A Lean Approach To Innovative Label Sourcing Strategies. Les Wallace, CPP Packaging Manager

Transcription

1 A Lean Approach To Innovative Label Sourcing Strategies Les Wallace, CPP Packaging Manager

2 What is Lean???

3 Lean - Wikipedia Lean manufacturing, lean enterprise, or lean production, often simply, "Lean," is a production practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination. Working from the perspective of the customer who consumes a product or service, "value" is defined as any action or process that a customer would be willing to pay for.

4 Lean Tools Lean is the set of "tools" that assist in the identification and steady elimination of waste or the focus is upon improving the "flow" or smoothness of work.

5 Keep Lean Simple Maximize Customers Value & Minimize Waste Sourcing Strategy: Create sustainable value for customers with fewer resources. Objectives: Purchase Price Reductions Increase Asset Utilization Improve Productivity

6 Lean Sourcing Approach Measures for Improvement Improvement Categories Purchase Price Customer Value Material Reduction Inventory Reduction Transportation Material Quality (Product and Process) Delivery Issues & Time New Product Development Cycle Time Overall Equipment Effectiveness (OEE)

7 Key Benefits Greater buy-in from Purchasing, Operations, and Strategic Suppliers. Greater success rate of implementing identified savings and improved performance. Improve quality and reduce waste across the supply chain. On-going cost reduction opportunities via collaboration with integrated partners.

8 Where Do We Start?

9 Basic Wine Label Designs

10 Designing for Lean Label Innovations Approximately 80% of product costs are determined in design. Baseline Label Cost = 98mm x 153mm coated stock, medium format press(6 colors or less), no other value adds.

11 Designing for Lean Label Innovations Added Value Alternatives* Purchase Price Impact Extra Color + 3% Flexo Gold + 5 % Stardust + 10% Uncoated or Specialized Paper + 20% to 30% Screen/High Build + 11% Polymer Emboss + 8% Foil: First, Second, Third +30%,+60%,+90%

12 Designing for Lean Label Innovations Alternatives* Potential Savings Impact Select the Correct Press Format 10% - 20% Reduce Label Size or Optimize for Press 24% - 36% Group Production Runs 10% - 40% High Volume Paper Stocks 25% - 35% Innovative Printing Techniques 2% - 20%

13 Select the Correct Press Format or Bottle Decoration Process

14 Select the Correct Press Format: UV Offset Large Press Format: 58%of Total Print Process Optimal Print Run Size: Over 200K Labels Optimal # of Colors: 6 to 9 Full Rotary Foil, Emboss or Screens: Full Rotary, Minimum one each depending on press. UV Flexo Large Press Format: 31%of Total Print Process Optimal Print Run Size: Over 200K Labels Optimal # of Colors: 5 to 11 Full Rotary Foil, Emboss or Screens: Full Rotary, Minimum one each depending on press. UV Offset Medium Press Format: 8%of Total Print Process Optimal Print Run Size: 10K to 200K Labels Optimal # of Colors: 4 to 6 Foil, Emboss or Screens: Semi Rotary, Minimum one each depending on press.

15 Select the Correct Press Format: ACL (Direct Bottle Printing): 2% of Total Print Process Optimal Print Run Size: 1 to 100K Bottles Optimal # of Colors: 3 to 5 Screen Inks Design Options: Frost, Glass Color, Gold or Metallic Inks Digital : < 1% of Total Print Process Optimal Print Run Size: 1 to 100K Labels Optimal # of Colors: 4 to 7 + UV Varnish Foil, Emboss or Screens: Generally Off Line, Minimum one each depending on press.

