dowjones international newspaper group pre-press operations….a journey september 2013
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DOWJONES
International Newspaper Group
Pre-Press Operations….A Journey September 2013
Pre-Press Operations Assessment…A Journey
• A common lament?
– Through acquisition and evolution, our publications have different processes and software applications.
– This has brought challenges:• Too many different processes.• Technology and process was implemented to “do it like we used to”.• Process and technology is ever changing.• HUMAN ERROR; SYSTEM OUTAGES; PROCESS PROBLEMS
2
– Objectives :• Leverage existing assets and minimize technology platforms across the
publications.• Create the most efficient operating model of People, Process and
Technology• Determine what if any processes should be outsourced.
• A work in progress across three companies, – Dow Jones/New York Post: Started with the 9 publications– News UK: Followed with the 17 publications– News Australia: To follow
• Utilize PROCESS ENGINEERING– Applied Lean and Six Sigma Improvement tools
PROCESS– We started by mapping out the current pre-press processes by publication,
to understand: • Who does what and when.• What technology is employed (applications).• What are the opportunities identified throughout the process.
3
Pre-Press Operations Assessment…A Journey
4
PRODUCTION OPERATIONS – PAGE FLOW and PROOFING – ALEXA – AS IS /September/October 2012/Jgreer; CGalliard/ M. Bird; J. Moyer; K. Oechsner; M. Carpena; D.O’Callaghan; L. Warshawsky
Glo
bal L
ayo
uts
Pagin
atio
nE
dito
rial
Ad O
ps
Sale
s
4
Ad Booker EVO Black Magic MethodeGCR QMS OneVision Kraus CTPInDesign
Release Final Pages
Using generic QMS which requires manual setup to match Methode. 1 hr setup daily?
Does QMS Pair Pages for Alexa?
Generate OutputFlatten
transparencies and generate pdf X-1A
Run GCR software
Create “plate” in QMS and transmit to Receive
Site
Site uses QMA to route
Generate Onsite Proof
Drag PDF EVO RIP (Kodak)
Create Plate
PRINT SITE
Setup QMS To
Pair Pages
PRODUCTION OPERATIONS – PAGE FLOW and PROOFING – ALEXA – AS IS /September/October 2012/Jgreer; CGalliard/ M. Bird; J. Moyer; K. Oechsner; M. Carpena; D.O’Callaghan; L. Warshawsky
Pa
gin
atio
nE
dito
ria
lG
lob
al L
ayo
uts
Ad
Ops
Sa
les
1
Layout placementinstructions
supplied
Advise that layout is complete
1-2 weeks before run
2Run EVO RIP
(Kodak)Compose Page
(Editorial and Ad) Compare via visual check
All quality checks OK?
Run GCR software
Render simulation of press quality on
actual stock
Compose Page (Advertising)
Ad Booker EVO Black Magic MethodeGCR QMS OneVision Kraus CTPInDesign
3
Flatten transparencies and generate pdf X-1A
Generate proof Output Color?
Run EVO RIP (Kodak)
PDF GEN Server
moves to EVO
N
Y
Print on BW printer
N
4Y
Unable to generate quick proofs with current IT solution for printing. Printing one sheet takes up to 5 min.
16-24 pgs @ 2-3x each page
Legacy system no longer needed. Potential point of failure. Slows
troubleshooting for system problems.
Note: Color printer produces inaccurate representation of colors – ICC needs adjustments - 5 imaging technicians spend 30-45 min per day adjusting ink colors (NYC)
PROOFING
PRODUCTION OPERATIONS – PAGE FLOW and PROOFING – ALEXA – AS IS /September/October 2012/Jgreer; CGalliard/ M. Bird; J. Moyer; K. Oechsner; M. Carpena; D.O’Callaghan; L. Warshawsky
Glo
bal
Layo
uts
Ad
Ops
Pag
inat
ion
Edi
toria
lS
ales Book Ad
Is this in “Ad Booker”? (Jim Riley) Can Ad Watch or Ad Base be used here?5-7 ads/month
Receive Ad Copy (pdf)
Identify when ad is to run
Note: This is a cumbersome task as there is no formal alert before ads are received. Sales may contact Ad Ops or vice versa. Usually Ad Ops will then request for a listing of other ads running in the same issue, along with sold status and the ATC (Ad to Come). The “Special Section” Calendar is not issued regularly to Ad Ops.
