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Summary: |
Waste Prediction Method |
6.15.99
A formula has been developed in-house by a book printer which predicts the amount of waste
in the printing process. Utilizing this formula, the job planner can order appropriate
amounts of materials and specify production quotas which reduce further waste in materials
and time.
Each major typical printing task is described with its own production formula. Anticipated
levels of make-ready and running waste are specified which allow sufficient but not overly
large quantities of sheets to be prepared, printed, cut and bound. The formula was
incorporated into a spreadsheet workbook which runs on the printer's computer systems,
taking input from the planning department, warehouse
and press operators. It provides printouts and screen displays which guide each aspect of
production and provide a mechanism for record keeping, feedback and improvement.
The system was tested on 64 jobs. It was found to predict waste within 0.5%, at 4.5%
overall. Using the system has resulted in reduced overruns of individual sheets,
signatures and book covers. Attention to detail and consciousness toward waste have also
improved among the workers.
Author: Qian Li and Walton Hancock, Dept. of Industrial and Operations
Engr. U-Mich, and Larry Kruger, BookCrafters Inc.
Source: GATFWorld, May/June 1999, p. 13-18. |
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