A Lean Approach To Innovative Label Sourcing Strategies
Transcript of A Lean Approach To Innovative Label Sourcing Strategies
A Lean Approach To Innovative Label Sourcing Strategies
Les Wallace, CPP Packaging Manager [email protected] 425-415-3695
What is “Lean”???
“Lean” - Wikipedia
Lean manufacturing, lean enterprise, or lean production, often simply, "Lean," is a production practice that considers the expenditure of resources for any goal other than the creation of value for the end customer to be wasteful, and thus a target for elimination. Working from the perspective of the customer who consumes a product or service, "value" is defined as any action or process that a customer would be willing to pay for.
Lean is the set of "tools" that assist in the identification and steady elimination of waste or the focus is upon improving the "flow" or smoothness of work.
http://www.expertrating.com/certifications/Lean/LEAN_FILES/Lean1.gif
Lean Tools
Keep Lean Simple Maximize Customers Value & Minimize Waste
Sourcing Strategy: Create sustainable value for customers with fewer resources.
Objectives: • Purchase Price Reductions • Increase Asset Utilization • Improve Productivity
Lean Sourcing Approach Measures for Improvement
Improvement Categories
Purchase Price
Customer Value
Material Reduction
Inventory Reduction
Transportation
Material Quality (Product and Process)
Delivery Issues & Time
New Product Development Cycle Time
Overall Equipment Effectiveness (OEE)
Key Benefits
• Greater buy-in from Purchasing, Operations, and Strategic Suppliers.
• Greater success rate of implementing identified savings and improved performance.
• Improve quality and reduce waste across the supply chain.
• On-going cost reduction opportunities via collaboration with integrated partners.
Where Do We Start?
Basic Wine Label Designs
Designing for Lean Label Innovations
Approximately 80% of product costs are determined in design.
Baseline Label Cost = 98mm x 153mm coated stock, medium format press(6 colors or less),
no other value adds.
Designing for Lean Label Innovations
Added Value Alternatives* Purchase Price Impact
Extra Color + 3%
Flexo Gold + 5 %
Stardust + 10%
Uncoated or Specialized Paper + 20% to 30%
Screen/High Build + 11%
Polymer Emboss + 8%
Foil: First, Second, Third +30%,+60%,+90%
Designing for Lean Label Innovations
Alternatives* Potential Savings Impact
Select the Correct Press Format 10% - 20%
Reduce Label Size or Optimize for Press 24% - 36%
Group Production Runs 10% - 40%
High Volume Paper Stocks 25% - 35%
Innovative Printing Techniques 2% - 20%
Select the Correct Press Format or Bottle Decoration Process
Select the Correct Press Format: UV Offset Large Press Format: 58%of Total Print Process Optimal Print Run Size: Over 200K Labels Optimal # of Colors: 6 to 9 Full Rotary Foil, Emboss or Screens: Full Rotary, Minimum one each depending on press.
UV Flexo Large Press Format: 31%of Total Print Process Optimal Print Run Size: Over 200K Labels Optimal # of Colors: 5 to 11 Full Rotary Foil, Emboss or Screens: Full Rotary, Minimum one each depending on press.
UV Offset Medium Press Format: 8%of Total Print Process Optimal Print Run Size: 10K to 200K Labels Optimal # of Colors: 4 to 6 Foil, Emboss or Screens: Semi Rotary, Minimum one each depending on press.
Select the Correct Press Format:
ACL (Direct Bottle Printing): 2% of Total Print Process Optimal Print Run Size: 1 to 100K Bottles Optimal # of Colors: 3 to 5 Screen Inks Design Options: Frost, Glass Color, Gold or Metallic Inks
Digital : < 1% of Total Print Process Optimal Print Run Size: 1 to 100K Labels Optimal # of Colors: 4 to 7 + UV Varnish Foil, Emboss or Screens: Generally Off Line, Minimum one each depending on press.
