JAPS-‐OLSON COMPANY - Printing Industries of America

Transcription

“The most vertically integrated direct mail company in the country” Printing
Direct Mail
Postal Logistics
JAPS-‐OLSON COMPANY 7500 Excelsior Boulevard – St. Louis Park, MN 55426-‐4519 – 952-‐932-‐9393 – www.japsolson.com Chris Peddicord
Information Systems and Technology Manager
  Security and Compliance   Policies and Procedures   Software Development   Systems Architecture   Telecommunications   Data Center   Networking   Service Desk   Mobility Who is Japs-‐Olson Company?   Founded in 1907 by Barney Japs and G.F. Olson   Among the top 10 largest direct mail printers in the country   Operates 24 x 7 in 517,000 sq. ft. facility   Employs over 700 skilled professionals   Privately owned and operated   One stop shop for printing, imaging and mailing Japs-‐Olson is Industry Involved Our management team is actively involved in the following industry organizations in order to stay well informed on issues that affect our customer’s business. Environmental ini:a:ves ¡  FSC has developed a set of Principles and Criteria for forest management that are applicable to all FSC-‐certified forests throughout the world. There are 10 Principles and 57 Criteria that address legal issues, indigenous rights, labor rights, multiple benefits, and environmental impacts surrounding forest management. ¡  What makes a printer a Great / Green Printer? Participation in the PIM Great Printer Environmental Initiative is a totally voluntary effort by printers to demonstrate their commitment to minimize their company’s impact on human health and the environment while producing quality printed products for their customers. Great Printers go beyond what is required by government regulatory agencies in environmental, health and safety compliance. Great Printers are green printers. Overview of Japs-‐Olson Company Printing, imaging and mailing services:   Prepress   Pressroom   Inline Imaging – Simplex & Duplex Versamark imaging on web presses   Bindery   Data Services   Lettershop – inserting, sorting, mailing   Postal Logistics – BMC/SCF logistics, commingling, transportation Customer Mix   Banking   Financial   Retail   Travel / Transportation   Telecommunications   Non Profit Associations   Healthcare
  Insurance
  Catalogs
  DM Creative Agencies
  Technology & Internet
Unique Benefits   ONLINE MAIL TRACKING – Japs-‐Olson’s proprietary mail tracking systems allow customers to track status of mail pieces.   COMMINGLING OF MAIL – Our in house commingling of mail provides the best postage savings available today to our customers.   INLINE IMAGING – Our web press equipment allows customers to duplex image, diecut, perforate, sort and mail direct mail projects inline providing printing and mailing efficiencies. Japs-‐Olson’s Philosophy “Nobody know your business better than you. At Japs-‐Olson we make it our job to get to know you, To listen to your views, to understand your business, And to anticipate the challenges you see ahead. Once we know what you’re aiming for, We can help you achieve your goals.” Impact of Technology at Japs-‐Olson  GMI Color Correction  Commingling  High-‐Speed Inserting  Storefront Impact of Technology at Japs-‐Olson  Nexpresses  Virtualization  Sunday 2000 Presses  Inline finishing and personalization Future Technology at Japs-‐Olson  MIS System Replacement  Warehouse Management System  Human Resource Scheduling  Video Wall  Virtualized, Multi-‐Location Clusters  High-‐speed color inkjets  Cloud Plant Tour   Assemble in a conference room   DP/Prepress   Bindery   Main aisle of press room   Commingle   Mailing   Imaging   Reassemble in conference room Ground Rules   Will NOT be looking extensively at inline operations   Please do NOT leave the tour group   No cameras/cell phones This is a secure facility. If you are caught using a camera or cell phone or leaving the group you will be asked to leave and may have your device confiscated by security. Enjoy the Tour We appreciate your time, and want to Thank You for visiting our facility! Automation Solutions Network September 2012 Japs-Olson Company"
Dr Mark Bohan"
Vice President, Technology and Research!
Printing Industries of America!
!
Tour Thank you"
§  Japs-Olson Company! !
© Printing Industries of America, Dr Mark Bohan, [email protected], www.printing.org
Introductions All"
§  Everyone to introduce each other, start
with myself, then on to …….!