Check PDF to WSJ
specifications
Drag PDF into GCR software
Drag PDF post GCR into EVO-3
BM3 (Kodak)
Drag PDF non GCR into EVO-3
BM3 (Kodak)
Compare via visual check
All quality checks OK?
Sales Rep or Client provides new material
Render simulation of press quality on
actual stock (2 prints)
Post PDF to Pub Server
Post PDF to One Vision Server
Set up NYPost Methode
Page Plan by Run date
Transmit “Methode
ready PDF” to NYPost Methode
1
1-2 days before send to print
Manual
NManual
Auto
Y
Note: Any changes made here have bypassed the QA
process
This is not the same BM as NY Post
Desktop Acrobat may
not be the same and
result in variation
Receive Editorial Copy (pdf)
Ad Booker EVO Black Magic MethodeGCR QMS OneVision Kraus CTPInDesign
Create Editorial
Page Units
Post PDF to One Vision
Server (Bldg 1211)
Conduct Preflight Check of
Create Ad Layout
Create pdfs
Manual process,
automated for NY Post
Transmit “Methode
ready PDF” to NYPost Methode
A
A
2
3
NY proofing workflow not available in SBK. Photo ads for high profile
customers, i.e. Tiffany’s, Ralph Lauren not produced accurately – credits are
applied
One server no backup. Vulnerable – potential failure
“POINT OF INTEREST”Grouped by:
• Proofing• Manual processes• Ad Production• Process Performance• Software/Technology
GROUP PERFORMING THE TASK
PUBLICATION
Alexa
COLOR IDENTIFIES THE APPLICATION USED
Pre-Press Operations Assessment…A Journey
5
PRODUCTION OPERATIONS – PAGE FLOW and PROOFING – ALEXA – AS IS /September/October 2012/Jgreer; CGalliard/ M. Bird; J. Moyer; K. Oechsner; M. Carpena; D.O’Callaghan; L. Warshawsky
Glo
bal L
ayo
uts
Pagin
atio
nE
dito
rial
Ad O
ps
Sale
s
4
Ad Booker EVO Black Magic MethodeGCR QMS OneVision Kraus CTPInDesign
Release Final Pages
Using generic QMS which requires manual setup to match Methode. 1 hr setup daily?
Does QMS Pair Pages for Alexa?
Generate OutputFlatten
transparencies and generate pdf X-1A
Run GCR software
Create “plate” in QMS and transmit to Receive
Site
Site uses QMA to route
Generate Onsite Proof
Drag PDF EVO RIP (Kodak)
Create Plate
PRINT SITE
Setup QMS To
Pair Pages
PRODUCTION OPERATIONS – PAGE FLOW and PROOFING – ALEXA – AS IS /September/October 2012/Jgreer; CGalliard/ M. Bird; J. Moyer; K. Oechsner; M. Carpena; D.O’Callaghan; L. Warshawsky
Pa
gin
atio
nE
dito
ria
lG
lob
al L
ayo
uts
Ad
Ops
Sa
les
1
Layout placementinstructions
supplied
Advise that layout is complete
1-2 weeks before run
2Run EVO RIP
(Kodak)Compose Page
(Editorial and Ad) Compare via visual check
All quality checks OK?
Run GCR software
Render simulation of press quality on
actual stock
Compose Page (Advertising)
Ad Booker EVO Black Magic MethodeGCR QMS OneVision Kraus CTPInDesign
3
Flatten transparencies and generate pdf X-1A
Generate proof Output Color?
