Printech Archives, April 1997: Re: Paper Waste Reduction Project

Re: Paper Waste Reduction Project

Bob Gifford (
Mon, 5 May 1997 15:32:38 -0500



I received the following information from
in response to a request for information about a press monitoring
and paper waste control system. The contact person's first name
is Richard.

Bob Gifford

Thank you for your interest shown in our waste control and paper
monitoring system. I thought it might be useful at this time to
provide you with a brief explanation of the system to highlight what
we believe are benefits to the industry as a whole, as well as the
potential customers that your organisation represents.


The system utilises a simple computer network (normally already
existing at the Customer's site) and extends it to obtain printing
press activity, operator movement, paper usage, event diary/messaging

The principle adopted has been rather than introduce new procedures of
working around the press to fit a new system , traditional systems are
adapted, so existing working and documentation methods are retained.
The recording of production information, and its use in subsequent
inquires with detailed information of what went on can be easily
retrieved. Each operator's activity is recorded "as it happens" and
material ordering, movement and consumption are all monitored at each
handling/production stage.

Paper yields are calculated and measured against the finished stacked
work rather than relying on either press clock counts or independent
laser counts used on more expensive systems. The problem with these
type of systems being that once copies have left the folder or passed
under the laser they have been counted as good but can often be lost
due to failures in the whole production process. Our design only ever
measures the finished good work at the point at which it is ready to
be transferred to the next stage, particularly important when storing
or transporting partially completed work as accurate records are kept
for as long as is necessary.

Because simple technology is used costs are kept to a minimum
providing immediate visibility of shop floor activity enabling
problems to be dealt with earlier, reducing unnecessary waste of all
printing materials and production time.

Any system that can help in "balancing the sections" of multi section
work without using traditional reelstand weighing scales and post
stacker scales just by simply increasing the visibility of paper usage
will give immediate savings on the bottom line of any printing
company. You only have to think of a 2-3% reduction in waste at
current market prices for paper to see how quickly a low cost system
will pay for itself.

A complete job event history is available with links into paper stocks
that provide accurate paper statements of paper usage by individual
section for each customer. This eliminates the need for manual
reconciliation of reel cards to paper used on jobs.

Human Communications

Common communication misunderstandings between minder, reelstand
operator, stacker operator and paper/production management has been
eliminated by the event diary linked directly to each persons area of
work and responsibility. A real-time messaging system has been
incorporated so that communications between key areas of the
production process become streamlined. For example, from the
production office to the minder on a particular press. Each message
sent/received is time stamped and recorded against the job for future
interrogation if required.

Down Time

Downtime analysis and recording does not rely on the modern shopfloor
data collection pads but rather interactive displays that work in
conjunction with the operators normal duties. The need to remember to
"press a key" when important downtime occurs has been completely
eliminated and requires no direct connection to the press.

Bar Coding

Extensive use of Bar Coding is made in the system for both the
tracking of Materials, and Part/Fully completed logs/pallets of
production gives important information without keeping manual files.


Good/Bad copy detection still remains the decision of the minder but
is available across the entire network to see how shop floor decisions
are being carried out by individual employees.

Reel, mill, operator, press performances and material consumption are
all monitored to give total manufacturing visibility across the entire
production process.




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