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 Munich-based media group Universal has converted to digital networking. In January, the company
started with the MIS system HIFLEX. A JDF network embedding a KBA Logotronic
Professional system went live only two weeks later. This has resulted in time and cost savings
through single data entry points, more transparency into production status, and increased productivity
on press.
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Universal is an ISO-accredited sheetfed offset operation with a workforce of approximately 50 people.
It was formed in spring 2000 from the merger of four veteran Munich printing houses.
Alongside its offset printing activities (business reports, magazines, books, promos and calendars),
Universal’s service spectrum also embraces prepress (including composition and litho), database
publishing, Web site design, and the production of CDs. Its press room houses two Heidelberg
Speedmasters—a five-year-old B1 (40”) and a four-year-old B2 (29”)—plus a B1 (41”) KBA Rapida 105
acquired last year. |
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The HIFLEX software greatly facilitated the transition to a fully-fledged, JDF-enabled Networked
Graphic Production™ environment. "The conversion to a HIFLEX MIS was completed in a matter of
weeks and went without a hitch. The system was accepted without
reservations by all our staff because it offers us concrete benefits in
order processing, job scheduling and management analysis," says
Contzen, who is also a board member of the Institut für rationale
Unternehmensführung in der Druckindustrie (IRD, Institute for
Rational Corporate Governance in the Print Industry). "Our prime
objective was to take on the most advanced technology in the marketplace
to enhance our efficiency and raise our competitive profile." |
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"The entire process of networking Universal’s operations is coordinated
and managed by the HIFLEX production planning and control system
functioning as a JDF controller," explains Stefan Reichhart, managing
director of HIFLEX. Reinhold Stange, Logotronic product manager at
KBA Radebeul, takes up the tale. "An exact description of the production
sequence is generated during preliminary calculations and initial
job costing. Once the data has been captured in the HIFLEX system, it
can be made available to the Logotronic Professional system via the
JDF interface." |
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The HIFLEX schedule supports the optimization of the production workflow
and compliance with deadlines. It also doubles as a master JDF
controller within the production sequence. A shift timetable is embedded
in the program to enable daily schedules and shift work to be
organized more effectively, and this can be amended with short notice
in response to changes in plant capacity caused, for example, by failures
or special shifts. The time allocated to the various links in the production
chain in the initial job costing can then be assigned by the
scheduler to the relevant cost centers, based on either the individual
sheets or individual signatures. This provides the option of either
assigning jobs to a number of presses that each print specific sheets,
or splitting up the signatures on a sheet and reassigning them to other
sheets if necessary. |
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Michael Barth at the delivery of the KBA Rapida 105 fivecolor installed last year |
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"HIFLEX Scheduling software furnishes us with a high-precision tool for
making our production processes more transparent and our scheduling
more effective. It is much easier for us to change schedules with
short notice if something unexpected crops up," says Contzen. "Since
production scheduling is now implemented electronically, internal
communications can be embedded at the click of a button—for example,
are the plates ready? Has the job been approved? When is the
client due? Has the paper arrived on time? It’s all so much more convenient." |
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Data screen for a print job on a Rapida, using HIFLEX scheduling software which also functions as a JDF controller.
The press data displayed in the lower left corner are downloaded from the 105 via a JDF/JMF interface |
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Once the job data has been transferred to the Logotronic Professional
computer, the CIP3 data is downloaded from prepress using a hot folder
system. Preset values for ink keys etc. are calculated using pressspecific
conversion curves, factoring in the type of stock. The job
queue is displayed at the press. As soon as the operator has selected
the job, the JDF preset data or repeat job data are downloaded automatically
onto the press.
"The big appeal for us is that makeready is much shorter, so output is
much higher," says Contzen. "But additionally, it has cut out the repeat
input of data. This saves time and eliminates errors." |
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Data exchange between KBA and HIFLEX moves in both directions.
During the production run, press status is reported in real time to the
HIFLEX MIS via the JDF/JMF interface. The status, speed and saleable
sheet count are displayed in the HIFLEX monitor, so the scheduler and
administration staff can track production instantly. |
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