Run EVO RIP (Kodak)
PDF GEN Server
moves to EVO
N
Y
Print on BW printer
N
4Y
Unable to generate quick proofs with current IT solution for printing. Printing one sheet takes up to 5 min.
16-24 pgs @ 2-3x each page
Legacy system no longer needed. Potential point of failure. Slows
troubleshooting for system problems.
Note: Color printer produces inaccurate representation of colors – ICC needs adjustments - 5 imaging technicians spend 30-45 min per day adjusting ink colors (NYC)
PROOFING
PRODUCTION OPERATIONS – PAGE FLOW and PROOFING – ALEXA – AS IS /September/October 2012/Jgreer; CGalliard/ M. Bird; J. Moyer; K. Oechsner; M. Carpena; D.O’Callaghan; L. Warshawsky
Glo
bal
Layo
uts
Ad
Ops
Pag
inat
ion
Edi
toria
lS
ales Book Ad
Is this in “Ad Booker”? (Jim Riley) Can Ad Watch or Ad Base be used here?5-7 ads/month
Receive Ad Copy (pdf)
Identify when ad is to run
Note: This is a cumbersome task as there is no formal alert before ads are received. Sales may contact Ad Ops or vice versa. Usually Ad Ops will then request for a listing of other ads running in the same issue, along with sold status and the ATC (Ad to Come). The “Special Section” Calendar is not issued regularly to Ad Ops.
Check PDF to WSJ
specifications
Drag PDF into GCR software
Drag PDF post GCR into EVO-3
BM3 (Kodak)
Drag PDF non GCR into EVO-3
BM3 (Kodak)
Compare via visual check
All quality checks OK?
Sales Rep or Client provides new material
Render simulation of press quality on
actual stock (2 prints)
Post PDF to Pub Server
Post PDF to One Vision Server
Set up NYPost Methode
Page Plan by Run date
Transmit “Methode
ready PDF” to NYPost Methode
1
1-2 days before send to print
Manual
NManual
Auto
Y
Note: Any changes made here have bypassed the QA
process
This is not the same BM as NY Post
Desktop Acrobat may
not be the same and
result in variation
Receive Editorial Copy (pdf)
Ad Booker EVO Black Magic MethodeGCR QMS OneVision Kraus CTPInDesign
Create Editorial
Page Units
Post PDF to One Vision
Server (Bldg 1211)
Conduct Preflight Check of
Create Ad Layout
Create pdfs
Manual process,
automated for NY Post
Transmit “Methode
ready PDF” to NYPost Methode
A
A
2
3
NY proofing workflow not available in SBK. Photo ads for high profile
customers, i.e. Tiffany’s, Ralph Lauren not produced accurately – credits are
applied
One server no backup. Vulnerable – potential failure
NYC proofing workflow is not available in SBK . This includes color proofing. REC: Investigate why this is not possible and what benefits would be gained by so doing (L,M)
Any changes made here, dropped directly into Méthode, have bypassed the QA processREC: Investigate why changes occur past this point (M,M)
Unable to generate quick proofs with current IT solution for printing. Printing one sheet takes up to 5 minutes, 16-24 pages x 2-3x each page. Note: this is between 3 .3 to 6 hours daily (16*5 min*2.5 times to 24*5 min *2.5 times) REC: Investigate replacement of printers for proofing. (H,M)
8
9 11
“POINT OF INTEREST”
What Did We Find? Process
6
Combined Benefit/Effort Matrix
Low Medium High
High
Medium
Low
EFFORT
BEN
EFIT
1
2
3
42 3
4
5
6
7
8
9 10
11
1
12
13
14
3
4
5
6 7
9
10
1
13 1514
11 12
2 8
9 108
6
7
1
2 3
4
5
1 xxx
1 zzz
1 yyy
1 vvv
What Did We Find? Process
In all, @100 opportunities for improvement were recorded
7
• Some Common Trends:
– Several different groups were doing common tasks, distinct by publication.– Some of the tasks were very time-consuming as a result of the technology
limitations.– Applications, even by the same vendor, were not used consistently across the
publications or companies.– Some changes to ad copy made later in the process were not re-checked by an
upstream Quality Control check.– Pre-flight checks of received ads for some publications failed quite often.– Unfamiliarity with editorial copy tools causes delays and rework.
