#COLOR19 Industry 4.0

Disrupting the Print Value Chain

Audience Make up

What’s your “Role”?§ Owner§ Manager§ Brand Owner§ Design/Creative§ Output Operator§ Vendor

Ask Yourself…

§How Mature is your companies Color Control System?§Basic, Intermediate, Advanced

§What level is your companies knowledge?§Delta E, E-Factor, ICC Profiles, G7, GRACoL

§What tools do you have to compete?§Measurement devices, workflow, RIP, quality viewing conditions

§What parts are you missing to be profitable?§What do you hope to learn in this session?

§Fix color, stop blame, sustain quality color, increase throughput, assign/accept responsibility, reduce waste, increase profits, etc.

Color Conformance Scale:

Color Conformance Scale:

Break/Fix

MentalityPredictive

Mentality

ProactiveMentality

What is Industry 4.0?

Four Industrial RevolutionsFundamentally Change how people live/work§1st: Mechanical Production (Steam engine: 1800’s)§2nd: Science/Mass Production (Electricity, gas engine 1900’s)§3rd: Digital Revolution, electronics (Computers 1990’s)§4th: Internet, connectivity of devices (Data management: Now)

Industry 4.0-Digital Transformation

Disruption Value Chain requires rethinking way to do business

§Build/enhance digital capabilities§Enables collaboration in ecosystem, definition of standards§Manage data as valuable business asset§Manage cyber security to protect operations and data

Printers must make foundational digital transformation from Graphic Arts to Print Manufacturer

Raw Material is no longer just ink and paper, in Industry 4.0, it is Data!

Key Objective Industry 4.0:

Make Manufacturing Efficient and Profitable§25% Printers make 4% margin or better on sales (Leaders)§50% Printers make < 2% margin on sales (Middle)§25% Printers make 0% margin on sales (Risk Bankruptcy)§Print Manufacturers are in the 4%+ margin on sales

§Fix color, stop blame, sustain quality color, increase throughput, assign/accept responsibility, reduce waste, increase profits, etc.

Data from PIA Industry Flash Forecast 2017

Industry 4.0 Agenda

Four Sectors of Disruptive Technology and Print§Data, Computational Power and Connectivity:

§Edge Computing, Cloud Technology, Automated Measurements

§Analytics and Intelligence§Intelligent reporting- Device Productivity balanced with Quality

§Human and Machine Interaction§Intelligent Operator Directions bases on measurement data

§Digital to Physical Conversions§Predictive analysis based on current situation

1. Data Management

Capture and Processing§Each step generates data, all captured and analyzed§Sole purpose: Make Manufacturing Sequence as efficient

and profitable as possible §Data Connects:

§Machines to Plant Environment §Plant Environment to Management Systems§Management Systems to Customers

§Automatic generation and distribution of performance reports

1. Data Management

Capture and Processing§Automatic generation and distribution of performance reports

Importance of Edge Computing

Computation and Analysis on distributed devices▪ Use Phone to capture data, and analyze in real time▪ Data Loggers to Capture Environmental conditions▪ Different interfaces for different users: manager vs operator▪ Different reports for different users▪ Lower costs▪ Improve cash flow

Importance of Cloud Computing

Reduce Capital Expenses▪ Don’t need servers, and server rooms▪ Pay on consumption not on infrastructure▪ Grow very quickly- don’t need personnel overhead▪ Increase speed and agility▪ Lower costs▪ Improve cash flow

Industry 4.0

Prepress▪ Proofers▪ Instruments▪ Platesetters▪ Light Booths▪ Substrates

▪ Machines to Machines

Industry 4.0 Data Capture and Processing

Reporting

Data ConnectsMachines to Environment§How does Instrumentation affect measurements?§How changing temperature and humidity affect results?§How aging bulbs change human perception?

Data HP Indigo with In-Line Measurement§Automatic measure/upload/assessment/correction...

2. Analytics and Intelligence

Proactive Analysis§Assessing why devices aren’t performing as expected§Taking data from multiple sources to predict the result

§Warn of problem, or actually perform correction to compensate

§Merging data from multiple sources to make intelligent guide§Printer Failing G7 due to TVI too high

§Humidity is 80%, 15% above normal operating range§Ink viscosity changes at high humidity causing High TVI§Warning to Operator to fix Humidity in room to get device in line

§OR- Create new G7 Tone Curve to compensate for high humidity

Industry 4.0 Data Capture and Processing

Reporting

How to Know that Prints are good?

Data ConnectsMachines to Machines Quantify Color Difference

Bulls Eye= GRACoL

Press= ManRolandProofer= Epson

Data ConnectsMachines to Machines Quantify Color Difference

Bulls Eye= GRACoL

Press= ManRolandProofer= Epson

Visual Difference=

Data ConnectsMachines to Machines Quantify Color Difference§How Close is Press to Proof? §How Close is Digital Press to Conventional Press?§How Close is Press to Press?

