Speed is the tip of
an iceberg. It's easy to see. But the real story lies
beneath the surface.
Faster speeds are good.
But only if accompanied by higher productivity. This
simple yet inescapable truth is being lost amid the
claims and counter-claims of inserting system vendors
as they introduce and promote faster and faster speeds.
There is no doubt that
faster cycling speeds can boost performance for virtually
any inserting operation. And customer messaging centers
everywhere want to lower costs, especially the total
cost per mailpiece.
But higher speeds alone
are not enough. The real key to superior performance
is productivity. After all, what is the advantage
of acquiring faster equipment if you can rarely achieve
your production goals?
Consistent performance
-- and not just raw speed -- yields the best productivity.
Managers of customer messaging centers in search of
better performance should focus less on equipment
with just the fastest cycling speeds. Instead, they
should look for the best combination of speed, performance
and mailpiece quality. That's the best way to assure
a consistent high-speed operation along with flawless
production.
Rugged Reliability
and Easy Operability
How do you determine which inserting systems
offer the best value? By looking beneath the surface.
The key is to determine whether the faster speeds
are the result of simply speeding-up an existing process,
or are accompanied by improvements in engineering
and design that are intended to boost productivity
as well.
Inserting systems that
feature high speeds plus reliable mechanics, smooth
paper-handling processes, and fast set-ups and switch-overs
will yield the best throughput and highest quality.
As a guide, here are a few key innovations to look
for when evaluating high-speed inserting system.
Advanced Motion
Control Technology
One of the best methods to boost productivity
is to replace the traditional mechanical drive mechanisms
-- such as clutches, brakes, solenoids, chains and
gears -- with individually controlled and highly reliable
servo motors These innovative devices provide value
in a number of ways.
First, they are extremely
durable, which reduces the instance of unscheduled
downtime and dramatically extends the interval, or
mean time, between regularly scheduled preventative
maintenance procedures. Inserting systems with servo
motors can typical operate without routine service
for periods that are two to three times longer than
the conventional mechanical technologies.
Servo motors are also
'instant on' and precise, which eliminates the unproductive
ramping-up period -- also known as the post-maintenance
'blues' -- that can occur when bringing the traditional
mechanical technologies back 'on-line.'
The new technology also
enables tight control and transport of collations
using a minimum, yet still accurate, space 'gap.'
This unique feature allows the system to boost productivity
by compressing the amount of empty space between collations.
This increases the density or number of collations
processed. In effect, more collations can be accommodated
at a slower speed, which results in less stoppages,
more productivity and less material spoilage.
Also, with fewer stoppages,
there's less wear and tear on components due to excessive
stopping and starting. Less wear and tear under 'normal'
operating circumstances means that components will
operate more reliably for longer periods of time,
which also translates into a higher level of consistent
performance and better productivity.
And if a stoppage does
occur, it is extremely precise. In almost all instances,
there's no damage to either the preceding or following
collation, which greatly reduces the incidence of
material spoilage due to secondary or ancillary jams,
and the time and cost to regenerate additional mailpieces.
Lastly, the photo cells
and servo motors, which feature a closed-loop processing
technology, are self-monitoring and provide operators
with an early warning of excessive wear or impending
failure. So even unscheduled maintenance and repair
procedures can be easily arranged during non-processing
periods, such as application switch-overs or end-of-work
day shift changes.
Flexible and
Efficient Enclosure Feeders
The enclosure feeders should also feature
an extended bin to accommodate greater volumes of
inserts. This added capacity will reduce the time
and labor needed to replenish materials. Ideally,
the enclosure feeders should also be modular in design,
so they can be removed and replaced quickly.
The ability to make
quick change-outs will help keep system uptime high
and enables any feeders needing service to be attended
to off-line, which also helps boost productivity.
The enclosure feeders
should also be engineered to facilitate quick application
set-ups and change-overs. A minimum number of adjustments,
including automated adjustments, will minimize any
delays resulting from human errors and enable the
system to return to production as quickly as possible.
Lastly, look for an
automatic capability to switch the use of feeders.
This feature will enable operators to use back-up
feeders to reduce the frequency of reloading and will
contribute to higher productivity as well.
File-Based Reporting
and Control Capability
Speed is irrelevant if the mailpiece is misassembled
or otherwise inaccurate or defective. Any high speed
inserting system must feature a state-of-the-art tracking,
controlling and reporting system. File-based tracking
systems provide precise tracking of individual mailpieces,
assure mailpiece integrity, and a key element of any
closed-loop messaging system.
Inserting systems should
also be equipped with a comprehensive on-board self-diagnostic
capability, which will alert operators and technicians
in advance to possible service needs and help assure
maximum uptime.
Additionally, the control
system should enable easy storage and retrieval of
all job specifications, to help speed set-up and change-overs,
and fast and full reconciliation of all jobs processed,
to provide assurance that every mailpiece was assembled
and processed as expected.
Ideally, the control
system should be capable of linking with the other
inserting systems in the messaging center, as well
as with other processing sites. This important feature
will allow managers to maximize productivity by balancing
work loads and shifting volume from equipment or sites
that are over-loaded to those with available or excess
capacity. Such a feature can also interact with a
remote monitoring capability to give customers an
up-to-the-minute view on the status of jobs in progress.
Simplified Paper-Path
Architecture
An open paper-path, coupled with innovations
such as an improved envelope feeding technology, can
provide smooth, high-speed processing and greatly
reduce any possible instances of production flaws.
This improved architecture also allows the paper path
to remain completely visible, giving operators an
unobstructed view of the entire inserting operation.
As a result, operators can instantly locate the source
of problems and quickly take any corrective actions
that might be needed.
An Ergonomically-Designed
Footprint
Like speed, a compact footprint is good.
But an ergonomically-designed footprint is even better.
What's the difference? Plenty, especially if you're
the operator and you're working an eight or ten-hour
shift.
On the surface, compact
should mean less area and fewer steps. But it doesn't
in every instance. Some systems are termed 'compact'
because they occupy a small footprint with fewer sq.
ft. of space. But these same systems, under normal
operating procedures, also require the operator to
walk around the perimeter or outside of the system,
instead of remaining in the 'cove.' These systems
are not designed for maximum efficiency.
An inserting system
that is ergonomically-designed will minimize the number
of steps required under normal operating conditions.
A good gauge is to measure the number of steps 'required
to reach the most frequently visited areas.' Such
a yardstick will provide an accurate measure of the
human effort actually needed to operate the equipment
under typical conditions.
About the Author
Shahzad Malick is a 14-year veteran with
Pitney Bowes. He holds eight patents and is responsible
for the development and introduction of the company's
Advanced Productivity Inserting System, a central
component in the firm's closed-loop messaging solution.
Analyst
Reports