Overview Today s meeting"
§  Japs-Olson Company: How we automated direct
mail and commercial printing to increase
profitability and market share: Opportunities,
Challenges, Headaches and Solutions!
§ Josh Schiro, Japs-Olson Company!
§  Digital Lizard: Continuously improving workflow
to reduce touch points to improve your business
model!
§ Bill Wieners, President of Digital Lizard!
§  Printer Panel!
§  Michael Murphy, Japs-Olson Company!
§  Bill Wieners, Digital Lizard!
§  Moderator: Brandon Iskey, Printing Industries of America!
§  Vendor Panel: How we implemented automation Japs-
Olson Company!
§  DiMS!!
§  Kodak!
§  GOSS!
§  Web Printing Controls!
§  MBO America!
§  Moderator: James Boudreau, Japs-Olson Company!
§  CIP4 Update !
§ Jim Harvey, CIP4!
§  The Automation Challenges and Solutions of
Integrating Inkjet and Offset Printing Processes!
§ Mark Bohan, Printing Industries of America!
CIP4 web site and email forum Overview"
§  All staff members from
member companies can have
access!
§  Email [email protected]
with member names to add!
§  Email discussion forum!
§  Record of discussion tracts!
§  Open resources available!
§  CIP4 resources for CIP4
members!
§  Document archive!
Document storage Overview"
§  New Wiki webpage - www.printing.org/asnwiki!
§  Login will be same as printing.org login!
§  Only Automation Solutions Network registrants will have
access to this information.!
!
§  Previous meeting presentations and notes loaded!
!!
§  Will upload all presentations from this meeting!
!!
§  Any suggestions for useful documents !
§  Please contact us – [email protected] !
Thanks for listening!"
!
Dr. Mark Bohan!
!
Vice President, !
!Technology & Research!
!
412 259 1782!
!
[email protected]!
!
www.printing.org!
www.printing.org/free !
www.printing.org/markbohan!
www.linkedin.com/in/markbohan !
!
!
How We Automated Our Direct Mail and
Commercial Printing to Increase Profitability
and Market Share
JAPS-‐OLSON COMPANY 7500 Excelsior Boulevard – St. Louis Park, MN 55426-‐4519 – 952-‐932-‐9393 – www.japsolson.com Who is Japs-Olson Company?
  Founded in 1907 by Barney Japs and G.F. Olson   Ranked in the top 10 of largest direct mail printers in the country   Operates 7 days per week / 24 hours per day   Employs over 600 skilled professionals   Privately owned and operated   Broad capabilities   One stop shop for your printing, imaging and mailing needs! Japs-Olson’s Philosophy
Japs-‐Olson’s philosophy for automation is to: •  Reduce touch points •  Reduce labor •  Decrease turn time •  Increase throughput •  Better communicate Data Processing
Opportunity •  Reduce turn time for data signoffs. Challenge •  How would Prepress deliver PDF backgrounds to Data Processing? Solutions •  Prepress used Kodak RBA and PowerSwitch to automatically create and move the PDF background to a designated location setup by Data Processing. •  Data Processing then wrote their own script to move that file to the matching job folder on their server. Prepress
Opportunity •  Reduce weekend labor. Challenge •  Find a way for Kodak RBA and our MIS system to communicate and to queue up remakes automatically over the weekend. Solutions •  Prepress and IS figured out a way to use a raised event to send a signal from our MIS system to Prinergy. •  We have virtually eliminated all weekend overtime costs from this one piece of automation. Bindery
Opportunity •  Increase throughput for the Polar and Pace cutters. Challenges •  Proper layout configuration coming from Prepress. •  Working with the vendor on connectivity •  Having the cutter operators trust the system Solutions •  Created Standard Work for both Prepress and Bindery, so the setup would be the same from job to job. •  Prepress creates CIP3 data for presetting the 2 cutters. Pressroom
Opportunity •  Reduce wait time and touch points through the plant by inline personalization. Challenges •  Learning data programming & setup for versamark system •  Incorporating the versamark system into our current inline •  Communication between Press operator and Imaging operator Pressroom
Solutions •  Revised internal training documents for data setup •  Worked with vendors to look at efficient solutions •  Updated our Standard Work documents for both Pressroom & Imaging to incorporate best practices from vendor meetings •  First systems were installed on the M130’s then the M100 and M110 and most recently, the S2000’s Key Points…