AnalyticsAnalytics and Intelligence§Assessing why devices aren’t performing as expected§ If the PH or Conductivity is wrong, the print is wrong§Send Notifications to responsible people

Industry 4.0 Multiple Facilities- Anywhere in World

Reporting

3. Human/Machine

Proactive Interaction and Notifications§Machines need maintenance- Humans maintain§System provides alerts/notifications when certain factors...

§Report Notifications: No Measurements, Check Instrument, Lighting

3. Human/Machine

Proactive Interaction and Notifications§Machines need maintenance- Humans maintain§System provides alerts/notifications when certain factors...

§Report Notification to check the Lighting Condition

§Advanced Reporting to Guide Operator for Maintenance§If wrong paper is loaded in printer- system warns operator

Human/Machine

Human and Machine Interaction§Human / Machine - Performance

ATLAUSBOSDFWDENDTWMSPNYCSEASTL

Human Performance

Automatically report (with automated measurements)§Compare Performance of Operators: Most Production

Human PerformanceAutomatically report (with automated measurements)§Compare Performance of Operators: Most Conformance

§System Provides Training for Operators based on results

Print Organization’s Sweet Spot

§Value Proposition: Determine Quality requirements§Then determine Productivity capabilities, for given quality

4. Digital to Physical Conversions

Predictive Analysis§System knows that Humidity is too high§System automatically generates new curve§Loads new curve into workflow with no operator intervention§Machine knows what to do and it does it when necessary

Print Industry FutureManufacturing Process- Not a Choice⬥Taking raw materials (Ink/Substrate) creating a

product (Brochure/Flyer etc) that meets customer expectations.

⬥Do you define customer expectations before printing? Tribal Knowledge?⬥How do you know it meets customer

expectations? ⬥If they pay/complain? If complain- do you

reprint?

Graphic Arts Print Companies

Break / Fix Mentality and Process❑Manual hand held measurement devices, no data history❑No defined Business Rules communicated to customers❑Run devices until they break, little preventive maintenance❑Run dedicated press run once a year for G7 plate curves❑Don’t optimize customer files for different print process❑Rarely check raw materials (Paper/Ink) for consistency❑Rarely check proof for variation and accuracy❑Rarely check Measurement Instruments for variation❑Rarely check Light Booth for variation and accuracy❑No idea measurement device differences

Graphic Arts Print Companies

Break / Fix Characteristics❑Finger Pointing the blame- Plates vs Operator❑No Operator Accountability❑No definitive definition of “waste” unacceptable❑Customer/Sales person is always right❑No time allowed for operators for maintenance❑No Training provided to employees to help them in job❑Too busy doing production to worry about quality issues

Print Manufacturers

Proactive and Predictive Mentality and Process❑Automated Measurement devices creating auto reports❑Defined Business Rules communicated to customers❑Keep track of equipment maintenance tied to color accuracy❑Build G7 plate curves as needed: G7 Calibrated color bar❑Optimize customer files for different print process❑Check raw materials (Paper/Ink)❑Check every proof for variation and accuracy❑Weekly check Measurement Instruments for variation❑Monthly check Light Booth for variation and accuracy❑Know measurement device differences

Print Manufacturer

Proactive and Predictive Mentality❑No Finger Pointing the blame- Reports prove the problem❑Direct Operator Accountability❑Definitive E-Factor definition of “waste” vs. production❑Company Rules determines what is right❑Operators allowed time for maintenance❑Training provided to employees to help them in job❑Too busy to do things wrong the first time, make it RIGHT❑Just because you are busy- doesn’t mean you make $$$

Graphic Arts vs. Print Manufacturing

Characteristics of the Print Manufacturers§More Profitable

§Calculate Make Ready vs. Production vs. Dead time

§Strive for zero waste§Doing things right the first time- no plate remakes, no re-prints

§Higher customer satisfaction§ IS the future§Know precisely what output devices make money§Know precisely what operators make money

Summary§Benefits of becoming Print Manufacturer

§ Providing Immediate Feedback for Pass or Fail Conformance§ Reduce and Eliminate waste

§Provide Training, Tools and Time to Users§Follow the process

§ Establishing guidelines- Printing Aims and E-Factor§ Quantifying variation- Understanding where you are...§ Creating quality assessment- Define where you want to be§ Reporting- Make operators accountable and prove performance

§Build digital transformation path to Industry 4

Thank You - Questions?

§David Hunter§david@chromachecker.com§Cell 651.238.3260 §Vendor Area