The Future Wine Label Press Format Large Format Combo Press: UV Offset & Flexo
Optimal Print Run Size: Over 200,000 Labels Optimal # of Colors: 7 to 9 Foil, Emboss or Screens: Minimum of one each Additional benefits: Wide web width increases production efficiencies Reduces waste Greater Design Flexibility Sleeve technology for quick changeovers
The Future Wine Label Press Format Large Format Combo Press: Flatbed Hot Foil & Emboss/Deboss
FEATURES • Optimum foil and embossing performance • Individual or simultaneous foiling and embossing capabilities • Combined foiling and embossing unit • Foil saving system • Designed for short runs
BENEFITS • Superior hot foil and embossing quality • Fast setup time & Minimum waste • Lower foil and tooling costs
www.nilpeter.com www.pantec.com
FP-4 RHINO™:
The Future Press Format Options Large Format Combo Press:
Offset, Flexo and FP4 or RHINO™:
Improvement Categories Impact
Purchase Price Improves Label Cost
Customer Value Improves: More Design Options
Material Reduction Reduced Material Usage
Inventory Reduction No Change
Transportation No Change
Material Quality (Product and Process) Improve Print Registration & Color
Delivery Issues & Time Improves, Shorter Run Times
New Product Development Cycle Time Increases If Not Planned
Overall Equipment Effectiveness (OEE) Improves For Printer
The Future of ACL UV Curable Inks
• Reduces carbon footprint, volatile emissions and energy usage. • UV inks support distinctive designs and enable printing directly on
bottle with entire bottle wrap printing. • Coat entire bottles with a full color range in opaque or transparent
UV ink.
The Future of ACL UV Curable Inks
Improvement Categories Impact
Purchase Price Improves Cost – Volume Dependent
Customer Value Improves Shelf Impact Material Reduction Reduced Material Usage – No Labels
Inventory Reduction No Label Inventory, Risk - Over Runs or Changes In Production
Transportation Increase Transportation Cost Material Quality (Product and Process) Improve Durability & Color Consistency
Delivery Issues & Time Complex Logistics
New Product Development Cycle Time Added Time – Due To Color Matching
Overall Equipment Effectiveness (OEE) Improves No Labeling
Reduce Label Size or Optimize for Press
Example for 10”Web Width
Layout
Across Around 4.875 4.375 2 2 3.208 4.375 2 3 2.375 4.375 2 4 1.875 4.375 2 5 4.875 2.875 3 2 3.208 2.875 3 3 2.375 2.875 3 4 2.375 2.125 4 4
Reduce Label Size or Optimize for Press
Optimize Label Size for Combo Runs
Label Size#1 Label Size#2
Layout label #1 Layout label #2 can be up
to .125''
smaller than #1 Across Around Across Around
4.875 4.875 4.875 3.875 1 2 1 2 4.875 5 4.875 3.75 1 2 1 2 4.875 5.25 4.875 3.5 1 2 1 2 4.875 5.5 4.875 3.25 1 2 1 2 4.875 5.75 4.875 3 1 2 1 2 4.875 6 4.875 2.75 1 2 1 2 4.875 6.25 4.875 2.5 1 2 1 2 4.875 6.5 4.875 2.25 1 2 1 2
Optimize Label Size
Improvement Categories Impact
Purchase Price Improves Cost
Customer Value No Change
Material Reduction Reduced Material Usage
Inventory Reduction No Change, But Watch Combo Runs
Transportation No Change
Material Quality (Product and Process) Improve Color Consistence for Combo Runs
Delivery Issues & Time No Change
New Product Development Cycle Time Increases if Not Planned
Overall Equipment Effectiveness (OEE) No Change
Group Production Runs
Group Production Runs • Design for one or two label sizes for multiple SKU’s • Target one to three plate changes to differentiate individual SKU’s. • Understand the printers requirements for group runs to maximize
economy of scale
Group Production Runs
Improvement Categories Impact
Purchase Price Improves Cost
Customer Value No Change
Material Reduction Reduces Make-Ready Material Loss
Inventory Reduction Adds Inventory Cost
Transportation No Change
Material Quality (Product and Process) Improve Color Consistence
Delivery Issues & Time No Change New Product Development Cycle Time No Change
Overall Equipment Effectiveness (OEE) Improves for Printer
High Volume Paper Stocks
High Volume Paper Stocks
In Line Polymer Graining • Unlimited range of emboss/deboss design options available for both
uncoated and coated stocks • Super Matte Varnish in combination of line grain emboss/deboss on
coated stocks can be used to replicate uncoated paper or two different stocks.