•  Identify Opportunities •  Set and Clarify Expectations •  Get Employee Involvement •  Create Great Vendor Relationships •  Most of all….. COMMUNICATION! Printing is Easy
Everything Else is Hard
William Wieners, President Digital Lizard
Who Are We ? Founded 6 years ago, Digital Lizard has grown to 1 of the top 20 Digital Print Producers in the United States, with facili@es in Las Vegas and Idaho. DL focuses on providing branded print collateral portals. These portals allow customers to order the highest quality print collateral with same day delivery. Digital Lizard became a CREEL company in August 2011. CREEL Prin@ng has been a staple of the Las Vegas community since its incep@on 60 years ago. As one of the largest print companies in the US.. What does Digital Lizard Offer Front End
Digital Lizard Print – Consumer Portal for quick turn POD
Private Labeled Print Stores (Currently Over 200)
API in place for accepting automated print orders
Premium Service
Self Service Portal
Constant improvement of the user experience based on feedback
Same-day service included in price
Orders in by 12:00 PM fulfilled same day
Shipping options which meet customer needs
FedEx, UPS, USPS, Pickup, Customer Account, Freight
High quality customer service
Phone, Live Chat, E-mail, FAQ
What we Need to make this happen The PrintTrak system was built from the ground up to ensure the highest level of
print automation possible. The system was built around 4 key workflow entry
points with full order automation as the goal. Orders are standardized and
controlled from one central point.
Order Entry Points
Partner Hosted Print Systems – Partners who already have a front end
and need a Print service provider who has the ability to provide 2 way
data stream.
Hosted Print Stores – Clients looking to offer print engine to their internal
staff, partners, or clients.
Custom Print Orders – Traditional commercial print work.
API Generated Work – High Volume Consumer work
PrintTrak features 3 core components
PrintTrak Watcher – Monitors all inbound entry points
PrintTrak Shop – Print Shop Management tool
PrintTrak Communicator – Allows communication to both partners and
customers.
Digital Lizard Order Process
Partner Hosted Stores DL Hosted
Stores
Commercial
Print Work
API Generated
Work
PrintTrak Watcher Auto Pre-‐Press Batching PrintTrak Shop Imposi@on Auto Mail Sort Loca@on Decider PrintTrak Communicator Press Pool Indigo & IGEN Finishing & Bindery Shipping and US Mail Automation Highlights
ü  All Orders are treated as strings of data. All orders are converted to
common format and flow.
ü  All Orders follow the same flow
ü  Every step of production maintains a 2 way communication between
production and PrintTrak.
ü  Data is available in real time - all the time
ü  Very little human interference before press. Orders are on press in
as little as 5 minutes from customer approval.
ü  Workflow is extremely linear – This is big shift from small
commercial shops. Requires very different thinking than traditional
print shops.
How did we do it?
Mostly Open Source Protocols, Software and languages
Why – Inexpensive, Easy to update and Not tied to specific vendor
Perl, MySQL, Postgres, JDF, JMF
Home Grown Software – Nothing commercially available had the overall
toolset we were looking for API, Storefronts, Shop Management,
ability to communicate with accounting.
Free resources – The key to the success has been the use of tools and
services that are available to everyone. Few great examples
HP’s JLYT – even though dated will still use this to control all imposition it is
screaming fast and was free. (is anything from HP really free?)
FedEx Engineers – They have a service that wrote our integration to their
backend systems. We now have 100% 2 way communication with them and it
cost us a few days of working with them.
Pageflex Users Group – We use this group to solve problems every day.
There are dozens of people on this group just eager to help solve a problem and
write some new code. Just last week we needed a new pricing module, we
posted the request and less than 24 hours later we have it in hand fully coded for
free.