16 The Future Wine Label Press Format Large Format Combo Press: UV Offset & Flexo Optimal Print Run Size: Over 200,000 Labels Optimal # of Colors: 7 to 9 Foil, Emboss or Screens: Minimum of one each Additional benefits: Wide web width increases production efficiencies Reduces waste Greater Design Flexibility Sleeve technology for quick changeovers

17 The Future Wine Label Press Format Large Format Combo Press: Flatbed Hot Foil & Emboss/Deboss FP-4 RHINO : FEATURES Optimum foil and embossing performance Individual or simultaneous foiling and embossing capabilities Combined foiling and embossing unit Foil saving system Designed for short runs BENEFITS Superior hot foil and embossing quality Fast setup time & Minimum waste Lower foil and tooling costs

18 The Future Press Format Options Large Format Combo Press: Offset, Flexo and FP4 or RHINO : Improvement Categories Purchase Price Customer Value Material Reduction Inventory Reduction Transportation Material Quality (Product and Process) Delivery Issues & Time New Product Development Cycle Time Overall Equipment Effectiveness (OEE) Impact Improves Label Cost Improves: More Design Options Reduced Material Usage Improve Print Registration & Color Improves, Shorter Run Times Increases If Not Planned Improves For Printer

19 The Future of ACL UV Curable Inks Reduces carbon footprint, volatile emissions and energy usage. UV inks support distinctive designs and enable printing directly on bottle with entire bottle wrap printing. Coat entire bottles with a full color range in opaque or transparent UV ink.

20 The Future of ACL UV Curable Inks Improvement Categories Purchase Price Customer Value Material Reduction Inventory Reduction Transportation Material Quality (Product and Process) Delivery Issues & Time New Product Development Cycle Time Overall Equipment Effectiveness (OEE) Impact Improves Cost Volume Dependent Improves Shelf Impact Reduced Material Usage No Labels No Label Inventory, Risk - Over Runs or Changes In Production Increase Transportation Cost Improve Durability & Color Consistency Complex Logistics Added Time Due To Color Matching Improves No Labeling

21 Reduce Label Size or Optimize for Press

22 Reduce Label Size or Optimize for Press Example for 10 Web Width Layout Across Around

23 Label Size#1 Optimize Label Size for Combo Runs Label Size#2 Layout label #1 Layout label #2 can be up to.125'' smaller than #1 Across Around Across Around

24 Optimize Label Size Improvement Categories Impact Purchase Price Customer Value Material Reduction Inventory Reduction Transportation Material Quality (Product and Process) Delivery Issues & Time New Product Development Cycle Time Overall Equipment Effectiveness (OEE) Improves Cost Reduced Material Usage, But Watch Combo Runs Improve Color Consistence for Combo Runs Increases if Not Planned

25 Group Production Runs

26 Group Production Runs Design for one or two label sizes for multiple SKU s Target one to three plate changes to differentiate individual SKU s. Understand the printers requirements for group runs to maximize economy of scale

27 Group Production Runs Improvement Categories Purchase Price Customer Value Material Reduction Inventory Reduction Transportation Material Quality (Product and Process) Delivery Issues & Time New Product Development Cycle Time Overall Equipment Effectiveness (OEE) Impact Improves Cost Reduces Make-Ready Material Loss Adds Inventory Cost Improve Color Consistence Improves for Printer

28 High Volume Paper Stocks

29 High Volume Paper Stocks In Line Polymer Graining Unlimited range of emboss/deboss design options available for both uncoated and coated stocks Super Matte Varnish in combination of line grain emboss/deboss on coated stocks can be used to replicate uncoated paper or two different stocks.

