"Plugging Cost Leaks with Prinect"
Prinect Print Shop Workflow
Many print shops fail to gain a competitive advantage because
they don't know about the "hidden" costs and internal expenditures
needed for the administration and processing of jobs. Prinect
Product Manager Reiner Bachthaler explains how you can reduce costs
and create higher margins with integrated print shop
Mr. Bachthaler, you claim that many print shops aren't aware of
the time and costs associated with the administration they do for
each job. If I may provoke you just a bit - does this mean
that some jobs are produced blindfolded and without a plan?
Bachthaler: No. But many businesses only record expenses for
materials, machines and employees, and not the administrative
costs - for example the time and work needed to enter job and
production data multiple times or to revise orders. Added to that
is the time and effort needed to procure information from other
departments, for example information for the sales and marketing
departments on whether or not desired changes from the customer can
still be factored in. Since these additional costs are difficult to
record, the connected savings potential remains hidden to managers
and therefore left unutilized.
Why isn't it enough to link prepress and the pressroom with one
another in order to plug these cost and productivity leaks?
Bachthaler: The classic integration is limited to the
automatic forwarding of production data, such as sending ink
presettings from prepress to the printing press. Naturally, this
saves an enormous amount of time. But only up to a certain point.
First of all, a network only ever connects individual departments.
Information is then sent between these bit by bit. This leads to
frictional loss and mistakes between departments that aren't
directly connected in the network chain, for example between order
acceptance and finishing.
Prinect Product Manager Reiner Bachthaler
What is the frictional loss?
Bachthaler: When an order is calculated using the Management
Information System Prinect Prinance, the software simultaneously
stores all relevant job data, for example the colors and run
length. As you can imagine, it's faster and safer to only have to
enter data once and then be able to reuse this throughout
production, as is the case with the integrated Prinect workflow.
Without integration, you have to enter this data again manually at
various points, which is both elaborate and increases the risk of
inconsistent data. If job data changes and has to be reentered for
all the production steps, it's easy to lose control once and for
all. Without integration, it's nearly impossible to produce
consistent production data, for example for analyzing the
profitability of certain product groups or customers.
How does integration work with the Prinect Integration
Bachthaler: The predefined job data from Prinance is
automatically stored in the Prinect Integration Manager - the
workflow system for the entire production process. All areas of
production have access to and use this central database. This leads
to higher production reliability and reduces the time and effort
needed to prepare, manage and analyze orders. The more departments
that are integrated, the greater is the increase in efficiency. Our
customer in Liechtenstein, BVD Druck & Verlag AG, shows us what
this looks like in real life. For every order, a production plan is
created using the Management Information System (MIS). This defines
which process steps need to take place for which orders. The
Prinect Production Workflow uses this information to automatically
initiate the respective production processes or assign which
machines will carry them out. All employees - whether the
scheduler or the printer - can access the exact order
information they need to carry out their jobs efficiently right
from their work place. In addition, production data from all
departments is forwarded back for post calculations and other
What else is hidden behind the new products Prinect Postpress
Manager and Prinect Scheduler?
Bachthaler: The Prinect Postpress Manager integrates
automated postpress machines like saddlestitchers and folders into
the online production workflow. Using data terminals, older
machines and manual work stations can also be integrated. The
Prinect Scheduler is an electronic production-planning tool.
Schedulers can plan more quickly and efficiently with the tool's
comfortable planning templates and its ability to provide a
detailed display of the current status of all jobs. In addition,
using so-called checkpoints, the Prinect Scheduler shows whether
milestones like proof releases have been reached. With a traffic
light system, it also signals whether deadlines are in danger of
being missed or there is a conflict with resources. In this way,
the scheduler can detect potential problems early on and help
employees avert or correct them.
What about the pay-off time?
Bachthaler: I've already mentioned our customer in
Liechtenstein, BVD. BVD utilizes an integrated Prinect Workflow
solution in their administrative department, prepress, the
pressroom, and they will add it in postpress as well. Thanks to the
integration, BVD is already saving around seven minutes per job and
is reducing waste by five percent. On average, these kinds of
integration projects pay off within two years. But the advantages
don't end there. Heidelberg is the only manufacturer to cover all
management and production processes with its workflow
solution - from Management Information Software (MIS), to
prepress, the pressroom and up to postpress. Drawing everything
from the same source doesn't only have a big functional advantage.
It is also noticeable in the form of cost reductions. This is
because the effort needed for integration is much smaller and the
individual building blocks are fitted ideally to one another.
Prinect integration at drupa: intelligent networking of print