PackAge Conference on Packaging Trends (9-10 July 2009)

Transcription

1 Introducing EskoArtwork Lean Workflow Solutions from Idea to Print Antony Conway Market Support Manager (Asia Pacific) PackAge Conference on Packaging Trends (9-10 July 2009)

2 Lean Manufacturing More Value with Less Work 2

3 Lean Manufacturing Lean manufacturing - often simply called "Lean"- is the term used to describe the management and production methodologies that were originally developed by Toyota and the Japanese automotive industry to maximize output while minimizing input. 3

4 Lean Manufacturing Lean manufacturing focuses on avoiding and eliminating wastes, defective products, overproduction, excessive work-in-progress inventory, over-processing, unnecessary movement of people, unnecessary movement of products, and idle-time. Organize Data Communicate & integrate Offload Tasks Automate tasks Centralize Expertise 4

5 Lean Manufacturing Lean Manufacturing is a process in which the focus is upon improving the "flow" or smoothness of work, thereby steadily eliminating waste through the system. As waste is eliminated quality improves while production time and costs are reduced. 5

6 The basic Lean principles include: Just-in-Time delivery Perfect first-time quality Quality control and inspection Waste minimization Continuous improvement Flexibility Production flow Load leveling Autonomation (smart automation) 6

7 Smart Automation Smart automation removes many routine and repetitive tasks which humans often do not enjoy and where they are therefore not at their most effective and potentially error prone. better design produce cheaper manage faster 7

8 Lean Workflow in Packaging PreProduction Technical Artwork Color Separation Graphic Design Print Tool Making Idea While it started in the automotive industry, these same principles also apply to the graphic communications market. Structural Design 3D Sampling Diemaking 8

9 Benefits of Lean Workflow in Packaging Waste reduction Production cost reduction Manufacturing cycle times decreased Labor reduction while maintaining or increasing throughput Inventory reduction while increasing customer service levels Capacity in current facilities increase Higher quality Higher profits Higher system flexibility in reacting to changes in requirements improved More strategic focus Improved cash flow through increasing shipping and billing frequencies 9

10 Lean Workflow in Packaging PreProduction Successful prepress, printing and converting companies are implementing Lean practices in order to reduce waste - in any form - that impacts time and materials. An example is the close association between Lean Worfklow and management information systems (MIS). 10

11 Lean Workflow Implementation Lean workflow implementation is focused on getting the right things, to the right place, at the right time, in the right quantity to achieve perfect work flow while minimizing waste and being flexible and able to change. MIS system * Center of the production workflow 11

12 Lean Workflow not only in Production One crucial insight is that most costs are assigned when a product is designed. Good organizations develop and review product designs and prototyping techniques to explore the different options to minimize risks in the early stages of production. 12

13 EskoArtwork s view on Lean Workflow

14 14

15 Cheaper Better Faster 15

16 16 The Typical Packaging Supply Chain

17 Packaging Design

18 Integrated design environment box structure 3D graphics 3D solids integrated design in-store visualization 18

19 19 3D in Packaging Development and QA Cycle

20 20 3D in Carton Packaging Design & Prototyping

21 21 3D in Flexible Packaging Design & Prototyping

22 22 3D in Metal Packaging Design & Prototyping

23 23 3D in Label Packaging Design & Prototyping

24 24 Explore the Creative Options

25 25 Experience the product packaging

26 26 Reduce time and materials during design & artwork

27 27 Reduce the need for physical Proofs

28 28 Virtual shelf testing

29 Packaging Artwork

30 If only there was just one product.. You always start with one design But then you make variations Standard / lite / flavours. And then you translate it into xx languages 30

31 One becomes Fifteen One artwork template, three variations, five languages 15 SKU s 31

32 32 A few examples Typing errors

33 Consistency & translation errors 300 pieces or 100? Missing copy? 33

34 Current content management workflow Different departments are responsible for generating text content Content is sent to the packaging designer in a variety of file formats The packaging designer must manually copy or re-type the text into the packaging artwork Copy & Paste 34

35 35 Dynamic Content Management

36 Packaging PrePress

37 PrePress Integrated Lean Workflow MIS system 37

38 Step and Repeat Automated Workflow Step and Repeat is Dynamic and completely automated 38

39 39 Press Preparation automatic overlap trapping

40 Press Preparation printability checking Press Tolerences Barcodes & Inks 40

41 41 Conventional Flexo vs. Digital Flexo

42 Digital dot vs. Conventional Analog dot Conventional Flexo Dot Digital Flexo Dot 42

43 43 Lean Printing Techniques saving press time

44 Packaging Approval

45 De-Centralized Packaging Communication Creative Agency Packaging Supplier Repro Creative Agency Creative Agency BRAND OWNER Packaging Packaging Supplier Supplier Repro Creative Agency Packaging Supplier Packaging Supplier Packaging Supplier Repro Repro Repro Repro Repro 45

46 Centralized Packaging Communication Structural Design Graphic Design BRAND OWNER Web Based Collaboration Artwork & Repro Plate & Cylinder Supplier Packaging Supplier 46

47 47 WebCenter - Login from your favorite browser

48 48 Collaborative Online Approval & Data Management

49 49 View & Review, Comment & Approve

50 Preview & Review Design Revisions Difference & Version Checking 50

51 Conclusions

52 Key Points To Take Away Early adopters of a Lean Workflow have realized: Significant decrease in errors in content Noticeable increase in speed-to-market Tighter integration with suppliers Increased agility to confidently make last minute changes 52

53 Connect for more information 53