allow us to expand our capabilities," Warner continues. "We're looking into ink-jet and direct mail personalization on the stitcher. It's a process that will enhance our capabilities, and will be a huge benefit for our client base of ad agencies."

Printers that are eyeing CIP4 and JDF but have not yet taken the full leap into these realms nonetheless find great value in continuing to invest in their binderies.

"We definitely subscribe to the advantages of computer-integrated manufacturing, JDF and open standards, and connectivity in our workflow," says Scott Lifschin, director of technology for L.P. Thebault Company (LPT), a $100 million, two-facility firm based in Parsippany, N.J. The commercial web and sheetfed operation is expanding into direct mail, folding carton, and packaging work, even launching earlier this year StudioLPT in Manhattan to provide prepress and post-production capabilities for a creative, high-end clientele.

Lifschin adds, "Recognizing how important it is to get things right as early in the process as possible, we started with prepress, with Creo Prinergy and UpFront driving our EFI Hagen OA system, which includes shop floor data collection for time and materials. Five of us went to Drupa to evaluate various systems that could help us accomplish our long-term goals."

In the meantime, says Joseph Corvino, director of finishing and materials handling, LPT is taking preparatory steps, including moving its bindery into the web facility. "This is great for press and bindery operators, who can communicate better; for example, edge-trimming on press can save a cut on a guillotine cutter, which is substantial on a run of 10 million pieces."

To Corvino, the combination of electronic job tickets and Hagen shop terminals reveals the true advantages of automation to a busy commercial shop: making job information accessible to all, to eliminate or at least minimize confusion or mistakes; properly allocating chargeable time and materials to jobs; and tracking raw materials delivery and consumption.

Says Lifschin, "We're not operating our three Pacesetter stitchers with CIP4 data yet, but we're on that path."

AccuLink, an 80-employee commercial printing firm located in Greenville, N.C., installed a new VAC-100 stitcher/folder/trimming line from Standard Horizon 18 months ago to go along with another stitcher/folder/trimming line and perfect binder, all from Standard. The new VAC-100 is JDF compatible.

"I do think that CIP4 and JDF will work for the bindery," says Tom O'Brien, president of AccuLink, which houses four NexPress Digimaster presses, a seven-color Indigo variable-data digital press, a half-size web, and a 25" and 12x18" sheetfed press line.

"Five or 10 years from now, we'll probably look back and ask ourselves why we didn't adopt it sooner," he says. "Using these systems to their fullest potential allows all of a job's parameters to be set up in prepress. Not only will this improve throughput and productivity, but it will help in overall operations because as we all know, it is becoming harder and harder to find a skilled work force."

To help meet increasing capacity in its bindery, W&C Printing Company, Inc., a 40-employee firm located in Winona, Minn., installed this past spring a Duplo System 5000, consisting of two DC-10/60 collating towers and a DBM-500/T bookletmaker and trimmer.

The new System 5000 complemented the firm's two-year-old System 4000 from Duplo, which comprises two DC-10/60 collating towers, a DBM-400/T bookletmaker and trimmer, and DBM-400STR stacker.

"We had to install a second Duplo system due to capacity," says Susan J. Meine, vice president of manufacturing for W&C, which uses a 28" Sakurai sheetfed press and a small Didde web press to print its work. "The new System 5000 is sturdier and more industrial strength. We needed it because we put through so much work."

Meine relates that W&C's two-shift bindery department produces approximately 175,000 booklets per week on its Duplo equipment, which it uses for saddle stitched work such as promotional booklets, catalogs, price and parts books, annual reports, and portrait photo studio brochures.

"The systems approach has worked out great for us," she continues. "Rather than having separate stations for cutting, folding, and stitching, we have everything in one piece of equipment. Plus, as we're really tight on space, having three functions in one piece of equipment has helped us tremendously. Our productivity has thus increased quite a bit, and we're able to provide faster turnaround."