30 High Volume Paper Stocks Improvement Categories Impact Purchase Price Customer Value Material Reduction Inventory Reduction Transportation Material Quality (Product and Process) Delivery Issues & Time New Product Development Cycle Time Overall Equipment Effectiveness (OEE) Improves Cost Improves Design Options Inventory Reduction for Printer Improves Material Consistency Reduces Material Qualification Time Improves For Both Printer and Bottling

31 Innovative Printing Techniques

32 Innovative Printing Techniques Inks and Screens Clear screens can embolden elements or create a raised effect instead of Emboss Metallic screens add luster and texture. Silver screen ink simulates silver foil and can add a metallic look when overprinted. White screen creates opacity Laying down of screen gloss or clear foil on an uncoated paper stock to give the inks overprinting on the top a glossy look, as if they were printing on coated stocks to create the look of two stocks on one label Metallic inks sit on top of the paper and look more vibrant. For label designs that have screen gloss and high build (which would require two screens), screen gloss can be applied to all areas and then emboss to the areas that are to be high build. The height of the emboss combined with the screen gloss can have the look and feel of high build, especially on the semi-rotary presses that have the flat-bed sculpted emboss capacity. This method keeps the label to the economy of the smaller press with one screen station.

33 Innovative Printing Techniques Inks and Screens Improvement Categories Purchase Price Customer Brand/Shelf Identity Material Reduction Inventory Reduction Transportation Material Quality (Product and Process) Delivery Issues & Time New Product Development Cycle Time Overall Equipment Effectiveness (OEE) Impact Improves Purchase Price Improves Brand Identity & Shelf Presence Can Reduce Material Usage Improves Depending on Technique Increases If Not Planned

34 Innovative Printing Techniques Sculpted Emboss/Deboss Sculpted embossing/debossing allows multi-level images and domed lettering or images. Images are embossed or debossed with a brass tool and can be combined to have raised and lowered elements on the same tool.

35 Innovative Printing Techniques Sculpted Emboss/Deboss Improvement Categories Purchase Price Customer Value Material Reduction Inventory Reduction Transportation Quality (Product and Process) Delivery Issues & Time New Product Development Cycle Time Material Quality (Product and Process) Impact Increase Tooling Cost for Rotary Improves Shelf Impact Add Complexity Can Add Timing For Approvals

36 Innovative Printing Techniques Offset to Flexo

37 Innovative Printing Techniques Offset to Flexo Improvement Categories Purchase Price Customer Value Material Reduction Inventory Reduction Transportation Material Quality (Product and Process) Delivery Issues & Time New Product Development Cycle Time Overall Equipment Effectiveness (OEE) Impact Improved Pricing No Impact Reduced Waste at Press Improved Color Consistency Print Quality Needs To Meet Marketing Approval

38 Other Areas of Improvement

39 Standard Label Shipping

40 Eco Bin Label Shipping

41 Eco Bin Label Shipping Difference in Corrugate needed to hold Approximately 10 Million Labels. Eco Bin Standard Corrugated Boxes

42 Eco Bin Improvement Categories Impact Purchase Price Customer Value Material Reduction Inventory Reduction Transportation Material Quality (Product and Process) Delivery Issues & Time New Product Development Cycle Time Overall Equipment Effectiveness (OEE) Corrugated Material Reduction Improved Load Utilization Improves, Reduced Material Handling

43 WEBRUNNER Labels A Continues Web Perforated Enough To Fold But Not Break Application Benefits (1999): Non Stop Labeling No Roll Change No Fixed Leading Edge Significant Productivity Gains And Flexibility For Bottling. Bottling SPEED EXTRA Cases Per DAY: 85 BPM: 2,000 extra cases per day 125 BPM: 3,000 extra cases per day 175 BPM: 4,000 extra cases per day Based on 24 hour operations with 3 labels ( Front, Back and Neck ) with 5,000 label per roll and 30 Change Over

44 WEBRUNNER Labels a continues web perforated enough to fold but not break Greater then 250 BPM

45 Improvement Categories Purchase Price Customer Value Material Reduction Inventory Reduction Transportation Material Quality (Product and Process) Delivery Issues & Time New Product Development Cycle Time Overall Equipment Effectiveness (OEE) Impact Improved Pricing Reduction in Material Loss Increased Transportation Reduced Quality Issues Improved Supper Production Flexibility Improves For Both Printing & Bottling

46 Lean is keeping lean simple!! What is Lean???