Pressroom Management System

Presentation Outline

1) Introduction/Background to Costs in the Pressroom

3) Saving Opportunity Areas

2) The CYPRO Pressroom Management Approach

5) Summary

4) Review “Live” CYPRO Application http://demo.monroegraphic.com

Pressroom CostsPress Throughput isreduced by hundredsof factors!

Goal of CYPRO is to provide tools to increase pressroom efficiency so you can produce a better product at a lower cost!

Monroe Graphic Service

Web Offset Printing Press Remanufacturer for over 20 yrs

Services include complete remanufactured printing presses, refurbished print units, press installations and electrical control upgrades Customer list includes small privately owned companies as well as many of the major printers worldwide

The CYPRO Solution

CYPRO securely leverages the power of the Internet, allowing all users to review data from anywhere.

CYPRO is electronically tied to the press to capture all impressions and time associated with press events. This includes press stops and starts, web breaks, splices and more.

CYPRO helps printers to substantially reduce costs associated with waste, press speed, downtime and paper consumption.

CYPRO automatically captures production data, paper consumption, pallets, maintenance and much more.

CYPRO Capabilities

Production Analysis

Paper Consumption

Finished Goods

Job Forecasting

Preventative MaintenancePressroom

Review

Savings Opportunities

Integration into Front Office System—Pallets, Paper, Estimate Info, etc.

Use of CYPRO Reporting Tools--Micro & Macro

Document System—Troubleshoot, Operations, etc.

Ability to react to other ideas to impact operations

Paper Savings—Running Waste Reduction, BW Monitoring, Slab Waste Analysis Maintenance System—PM, WO, etc.

Focus on Beating Estimate

Use “Pressroom” screen to discover jobs with potential issues

Cause of Issues If an issue exists, use “Forecasting” screen

to understandcause of issue (slow speed, excessive

waste, excessivedowntime, a combination of issues,

invalid estimate, etc.) and begin to formulate a plan to

address issue

Sources of Waste/DT Use “Job Report” screen to understand

sources of waste and downtime, etc. and use to

resolveissues while the job is still “On

Press”

Estimate vs Actual

Production Reporting

Improve Systemic ProblemsWhich has a bigger impact on productivity? Major Breakdown that happens 4 times a year for 4 hours of downtime vs. Minor issue that happens every third shift for 10 minutes 16 hours/year vs. 60 hours/year—The Minor

issue actually reduces total Press Throughput by 1% per year!

Running Waste easily identified and quantified!

Paper module allows for the entry of roll based consumption data.

Paper Consumption

CYPRO automatically calculates the “true” basis weight for each consumed roll of paper This value often exceeds the "Mill Basis Weight" and is a hidden source of waste.  In fact, excessive basis weight can result in 2 to 5% of additional waste which is often an overlooked cause for running out of paper on a job.

Paper Roll Tag Info

6.3% Difference in weight and linear feet between Rolls 1 &

3

Roll 1

Roll 2

Roll 3

Can you trust the paper suppliers?

Same Weight, Width and Basis Weight…Yet a 766 linear foot

difference!

Basis Weight Variation

Paper lots exhibiting excessive basis weight variation may warrant a Mill claim; CYPRO Paper Reports detail and quantify the problem to make justification easy

Changes in paper lots often lead to basis weight variation. This can result in tension problems on the press affecting register, color and converting as well as inaccuracies in scale based counting systems which rely on a specified basis weight as part of its calculation.

Comparing Paper Suppliers

CYPRO Paper Reporting allows for analysis of all rolls of paper consumed over a defined time period (BW, Slab & Core Weight)

Excessive Slab Weight

Maintenance SystemPreventative Maintenance Task Approach

Work Order Approach

Use of Maintenance System

PM results in Reduced Downtime due to reduction in

breakdowns due to premature wear Longer Lifetime of Equipment—M110B

in Green Bayhas not needed a replacement roller

or cylinder inthe machine in 7 years while running

430 millionimpressions

Work Order system promotes communication about

malfunctioning equipment in the pressroom and

gets it restored to proper operating order quicker;

this results in productivity gains and a safer work

environment

Documents

Document System available to provide Pressroom withneeded information on demand—Documents can include scans of user manuals, operating procedures, photos, etc.

Integration to Front Office Integrate CYPRO into Front

Office System using web services

Estimate Job & Form Data electronically can be uploaded to CYPRO

Actual Production Data electronically can be downloaded to Front Office System

Eliminates Duplicate efforts and Errors example—Finished Pallet Information available for Shipping System automatically

http://demo.monroegraphic.com/cypro/JobData.asmx

Additional CYPRO Uses

Scale Integration for Verifying Finished Good Counts

Makeready Reduction Project--Measure and reduce time and waste

Using Pallet Log to Verify Shipments to Binderies

Automatic Upload of Link Tech Ink Meters consumption data

Load Tickets for Roll to Roll Process incorporate Original Roll data

Using Preventative Maintenance System to track Press Operator Functions

In-line Finishing front end setup photos and documentation

Result—Elimination of Overruns and Underruns

Result—Savings of over $200,000 per year per press

Result—Complete and Reliable Audit Trail

Result—Job And Period Ink Cost data

Result—Improved Converting Process

Result—Reduced Downtime

Result---Reduced Makeready Times on similar jobs

Printstream Run Speed

0

5,000

10,000

15,000

20,000

25,000

30,000

5/1/20

08 to

5/31

/2008

7/1/20

08 to

7/31

/2008

9/1/20

08 to

9/30

/2008

11/1/

2008

to 11

/30/20

08

1/1/20

09 to

1/31

/2009

3/1/20

09 to

3/31

/2009

5/1/20

09 to

5/31

/2009

Time Period (Monthly)

Pres

s Sp

eed

Imps

/Hr

Run SpeedLinear (Run Speed)

Printstream Waste Percentage

0.0%2.0%4.0%6.0%8.0%

10.0%12.0%14.0%16.0%18.0%

5/1/20

08 to

5/31

/2008

7/1/20

08to

7/31/2

008

9/1/20

08 to

9/30

/2008

11/1/

2008

to 11

/30/20

08

1/1/20

09 to

1/31

/2009

3/1/20

09 to

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/2009

5/1/20

09 to

5/31

/2009

Time Period (Monthly)

Was

te %

Run Waste %Total Waste %Linear (Run Waste %)Linear (Total Waste %) Printstream Unproductive Time

0.0%

5.0%

10.0%

15.0%

20.0%

25.0%

5/1/20

08 to

5/31

/2008

7/1/20

08to

7/31/2

008

9/1/20

08 to

9/30

/2008

11/1/

2008

to 11

/30/20

08

1/1/20

09 to

1/31

/2009

3/1/20

09 to

3/31

/2009

5/1/20

09 to

5/31

/2009

Time Period (Monthly)

Dow

ntim

e

DT %Linear (DT %)

Graphs of UsersRun Speed has increased from 25,500 to 29,000 imps per hour

Run Waste has decreased from 8.5 % to 5 %

Downtime has decreased from 20 % to 18 %

Summary of Savings

Total Operating improvement of over $280,000 annually!

The PossibilitiesEncompasses your entire pressroom

Provides the opportunity to improve on various press functions Small improvements in many areas realize large productivity gains

Allows evaluation of measurable press activities

Increase your Net Output!