Case Studies

Case Studies

Review the following case studies to see how you can benefit from our services.

Financial Services Company

The Situation:
A large financial services and investment firm had in-plant printing operations in four different cities in the Northeast US. We were asked to perform an analysis of the competitiveness of the printing operations (output devices) located in Boston, Marlborough, Merrimack, and Rhode Island as well as provide a high level operational review. Additionally, we were asked to review:

Improvements to the output cost of the four printing operations

Additional sources of work within the company

Bindery practices

Workflow

Possible benefits and drawbacks to consolidation of the four operations.

Results:
Working closely with the client, we determined that the current operations were 65.5% more competitive than the print-for-profit industry. Customer service was considered excellent as indicated by the fact that internal customers sought out the in-plants for innovative solutions. It was determined that while there was some overlap, each of the four operations was providing rapid turn-around times and cost-effective services overall.

We also determined that an additional $2 million of digital work was currently outsourced and could be produced internally resulting in a $78,000 monthly savings.

We found the bindery practices and equipment are suitable for the needs of the customer and efficiency of the sites though some consideration for 2 sites should be made to upgrade to semi-automatic equipment.

There was wide dissatisfaction with the job submission tool employed at the company. Goals for a tool were found to be:

Customer ease of use which includes NOT requiring the customer to re-enter their account information

On the fly estimating of a job

A build a book module that allows the customer to upload multiple disparate documents and organize them in a book

Final PDF proofing of the order

Method to post to the MIS system for charge backs

Ability to transfer work between sites

Ability to control queues on machines within the department by a manager or pre-press individual

We researched various software solutions and suggested the company install one of two identified solutions that met their goals. The software also allowed the in-plants to balance their workload, sending jobs to the individual operation with the most appropriate skills, equipment and/or available capacity.

Book and Magazine Publisher

The Situation:
During discussions with a large religious book and magazine printer, we performed an analysis with regards to an addition of a Xerox DocuColor 8002 digital printer instead of replacing two Spinjet wide format proofing printers, which are failing.

The Spinjet wide format proofing printers are used to proof books and other publications prior to plating and printing. Because of the output size these printers utilize, operators are required to fold, cut and assemble the proofed publication by hand. Additionally, the slow speed of the inkjet technology requires two machines to meet production schedules.

The Xerox DocuColor 8002 digital printer with a recommended average monthly volume of 100,000- 400,000 pages per month can produce the same proofed pages without the document assembly time as currently required. An additional advantage is the 8002 printer is capable of performing other work that is currently outsourced or produced elsewhere at a higher cost thereby saving money on those pages and eliminating the cost for the Spinjet printers.

Results:
After careful analysis, it was determined that the combined savings on currently outsourced digital work and the proofs generated by the wide format proofing devices totaled $44,070 (32%).

West Coast Public University

The Situation:
During discussions with a West Coast State University’s Printing Services , we offered to perform an analysis of their printing output to determine how they currently line up with the print-for-profit market. A request for information was submitted to the printing department which in turn would be the basis for the analysis.

The areas reviewed in this analysis were:

Color Digital Print and Copy
- An HP Indigo 3050 capable of 4,000 8 ½ x 11 impressions per hour
Medium Format Two Color Offset Printing
- Heidelberg SM-74 2 color press with maximum sheet size of 20” x 28”
- Heidelberg MOZP 2 color press with maximum sheet size of 19” x 25”
Large Format One Color Offset Printing
- Heidelberg SORS 1 color press with maximum sheet size of 26” x 40”

Results:
After careful analysis, it was determined that the combined savings for the output equipment listed is 45.83% versus the print-for-profit printing market

Global Consumer Products Company

The Situation:
During discussions with a global consumer products company, we offered to perform an analysis of their printing output to determine how they currently line up with print-for profit printers as well as assist them in other ways regarding the development their strategic plan.

The consulting team visited with the customer to discuss the project and determine if we could be of any assistance. During this visit, we learned that the printing operation is comprised of two operating units; fine print and packaging.

It was decided that the focus of the report would be the fine printing portion of the operation.

The areas reviewed in this analysis were:

Color Digital Print and Copy
Black and White Digital Print and Copy
Large Format Miehle Offset Print - Two Color
Large Format Miehle Offset Print - Four Color
4 Unit Large Format Web – Offset
6 Unit Large Format Web - Offset

Results:
At first glance, the benchmarking results indicated a 21.87% financial contribution as compared to the outside, print-for-profit marketplace. However, upon closer examination of the large offset presses, a productivity gap was identified that resulted in an increase per operational hour of 250%. This “gap” is made up of differences in press printing speed and make ready times.

While the adjusted contribution that we arrived at has turned decidedly negative, certain opportunities have surfaced. The packaging operation utilizes an older 40” Heidelberg offset press. Similar to the Miehle presses, this press is also an older and of less efficient design. By replacing the two Miehle offset presses and the Heidelberg packaging press with a new six color 40” press operating three shifts, an improved contribution of 33% was arrived at. This "to be" analysis is not atypical of our consulting engagements.