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In April 2004, Druckerei Bauer KG (Bauer Druck), installed the first fully JDF-integrated postpress
using JMF (Job Messaging Format). Says Bauer Druck’s managing director, Michael Bauer, "The
JDF data transfer from HIFLEX greatly reduces the makeready time for our saddle stitcher and MAN
Roland presses. This increases the productivity of this valuable equipment. Through the direct JMF
status feedback from the machine control, we acquire production status and accurate data for calculating
actual costs." |
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Since 1987 KR Ing. Michael Bauer and his cousin Ing. Christian Bauer manage the company in the third generation. |
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A sheetfed offset commercial printer, Bauer Druck produces commercial printing, mailings, posters,
books, and other products. They employ approximately 50 people in modern production facilities
located a few minutes’ drive from downtown Vienna and the Vienna Airport. A major client is
McDonald’s restaurants, and in 2002, the company was awarded the highest hygiene and safety
certification for suppliers, the Superior certification from the American Institute of Bakery.
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Since 1997 Bauer is domiciled in highly modern production halls just a few driving minutes from downtown
Vienna and the Vienna airport. |
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The Networked Graphic Production™ (NGP) installation networks a Muller Martini PrimaPlus saddle
stitcher with a HIFLEX management information system (MIS), which in turn is interfaced with
four MAN Roland sheetfed offset presses. The machine states of the presses and saddle stitcher
are transmitted, via JDF/JMF, to the HIFLEX production control. The HIFLEX system displays the current
status and the products produced. This information also flows into the production analyses
and job statistics. The job’s progress is visible to the scheduler and customer service representatives
at all times.
The JDF network operates with the MIS at the top of the hierarchy, as
it controls the entire job processing procedure. The MIS transfers the
job calculation data from the production planning phase and makes
the data available to the production department for presetting
bindery machines. |
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The Muller Martini PrimaPlus saddle stitcher of the latest generation features automatically adjustable
axes (Amrys) and can be made ready within 3 minutes. |
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Bauer Druck system uses JDF to transfer saddle-stitching data (signature
size, product thickness, final trim size, staple type and position,
run length and page counts) to the Muller Martini machine control
console, and from there to the saddle stitcher. The saddle stitcher is
equipped with the Amrys Automatic Make ReadY System, which
allows it to be set up automatically using motorized controls. With the
JDF machine data, the complete saddle-stitching makeready takes
only three minutes. |
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Production manager Julius Daniel using the HIFLEX scheduling system |
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The HIFLEX scheduler helps optimize the production workflow, keeps
track of deadlines, and doubles as the master JDF computer. A shift
timetable enables daily schedules and work shifts to be organized
more effectively. Production steps are logically connected in a graphical
timeline flowchart. The timetable can be changed with short
notice, which helps Bauer Druck respond quickly to changes. |
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| This picture shows the planning of the job sequence in the HIFLEX scheduling which also functions as the JDF controller. In the bottom left corner the machine information is displayed that is received via JDF/JMF from the Muller Martini saddle stitcher. |
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The MM Port on the Muller Martini saddle stitcher links the MIS and
the finishing operation. The MM Port transfers JDF data—such as customer
name, run length, deadlines, and product specifications—from
the MIS to the finishing systems. Critical data, such as a job’s production
status, current output or copies already processed, are fed back
via the MM Port as JMF messages.
Bauer Druck’s MAN Roland presses are also JDF integrated. The HIFLEX
system sends relevant job information (job name, customer) and
technical data (format, colors, paper weight, product thickness) to the
PECOM system for makeready. The PECOM in return transmits various
machine-related events via JMF, back to the HIFLEX system. |
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In an effort to measure the efficiency benefits of NGP, HIFLEX, MAN
Roland and Muller Martini are collaborating on an IRD project (Institut
fuer rationale Unternehmungsfuehrung in der Druckindustrie), which
is evaluating the savings that networked printers can achieve using
JDF and JMF. HIFLEX has been a full member of the CIP4 organization
since January 2002, and a Networked Graphic Production Partner
since May 2003. |
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In 2002 the higest certification ("Superior") of the American Institute of Bakery (AIB) was achieved on
the first try, a demanding certification of the food industry. |
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