The following blog post was submitted by 2016 Continuous Improvement Conference sponosor, Heidelberg. What is OEE?  When optimizing your production, Overall Equipment Effectiveness (OEE) provides a valuable independent measure of how well a piece of equipment performs over time. It also helps gauge the impact of changes to workflow and production methods. There are several ways to define this, but for the purposes of this blog, I have used the definition we use (at Heidelberg) of OEE as: OEE = Speed Index × Quality Index × Time Index Where: Quality Index = Total of all good products                              Total of all printed products  Speed Index = Average equipment speed                            Maximum equipment speed  Speed Index = Total production time                       Total available time A typical OEE chart from the printing industry is shown in Figure 1 below. This figure illustrates the relationship between OEE and run length, with different equipment/facility combinations shown on the chart. Since there is typically a larger percentage of time spent on makeready, OEE will change as the run length reduces. There are many other factors that can move this value such as equipment type, configuration, controls, job make-up, and production efficiency. Understanding where the equipment is currently, versus where it can be, is critical to improving overall productivity. (The actual result will vary dependent on the industry.) There are many steps that can be completed to achieve optimal equipment performance. Many of these changes are cultural and need to be embraced by management and recognized by all employees in the company.   Training. Some operators do not fully utilize all of the available controls on the equipment, and many have never had formal training. Data has shown that operators need active training with hands-on situations, including the opportunity to get involved with training others. Additionally, a well-managed and repeatable color workflow will minimize any color changes that need to be adjusted on press. Finally, lean manufacturing tools can garner efficiencies, from 5S to value-stream mapping and Kaizen events. In all of these, the objective is first to evaluate what the current state is and then to evaluate where the biggest impacts can be made. It also helps to obtain “buy in” from staff, who will personally see the benefit from these changes. On one implementation of 5S on a press, an operator objected, stating it was “just to make the press look nice!” Three weeks later, with an average of more than 10 minutes saved per makeready, the same operator was asking if 5S could be rolled out across the facility.   Obtaining the best OEE To fully optimize your equipment and obtain the best OEE, a maintenance program should be the cornerstone of...

Printing Industries of America mourns the loss of one of its long-time allies, James (Jim) Mayes, Jr. Recognized as a faithful supporter and vocal advocate of the printing industry, Jim leaves behind an indelible mark. Jim owned and operated Colorcraft of Virginia for many years prior to his retirement. He was exceptionally active in Printing Industries of Virginia (PIVA), Print & Graphics Association of the Mid-Atlantic (PGAMA), and Printing Industries of America (PIA). Jim served on several committees within all three organizations, chairing both, the PIA and PIVA organizations, during his career. His most recent tenure was spent as the Chair of the PIA’s Premier Print Awards, a position he whole-heartedly embraced. Jim’s spirit will continue on in the many young people he introduced to the printing industry through his vigorous support of printing educational programs, including Print and Graphics Scholarship Foundation and the Monroe Technology Center. “Today is a very sad day for America’s printing industry as one of its greatest left this Earth. Jim Mayes was one of the most passionate promoters of print in the industry,” said Michael Makin, President & CEO of Printing Industries of America, upon hearing of Jim’s passing. “He was a consummate gentleman, champion of education, proponent of research and ambassador of print awards from coast to coast.  He will be sorely missed and PIA extends its heartfelt condolences to his wife Kathy, daughters Michelle and Meredith, and his grandchildren.” A funeral service will be conducted, Saturday, March 19, 2016 in Palmyra, Virginia. Friends and family may leave remembrances at the Thacker Brothers website. In lieu of flowers, the family requests that memorial contributions be made to the Jim Mayes Memorial Scholarship Fund at Monroe Technology Center, 715 Childrens Center Road, Leesburg, VA 20175, Attention: Janice...

Printing Industries of America mourns the loss of one of its long-time allies, James (Jim) Mayes, Jr. Recognized as a faithful supporter and vocal advocate of the printing industry, Jim leaves behind an indelible mark. Jim owned and operated Colorcraft of Virginia for many years prior to his retirement. He was exceptionally active in Printing Industries of Virginia (PIVA), Print & Graphics Association of the Mid-Atlantic (PGAMA), and Printing Industries of America (PIA). Jim served on several committees within all three organizations, chairing both, the PIA and PIVA organizations, during his career. His most recent tenure was spent as the Chair of the PIA’s Premier Print Awards, a position he whole-heartedly embraced. Jim’s spirit will continue on in the many young people he introduced to the printing industry through his vigorous support of printing educational programs, including Print and Graphics Scholarship Foundation and the Monroe Technology Center. “Today is a very sad day for America’s printing industry as one of its greatest left this Earth. Jim Mayes was one of the most passionate promoters of print in the industry,” said Michael Makin, President & CEO of Printing Industries of America, upon hearing of Jim’s passing. “He was a consummate gentleman, champion of education, proponent of research and ambassador of print awards from coast to coast.  He will be sorely missed and PIA extends its heartfelt condolences to his wife Kathy, daughters Michelle and Meredith, and his grandchildren.” A funeral service will be conducted, Saturday, March 19, 2016 in Palmyra, Virginia. Friends and family may leave remembrances at the Thacker Brothers website. In lieu of flowers, the family requests that memorial contributions be made to the Jim Mayes Memorial Scholarship Fund at Monroe Technology Center, 715 Childrens Center Road, Leesburg, VA 20175, Attention: Janice...

