Automation is the process of using technology to make repetitive tasks easier and to reduce human intervention to a minimum. Increased technological advancements enable enhanced levels of productivity in our everyday lives, from automated home appliances to alarm clocks that wake us up when we want, to cars that automatically regulate the internal temperature of the vehicle. We all experience automation daily in our personal lives, and we can also experience automation in our printing lives, too. From front-end processes, to the pressroom floor, to bindery and post-bindery, the automated options for our industry are growing at a steady pace.
Automation within a printing company assists with increased performance, whereby the level of quality is not solely dependent on the operator running the equipment. Machine automation shifts processes from an operator-centric to a machine-centric control system, whereby fewer fundamental decisions have to be made by independent personalities with varying levels of experience and skill. This helps maintain higher levels of consistent quality between different runs or different shifts.
Automation also allows for the responsibility of approvals and workflow management to shift from the printer to the client. Integrated front-end workflows provide instant file feedback, soft proofing options and online approvals that transfers the obligation to the client to achieve milestones that impact the overall production cycle of a job.
Increased automation also leads to a lighter environmental footprint because increased efficiency results in less material waste. Minimizing waste can positively affect a printer’s bottom line, especially as material costs continue to rise.
FRONT END
Fujifilm’s XMF Remote R6 is an online job submission, previewing, approval and output tool used to control Fujifilm’s XMF cross-media workflow. This technology allows for minimal human intervention because everything is automatically driven from the workflow. Automated pre-flighting features and remote proofing of full resolution RIPped data, allow for greater integration between client and printer. The client can submit revised pages if required, and provide approval with the simple click of a button. Fujifilm also recently announced the creation of an iPad app, whereby the client has all of the above capabilities in the palm of their hand. This example of automation in a prepress workflow enables faster turnaround in prepress, shorter production schedules and the facilitation of client-managed workflows.
Additionally, automated imposition software like LithoTechnics’ Metrix, aims to streamline print imposition processes. Instead of duplicating effort throughout the workflow, one automated imposition plan is created for use from start to finish. Traditionally, estimators plan a job to price, production planners re-work the imposition if a job is won, prepress operators complete digital imposition and then print finishing operators recalculate and enter values based on previous plans. This technology not only helps eliminate time inefficiencies associated with duplication of effort, but also helps eliminate costly human errors associated with incorrect manual data entry. Metrix is JDF-enabled, which helps achieve increased levels of consistency and automation throughout the workflow. There are comprehensive Metrix solutions for offset and digital markets, as well as web-to-print solutions.
ON THE PRESSROOM FLOOR
Automation on the pressroom floor suggests that there are fewer physical knobs and keys to work with when mounting plates, setting ink levels and setting up the feeder or delivery systems. Mounted computer monitoring systems provide intuitive controls and enhanced systems for accurate operator use.
GMI’s ColorQuick/Clarios technology includes an in-line spectrophotometer that provides CIE L*a*b* and CIE L*C*h values to quickly and clearly show the operator where a job is out of tolerance. Concise summaries are easy to understand and allow the operator to react faster and more confidently to press problems.
QuadTech’s SpectralCam system allows for in-line inspection of both web-fed paper and packaging film substrates. Film substrates prove challenging due to the wrinkling and fluttering that can occur throughout the run. However, the system continually monitors the printed product at high speeds, including substrates that are translucent and transparent. This unique SpectralCam technology measures 100 percent of the substrate traveling through the press and calculates the L*a*b*, delta E and delta density values at maximum press speeds.
BINDING & FINISHING
Continuing to update and automate processes is essential to increasing internal efficiencies and remaining competitive in the marketplace. If you do not take advantage of automated technologies available, chances are your competitors will. Innovation leads to greater automation, facilitating shorter production turnaround times, reduced waste and increased quality consistency. You can’t afford not to automate.