CIP4 Update
James E. Harvey
Executive Director, CIP4 Organization
Topics
•  JDF 1.5 and Recent Developments
•  Digital Printing Discussions
•  PACS Database
New Education & Marketing Officer
Dr. Mark Bohan
Vice President, Technology and Research
Printing Industries of America
JDF 1.5
•  Topics Set Spring of 2011/Publishing Target: Fall 2013
•  Mainly additions and enhancements
–  Automated Layout
–  Wide Format
–  Ganging
–  Digital web press enhancements
–  JMF Activity Elements
–  Digital Finishing
•  Only minor deprecation / No architectural modifications
•  Tokyo Interop: October 22-26 2012
Other Work In Progress
•  PrintTalk
•  Wide Format ICS
•  Digital Web Press
Digital Printing Project
• 
• 
• 
Digital Printing Workflow Working Group
JTWG Digital Printing Model
J-Digital: The bigger picture
– 
– 
– 
• 
A simplified JDF is needed for web-to-print systems
There is a need for an industry definition for the
interface between RIPs and digital print engines.
The is a need for more adoption of JDF by postpress
systems and MIS systems that communicate with
postpress systems, especially in near-line postpress
systems intended for digital printing workflows.
The path forward
PACS Database
Print Automation Case Study Database
•  Why?
–  Over 70 case studies
–  Evolution of the CIPPI Awards Program
–  More variety of participation
–  Ease of use and access
Print Automation Case Study Database Record and Search Elements
Parameter
Values
Restrictions
Printer Size
Small (20 or less Employees), Medium (20-100
Employees), Large (More than 100 Employees)
Pick one
Country
Country
Pick List
Integration Scope
Device-to-Device, Interdepartmental, Full Plant,
Integrated with customer
One of Device-to-Device, Interdepartmental, or Full
Plant and/or Integrated with customer
Integration Components
Creative, W2P, Ecommerce, Cloud, Scheduling,
Prepress, Estimating, MIS, Planning, Imposition,
RIP, Plating, Printing, Postpress, Mailing,
Inventory Management, CRM, Reporting, Quality
Control, Delivery
All that apply
Vendor
Vendor Name
Member Roster pick list or from Applications?
Financial Data
Yes/No
Pick one
Company Type
General Commercial, Packaging, Newspaper, labels,
Digital Printer, Sign, Wide Format, Offset,
Gravure, Web, Sheetfed, Screen, Publication
Printer, Security Printer, Prepress, Premedia,
Customer, publisher.
Pick all that apply/Optional
Year of application
Year
Automatic from upload/initial value
Contact
Name, Company, Title, Email and Phone number
Submitter's contact information (optional) ?
Product
Product Name
Name only ?
Certified Product
Yes/No
Is at least one product used CIP4 certified?
(Optional)
Format
HTML, PDF, Word, Open Doc
One or more (Automatic upon upload)
Pages
Number
Number of pages (automatic)
See JDF Integration Matrix
Yes/No
Does vendors/products have JDF Integration Matrix
listings? (Optional)
And …
GraphExpo
Jim: Don’t forget the book …
Thank you!
www.cip4.org
[email protected]
The Automa+on Challenges and Solu+ons of Integra+ng Inkjet and Offset Prin+ng Processes!
!
Mark Bohan Vice President, Technology and Research"
Printing Industries of America"
"
"
InterTech Technology Awards www.printing.org/intertechrecipients !
§  Kodak NexPress Red
§  Color Control and Web
Fluorescing Solution"
Inspection System with
AccuCam™"
Eastman Kodak Company!
§  Enterworks® Enable"
QuadTech, Inc.!
§  SunPak™ LMQ"
Enterworks, Inc.!
Sun Chemical!
§  i-cut Suite, "
§  iTechnique"
Esko!
Technique Business Systems Ltd.!
§  Fujifilm J Press 720"
§  Avatrex Transportable Imaging"
FUJIFILM North America
Corporation!
Utopia Digital Technologies!
§  Prinect Performance
§  Xeikon X-800 VariLane"
Benchmarking"
Xeikon!
Heidelberg USA!
