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 In February 2003, Druckhaus Berlin Mitte GmbH (DBM) implemented the world’s first JDF workflow
to operate under real-life production conditions, ushering in a new era of JDF connectivity.
Made possible by a collaboration between two Networked Graphic Production™ (NGP) Partners;
management information system (MIS) provider HIFLEX and MAN Roland, the result is a significant
time savings, more precise data handling, and a dramatic increase in productive runtime.
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General manager and JDF pioneer Herbert Preissler |
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Says general manager Herbert Preissler: "HIFLEX Scheduling, HIFLEX shop floor data collection and
HIFLEX JDF connectivity to our MAN Roland printing presses raised our production by 7 percent.
Despite the bad market prices, we can still earn money. A printing house without JDF connectivity
will definitely not be able to compete in the long run."
DBM is a modern sheetfed offset printing plant with approximately 100 employees. The company’s
production centers around general commercial printing, direct mail, posters and books, and
a PDF workflow is used. The pressroom features two MAN Roland 700 (74 x 104 cm) presses, one
MAN Roland 900 (100 x 140 cm), and a Heidelberg Speedmaster (72 x 102 cm). In finishing, DBM
has a variety of folding machines, mailing machines, a gang-stitcher, and a perfect binding line. |
The JDF-networked production now implemented at DBM was preceded by the introduction of
HIFLEX Production Planning and HIFLEX Production Data Collection (PDC). The project objective was
to greatly improve efficiency in the areas of job planning and processing. Significant cost savings
have been achieved; in particular through organizational streamlining
and doing away with unnecessary production discussions between
internal sales staff, administration, and management.
"The introduction of HIFLEX Production Planning has given us a much
more precise planning instrument, which also puts us in a better position
to handle rush jobs," says Preissler. "This requires a high degree
of technological discipline from all involved, which is why we prepared
ourselves by introducing an integrated Quality and
Environment Management system in 2002." |
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Makeready times are reduced through more precise and faster job preparation |
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"Our commitment to the ideas of NGP is a logical
step because it allows our customers to benefit
significantly from synergies within the pressroom
management business," says Stefan
Reichhart, managing director of HIFLEX GmbH.
"The advantages of NGP are so obvious that we
are in no doubt of the ability to crucially strengthen
our customers' competitive position." |
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HIFLEX Production Planning provides the basis for this NGP environment
because the electronic planning board is also the JDF control
console for the production sequence. The industry software is the
leading system for company-wide data exchange via JDF because it
controls job processing in its entirety. It transfers technical data from
estimation to production planning, and makes it available to production
for machine presetting. Feedback from production flows into
HIFLEX Production Planning in the form of administrative evaluations
and statistics for the job. |
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Since the JDF-link has been installed, more sheets per day are coming out of the fourcolor MAN Roland 900 |
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Says Preissler: "Direct production data collection has not only reduced
our wage bill by half a person; it permanently and promptly updates
our historic costing and gives us an exact overview of job status. This
means we can provide our customers with more precise information
much faster." |
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The forwarded data is based on the job sequence—rough planning,
outline planning, and fine planning—as determined by production
planning and control (as the process control system). The precise
manufacturing description is generated in the course of estimating. If
there are any last minute changes, the job estimate is converted into
a production estimate. Machines with a JDF interface receive their
data directly from the process control system. Feedback takes place
via production data collection. |
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JDF is the key technology for complete networking of the printing
plant. As Christian Gugler, PECOM Product Manager at MAN Roland
explains: "We announced it at IPEX 2002 and now it’s a reality: the first
installation running under real-life production conditions. This is the
start of the next integration phase. MAN Roland is one of the four initiators
of the JDF standard and a driving force behind its use in practice.
We contributed our many years of integration experience to the
DBM project, and with this JDF-based installation, we are resolutely
pursuing our conviction: workflow software is intended for professional
production environments where it must prove itself as early as possible." |
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Founded in 1992, the printing house is located in the traditional Mosse-Center in the
heart of Berlin |
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"Our commitment to the ideas of NGP is a logical step because it
allows our customers to benefit significantly from synergies within
the pressroom management business," says Stefan Reichhart, managing
director of HIFLEX GmbH. "The advantages of NGP are so obvious
that we are in no doubt of the ability to crucially strengthen our customers'
competitive position." |
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The screenshot displays the production planning in the HIFLEX Scheduling system which acts as a
JDF controller in the production sequence |
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The HIFLEX MIS supports many languages and has been installed in
printing facilities in a dozen countries. The HIFLEX MIS handles production
information, including estimates, job-relevant correspondence,
costing and statistics, and integrates data from material management,
production planning and control, the JDF/CIP4 interface,
and e-business. HIFLEX has also implemented JDF-based interfaces for
the exchange of production information with prepress and postpress
vendors at various customer sites. |
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The diagram (HIFLEX / Euprima networking model) illustrates data exchange between the HIFLEX MIS and production at DBM |
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Concludes Preissler: "The JDF link between HIFLEX and MAN Roland
saves us around three hours office work every day, with some 90 percent
of all jobs being passed to the MAN Roland presses without any
further processing needed. This streamlining has given us an important
competitive edge and also provided the prerequisites to respond
better to our customers’ delivery requirements. For the next step, we
are looking to integrate the Heidelberg Speedmaster and finishing
operations into the system so that all suitable jobs can be completely
controlled with JDF." |
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