Burt Users Group

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• Burt Users Group
• Conference 2003
• Phoenix, Arizona

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Pensacola, FL

• One of Americas most historic cities
• Pensacola Beach
• Home of
• Blue Angels
• Emmitt Smith, Roy Jones Jr., Jay Bell

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Under pressure to increase productivity and
reduce costs?
www.apsolut.net
PRESS
POSTPRESS
Inserter Machine Control
Roll Handling
APSOLUT Integration Simplifies complex
production processes found within a legacy
production facility. Integration of independent
OEM production components is the catalyst that
allows the mailroom to transform into a
state-of-the-art Packaging and Distribution
Center.
Collator Machine Control
APSOLUT Automation Increases the efficiency of a
production facility by processing complex tasks
quickly. Automation increases process throughput
and reduces the amount of costly human errors
within the production facility.
Tray System Control
APSOLUT Innovation Optimizes the entire
production process to create new sources of
income. Innovative solutions help production
facilities realize more aggressive zoning
strategies and become a successful profit center.
...transform your mailroom into a
state-of-the-art Packaging and Distribution
Center.
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Experience is Key

• Over 35 combined years of Industrial Control and
  Systems Integration
• Over 15 combined years of Publishing Industry
  experience
• Washington Post
• Atlanta Journal-Constitution
• Arizona Republic
• Orlando Sentinel
• Omaha World Herald
• Dallas Morning News
• Chicago Tribune
• Over 3,300,000 combined Daily Circulation
• Source Audit Bureau of Circulations

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Overview

• Miscellaneous
• Control Features
• Network Issues
• People Issues
• The Open Control Interface (OCI)
• Why a Database?
• Database Pluses
• All the Data All the Time
• OCI Table Roundup

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Control Features

• Tight Integration with OCI
• Controls built around data
• Execution is the Key
• A great plan without execution is not as valuable
• Just-In-Time Job Delivery
• Richer editing manipulation
• Data integrity
• Upgrade Photo Eyes
• Legacy photo eyes are easily confused
• Photo eye errors compromise data

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Reconciliation

• What is it?
• The process of counting packages at certain
  points throughout the workcell
• Reconciliation Points
• Infeed
• Discharge
• Stacker
• Bundle Counter
• Speed vs. Accuracy
• Inherit tradeoff between speed of job changeover
  and accuracy of bundle counts

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Reconciliation Points

• Infeed
• The total number of jackets fed into the machine
• PRO Fast job changeover
• CON Inaccurate bundle counts
• Discharge
• The total number of packages discharged from the
  machine to the conveyor
• PRO Fast job changeover
• CON Inaccurate bundle counts

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Reconciliation Points

• Stacker
• The total number of packages delivered to all of
  the stackers
• PRO Accurate bundle counts
• CON Moderate job changeover
• Bundle Counter
• The total number of packages delivered to the
  dock
• PRO Most accurate bundle counts
• CON Slow job changeover

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Reconciliation Compromise

• Bypass the Final Reorder
• Production Mode Single Out
• Continuous reorder occurs during Full Production
• Reorder ends when the last jacket is fed into the
  machine
• Next job begins when the last package of the
  previous job is discharged from the machine to
  the conveyor
• PRO Faster job changeover
• CON Slightly inaccurate bundle counts (usually
  within a few packages)

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Zero GapRoadmap to Success

• Background
• RD performed at the Orlando Sentinel
• Tested and Deployed at the Arizona Republic
• Accuracy vs. Throughput
• 100 Accuracywait for the final package to
  reach the furthest reconciliation point
• 100 Throughputmake best guess decision, end
  current job, begin next job
• True Zero Gap Technologyallows both Accuracy
  AND Throughput with two downstream stackers

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Zero GapOperation

• Full Production
• A workcell is running a single job (Job A)
• Job A is delivering to both stackers
• Stackers are in Backup Mode
• Job A Appears to be Done
• The package count at the reconciliation point
  matches the required draw amount
• New jackets are assigned to the next job (Job B)
• The workcell waits for the last package of Job A
  to reach the stacker

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Zero GapOperation

• Job A Emptying / Job B Full Production
• Job B packages are approaching the stackers
• Stackers transition to Dedicated Mode
• Job A packages continue delivering to the first
  stacker
• The second stacker is cleared in preparation for
  Job B packages
• Job B packages are delivered to the second
  stacker
• Job A is Ready for Final Reconciliation
• The last Job A package reaches the stacker
• A final quantity of Job A packages is computed
• The final quantity of Job A packages is produced

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Zero GapOperation

• Job A is Done and Job B continues in Full
  Production
• Job A is done when the last package enters its
  stacker
• The zero gap cycle is complete and both stackers
  are assigned to Job B in Backup Mode

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Network Issues

• The Network Becomes Mission Critical
• The Network Should be Isolated
• The Network Should be Simple
• Fixed addressing
• Unmanaged switches

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People Issues

• Data is Important
• We are producing data and packages
• Employees will be More Productive
• Reduced idle time driven by automation
• Zero gap
• More competitive
• Electrician Database Computer
• You need at least one
• Takes ownership of cross-discipline problems
• Strong communication/cooperation from all sides
  of the house maintenance, IT and production
• Doesnt have to do the work, must be able to
  identify who should do the work

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What is a Miss?

• Hopper Miss
• How many times the hopper missed
• How well the hopper is operating
• Piece (FSI) Miss
• How many times a Piece (FSI) missed
• How well the Piece (FSI) is operating
• Package Miss
• How many packages left the machine without the
  Piece (FSI)
• How well the job is producing
• Inhibit Fault
• Seeing an FSI when you shouldnt

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The Open Control Interface (OCI)

• A Truly Open Interface
• Build Your Systems to Meet Your Data
• You really cant do it the other way around
• All Databases Have a Bias
• Thanks to all the Many Contributors
• Rich Burt
• David Ferguson
• The Washington Post

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Why a Database?

• There are many ways to build an API
• Flat files
• Socket Messages
• Other Ad Hoc
• You end up adding
• Persistence
• Consistency Checks
• Logging
• Eliminating race conditions
• Stop Reinventing the Wheel, Use a Database

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Database Pluses

• Some Freebees That Come With a Database Approach
• Leverage advances in existing technologies
• Known methods of scalability
• Known methods of tracing and troubleshooting
• Known application design patterns
• Easier reporting

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ALL the Data ALL the Time

• Designed to Capture all the Data
• Negative job numbers are manual jobs
• No Job is ever forgotten
• Future Edit Tool to Match Manual and Planned
  Jobs

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OCI Table Roundup

• Diagramming Tools
• Enterprise Manager
• VISIO
• PDF Includes 31 of the Key Tables
• Drawn Left/Input to Right/Output
• Future Using Device.Count for Preventive
  Maintenance

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