§  i1Pro 2"
§  Keen MIS and Web-to-Print"
X-Rite, Incorporated!
Keen Systems, Inc.!
© Printing Industries of America, Dr. Mark Bohan, [email protected], www.printing.org
Session Overview!
§  Inkjet technologies"
§  Single pass inkjet!
§  Hybrid systems!
§  Why integrated solutions!
§  System integration"
§  System considerations!
§  Workflow optimization!
§  3rd party integrators!
§  Closure"
The inkjet market today…!
§  The consumer market represents 95% of global
sales for inkjet heads. The industrial and large
format market, represents only about 5%."
"
Are there inkjet developments? Let s look at the patents!
§  Significant changes
happening in inkjet"
§  Increased speed of production!
§  Ink technologies!
§  In 2009"
§  Over 4,000 patents filed!
§  Head technologies are
being addressed (30+)"
§  Nanotechnology used to
speed up process!
§  Media wars!!
Single pass inkjet Is dramatically effect the industry!
§  Big focus on single pass"
§  One time attempt to print!
§  Newspaper, books,
transpromo, magazines"
§  Personalization!
§  High speed presses "
§  Speed increasing !
§ >800 ft/min"
§  Width increasing!
§ > 40 "
Production inkjet presses www.printing.org/productioninkjet !
§ 
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§ 
§ 
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§ 
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§ 
§ 
FUJIFILM Jet Press 720 , sheetfed."
HP T Series web press, utilizing thermal drop generation"
KBA RotaJET 76, piezo inkjet technology "
Kodak Prosper Series, stream inkjet head technology."
Kodak Versamark Series, high-volume variable solutions, - transactional "
Komori Impremia, web and sheetfed inkjet presses !
Landa Technologies, next year"
Konica Minolta KM-1, sheetfed B2-format "
Océ JetStream Series, used in transactional and direct mail solutions."
Ricoh InfoPrint 5000, direct mail, transactional, and by service bureaus"
RISO ComColor series, cut sheets, applications in medium-volume production"
Screen Truepress Jet520, piezoelectric drop-on-demand water-based inks "
Timsons T-Print, piezoelectric drop-on-demand"
TKS JetLeader, piezoelectric focusing on the newspaper market"
Xerox CiPress™, resin-based ink formulation, piezoelectric "
§  And more that I have missed L"
Inkjet Technologies Nozzle technology!
Inkjet Printing
Continuous
Drop-on-Demand
Thermal
Piezoelectric
Kodak
Hybrid print production Utilizing different processes!
§  Still relatively new!"
§  Integration of multiple
processes"
§  Inkjet in line with offset !
§  Personalizing information!
§ Addresses to variable images"
§  Inline post processing"
§  Integrated into digital!
§  Additional processes
included"
Some of the vendors to consider Many different applications!
§  Mailing, Direct Mail, Labels, Tags, Pharmaceutical,
Packaging, Marking, Barcodes, MICR, Graphics etc."
§  Atlantic Zeiser, piezoelectric and thermal, print head configuration specific,
§ 
§ 
§ 
§ 
§ 
§ 
§ 
§ 
packaging and labels"
Buskro, Water based, solvent, wax and UV inks, mailing and printing industries"
Domino, piezoelectric and thermal, narrow web applications"
Graph-Tech, Spectra head technology for addressing and numbering"
HP C800, thermal heads, print head 4.25 "
Impika iEngine 1000L, piezoelectric, print head 8.66 "
Kirk Rudy, piezoelectric and thermal, labels and mailing applications"
Kodak S10, continuous stream, print head 4.16 , "
MSC Eagle, piezoelectric heads"
§  And more that I have missed L"
HP C500 and C800!
§  Built upon HP technology
from their T Series
presses"
§  C500"
§  Mailers and inserters!
§  500 ft./min!
§  C800"
§  Roll fed offset presses!
§  800 ft./min!
Kodak S10 (S5, S20 and S30)!
§  Continuous stream
droplets"
§  Up to 1000 ft./min"
§  600x600 dpi!
§  Fully integrate into web
systems"
§  Use by different press
developers"
§  Timsons T-Print!