The 2016 Premier Print Awards opened for submissions in February, and all of us at PIA headquarters are excited to see what printers around the world have produced over the past year. Often referred to as “The Oscars of the Industry,” this international competition brings together printers from around the globe to have their pieces meticulously judged by our panel of industry experts. Together, our judges have over 100 years of industry experience and will thoroughly examine each piece down to the last drop of ink. Now in its 67th year, the Premier Print Awards prides itself on honoring every deserving company no matter their size; from the mom-and-pop shop to the million dollar franchise, every organization has their fair shot at the prestigious, coveted Benny statue. Recipients of the Premier Print Awards benefit from substantial industry exposure. Winners are announced to a list of over 800 industry media contacts and included in the PPA Supplement that is available at the Premier Print Awards Gala as well as the Printing Industries of America GRAPH EXPO booth. Winners are also invited to attend the Premier Print Awards Gala featuring the InterTech™ Technology Awards, where the Best of Show winners collect their Benny statues. During this event, print’s biggest winners gather to rub elbows and show off their winning pieces. Shortly after the results are announced, self-promotion kits are mailed to help you highlight your win. As a recipient of a Premier Print Award, you have access to a pre-drafted press release and Premier Print Award logos. By prominently displaying your statue, certificate, and logo, you let the whole world know that you are the best of the best in print! There are lots of ways to use award wins to grow your customer base. Join us on March 2 at 4:00 p.m. EST when we co-host Print Chat and talk about your options. Simply log on to http://nurph.com/PrintChat/chats/3135 with your Twitter handle and join the conversation. We hope to see you...

The 2016 Premier Print Awards opened for submissions in February, and all of us at PIA headquarters are excited to see what printers around the world have produced over the past year. Often referred to as “The Oscars of the Industry,” this international competition brings together printers from around the globe to have their pieces meticulously judged by our panel of industry experts. Together, our judges have over 100 years of industry experience and will thoroughly examine each piece down to the last drop of ink. Now in its 67th year, the Premier Print Awards prides itself on honoring every deserving company no matter their size; from the mom-and-pop shop to the million dollar franchise, every organization has their fair shot at the prestigious, coveted Benny statue. Recipients of the Premier Print Awards benefit from substantial industry exposure. Winners are announced to a list of over 800 industry media contacts and included in the PPA Supplement that is available at the Premier Print Awards Gala as well as the Printing Industries of America GRAPH EXPO booth. Winners are also invited to attend the Premier Print Awards Gala featuring the InterTech™ Technology Awards, where the Best of Show winners collect their Benny statues. During this event, print’s biggest winners gather to rub elbows and show off their winning pieces. Shortly after the results are announced, self-promotion kits are mailed to help you highlight your win. As a recipient of a Premier Print Award, you have access to a pre-drafted press release and Premier Print Award logos. By prominently displaying your statue, certificate, and logo, you let the whole world know that you are the best of the best in print! There are lots of ways to use award wins to grow your customer base. Join us on March 2 at 4:00 p.m. EST when we co-host Print Chat and talk about your options. Simply log on to http://nurph.com/PrintChat/chats/3135 with your Twitter handle and join the conversation. We hope to see you...

Jim Workman, Vice President, Center for Technology and Research, Printing Industries of America Technological capability is a critical competitive advantage for commercial printers. It is one reason that even companies with in-house printing capabilities rely heavily on commercial printers for their business printing needs. The issue came to the forefront again during a recent survey of 400-plus marketing and business executives at medium and large companies across different industrial sectors. Printing Industries of America and FedEx Office jointly conducted the survey, which delved into the executives’ use of and attitudes toward business printing. Among the many topics explored in the survey, respondents indicated if they would like more services in seven specific areas. Technology-related services were three of the top four print-related requests by business and marketing executives. The top four included the ability to print from the Cloud, access to advanced technology for color printing, access to advanced digital imaging, and the management of digital assets. Print’s marketspace is evolving in a very specific direction—from the simple provision of printed products to adding ancillary services to providing communications solutions. It’s not uncommon for in-plant operations, such as those at universities, businesses, and government entities, to be well behind the curve when it comes to reacting to changing customer needs. It is doubtful, for example, that most of them can provide an easy way of submitting files and ordering print via Web portals. They are unlikely to be able to enhance direct marketing campaigns with customized and variable-data printing. Nor are they as responsive as commercial printers to providing new digital print technologies and applications, such as signage, posters, and point-of-purchase displays. Make sure your firm is on the proper trajectory in technological evolution and in thinking about how you can take advantage of technical and process superiority when selling against in-house print resources. Emphasize the careful attention given to product quality, since the survey showed that product quality was the number one reason why customers rely on commercial printers compared to in-house resources. Customers of commercial printers reported lower instances of content being displayed incorrectly, color consistency problems, color accuracy problems, and product quality challenges. You might even consider joining the group of printers that are getting involved with print management services, by which we mean the practice of a customer outsourcing all of their print needs to a commercial printer—not just on a job-by-job basis. In that situation the commercial printer is managing the overall printing process for the customer. This may even include operating and staffing the customer’s existing in-plant facility. The complete survey findings, contained in an eight-page Flash Report, should be very helpful to company owners and executives determining how best to position their...