• Many of these are already being corrected.
What Did We Find? Process
In all, @100 opportunities for improvement were recorded
8
• Companies used different applications to get the same work done.
– One company is using three times the number of applications than another.– One publication alone has eighteen applications strung together, just to perform
pre-press.– A majority of the overall applications are unique to a single publication.
• Why is this important? – Production is being affected by technology breakdowns.– Significant cost and effort to maintain applications.
We need a common solution to handle a common process
What Did We Find? Technology
9
The systems/applications used are in a constant state of change, mostly dictated by the needs of business.
This volatility requires that we simplify and standardize processes and supporting applications to prevent increases in cost to maintain and operate.
What Did We Find? Technology
Mer
lin
NYP
-CN
G M
AC
Exte
rnal
FTP
File
& P
rint
NYP
-CN
G F
ile &
Prin
t
QM
S
Which applications affect print production the most
6005004003002001000
Median
Mean
2520151050
1st Quartile 0.659Median 1.6363rd Quartile 7.694Maximum 597.392
6.687 26.120
1.144 2.657
52.249 66.096
A-Squared 33.75P-Value < 0.005
Mean 16.403StDev 58.358Variance 3405.637Skewness 7.7717Kurtosis 72.1280N 141
Minimum -10.889
Anderson-Darling Normality Test
95% Confidence Interval for Mean
95% Confidence Interval for Median
95% Confidence Interval for StDev95% Confidence I ntervals
Summary for Elapsed Time (Hours)
Median Elapsed Time –1.6 Hours
Median Elapsed time that the application is down
10
• The review noted that “tribal knowledge” (the practice of subject matter experts fully knowledgeable in their areas but largely undocumented) was commonplace.
• An overall lack of reference materials, consistent training and support supplied to the process participants that should be addressed.
• The non-standardized processes (each publication performs similar tasks differently) adds to the general inability to leverage resources in times of need across publications.
What Did We Find? People
11
Pre-Press Operations Assessment…Our Next Steps
MINIMIZE VARIATION of the tasks, they should be consistent
SIMPLIFY THE TASKS to reduce complexities and reduce cycle-time
STANDARDIZE THE APPLICATIONS to reduce complexities and cost
CONSIDER CONSOLIDATING IN A SHARED SERVICE OR OUTSOURCING
Common Pre-Press Tasks across all publications
Manage Ads
Create Pages
ContentTransmitProof
Assemble Pages
Plan Book
Typeset and Pre-
flight
Create Classified Ad Copy
DJ
NI
NL
Broadsheet; Tabloid;
Magazine
Broadsheet; Tabloid;
Magazine
“Strawman”Common
NewsCorp
Review proposed plan (DJ;NI;NL; tech and pre-press)
Broadsheet; Tabloid;
Magazine
Common NewsCorp
AS ISDefine, Measure
AS IS – TO BEAnalyze, Improve
TO BEAnalyze, Improve
TO BEImplement, Control
Pre-Press Operations Assessment…Our Next Steps
PRESENT STATE
BENCHMARK, IDENTIFY STANDARDS
ASSESS COSTS, ALTERNATIVES, EFFORT
IMPLEMENTATION
12
• Objective:– A standardized process and technology solution to address each type
of publication that can be leveraged for like products across News Corporation.
– Use the least amount of company resources while maintaining or improving product quality and customer service.
– Our PROCESS ENGINEERING approach helped us get here…
13
Pre-Press Operations Assessment…Our Next Steps
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