Can you tell me about …. Well it depends!!!
Planning for inkjet Integrated solutions!
§  Clearly define objectives"
§  Business case for CMYK or monochrome"
§ Much more difficult than at first thoughts!!
§  How wide a swath do you need?"
§  Service and maintenance"
Stitching together heads Wider print swath!
§  Many of the solutions are narrow print heads"
§ Need to stitch multiple heads together to go across
web!
§  Control required"
§ Substrate and electronic!
§  If happy with a small gap it is not a problem"
§ 1-2 pixel!
Differences In offset and inkjet paper!
Properties!
Offset Paper!
Inkjet Paper!
Coating/Ink strength"
High binder content"
Low binder content"
Ink Film Uniformity"
Highly dependent on base
sheet uniformity and coat
weight"
Less dependent on base
sheet uniformity and coat
weight"
Ink Hold Out"
Coating structure
dependent on oil
absorptivity"
Coating structure
dependent on water
absorptivity and ionic
charge"
SAPPI
Differences In offset and inkjet paper quality needs!
Offset Quality Requirements!
Inkjet Quality Requirements!
!
!
§  Paper Gloss, Brightness,
§  Paper Gloss, Brightness,
Smoothness, Opacity"
§  Show Through"
§  Ink gloss"
§  Mottle characteristics"
§ 
§ 
§ 
§ 
§ 
§ 
§ 
Smoothness, Opacity"
Ink Bleed Through"
Color Density"
Print Mottle"
Color to Color Bleed"
Feathering"
Water Fastness"
Water & Highlighter Permanence"
Ink considerations Overview!
§  Dye or pigment based"
§  High density pigments!
§  Specialty inks"
§  Security …!
§  Overprinting offset images"
§  Limited coverage, especially
with aqueous inks!
§  Cost"
"
Workflow Getting the data there!!
§  Driving the variable data
is one of the biggest
challenges"
§  Many different formats"
§  PDF, Postscript, PPML,
IJPDS (Inkjet Printer Data
Stream) …..!
§  Integrating with existing
workflows"
System Integrators GSS, Adphos, Integrity ….!
§  More than just adding a head"
§  Integrating into the existing
web path"
§  Extra space required"
§  Web splice detection"
§  Drying in certain applications"
§  Speed, coverage and substrate
dependent!
Problems with adoption Challenges ahead!
§  Inertia and status quo"
§  Market readiness!
§  New technology"
§  There will be some failures!!
§  Existing equipment"
§  Just because you can do
it – should you"
§  Your USP"
§  Data availability"
Challenges and opportunities today Thoughts!
Thanks for listening!!
"
Dr. Mark Bohan"
"
Vice President, "
"Technology & Research"
"
412 259 1782"
"
[email protected]"
"
www.printing.org"
www.printing.org/free "
www.printing.org/markbohan"
www.linkedin.com/in/markbohan "
"
"
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Company
Thomson Reuters
Mayo Clinic
DALiM Software, GMBH
Japs-Olson Company
IWCO Direct
Nahan Printing, Inc.
Royle Printing Company
EFI, Inc.
Suttle-Straus, Inc.
Pro Print, Inc.
PDM International
GLS Companies
Printing Industry Midwest
Wright Global Graphics
American Spirit Graphics Corp.
Lofton Label, Inc.
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CIP4
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Web Printing Controls
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Travel Tags, Inc.
DiMS! organizing print
MBO America
Mayo Clinic
Democrat Printing and Lithographing Co.
Japs-Olson Company
Duplo USA Corporation
Japs-Olson Company
GLS Companies
GLS Companies
GLS Companies
Japs-Olson Company
Kodak
Duplo USA Corporation
Japs-Olson Company
IWCO Direct
Travel Tags, Inc.
Mimeo.com
Mimeo.com
Consolidated Graphics
Democrat Printing and Lithographing Co.
GOSS International
Suttle-Straus, Inc.
DiMS! organizing print
Mayo Clinic
Digital Lizard
Kodak
Technique MIS
Integral Metrix Group, Inc.

JAPS-‐OLSON COMPANY - Printing Industries of America

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