High Volume Paper Stocks
Improvement Categories Impact
Purchase Price Improves Cost
Customer Value Improves Design Options
Material Reduction No Change
Inventory Reduction Inventory Reduction for Printer
Transportation No Change
Material Quality (Product and Process) Improves Material Consistency
Delivery Issues & Time No Change
New Product Development Cycle Time Reduces Material Qualification Time
Overall Equipment Effectiveness (OEE) Improves For Both Printer and Bottling
Innovative Printing Techniques
Innovative Printing Techniques Inks and Screens
• Clear screens can embolden elements or create a raised effect instead of Emboss
• Metallic screens add luster and texture. Silver screen ink simulates silver foil and can add a metallic look when overprinted.
• White screen creates opacity • Laying down of screen gloss or clear foil on an uncoated paper stock
to give the inks overprinting on the top a glossy look, as if they were printing on coated stocks to create the look of two stocks on one label
• Metallic inks sit on top of the paper and look more vibrant. • For label designs that have screen gloss and high build (which
would require two screens), screen gloss can be applied to all areas and then emboss to the areas that are to be high build. The height of the emboss combined with the screen gloss can have the look and feel of high build, especially on the semi-rotary presses that have the flat-bed sculpted emboss capacity. This method keeps the label to the economy of the smaller press with one screen station.
Improvement Categories Impact
Purchase Price Improves Purchase Price
Customer Brand/Shelf Identity Improves Brand Identity & Shelf Presence
Material Reduction Can Reduce Material Usage
Inventory Reduction No Change
Transportation No Change
Material Quality (Product and Process) Improves Depending on Technique
Delivery Issues & Time No Change
New Product Development Cycle Time Increases If Not Planned
Overall Equipment Effectiveness (OEE) No Change
Innovative Printing Techniques Inks and Screens
Innovative Printing Techniques Sculpted Emboss/Deboss
• Sculpted embossing/debossing allows multi-level images and “domed” lettering or images. Images are embossed or debossed with a brass tool and can be combined to have raised and lowered elements on the same tool.
Improvement Categories Impact
Purchase Price Increase Tooling Cost for Rotary
Customer Value Improves Shelf Impact
Material Reduction No Change
Inventory Reduction No Change
Transportation No Change
Quality (Product and Process) Add Complexity
Delivery Issues & Time No Change
New Product Development Cycle Time Can Add Timing For Approvals
Material Quality (Product and Process) No Change
Innovative Printing Techniques Sculpted Emboss/Deboss
Innovative Printing Techniques Offset to Flexo
Improvement Categories Impact
Purchase Price Improved Pricing
Customer Value No Impact
Material Reduction Reduced Waste at Press
Inventory Reduction No Change
Transportation No Change
Material Quality (Product and Process) Improved Color Consistency
Delivery Issues & Time No Change
New Product Development Cycle Time Print Quality Needs To Meet Marketing Approval
Overall Equipment Effectiveness (OEE) No Change
Innovative Printing Techniques Offset to Flexo
Other Areas of Improvement
Standard Label Shipping
Eco Bin Label Shipping
Eco Bin Label Shipping Difference in Corrugate needed to hold
Approximately 10 Million Labels.
Eco Bin Standard Corrugated Boxes
Eco Bin
Improvement Categories Impact
Purchase Price No Change
Customer Value No Change
Material Reduction Corrugated Material Reduction
Inventory Reduction No Change
Transportation Improved Load Utilization
Material Quality (Product and Process) No Change
Delivery Issues & Time No Change
New Product Development Cycle Time No Change
Overall Equipment Effectiveness (OEE) Improves, Reduced Material Handling
WEBRUNNER Labels
Application Benefits (1999):
Bottling SPEED EXTRA Cases Per DAY: 85 BPM: 2,000 extra cases per day 125 BPM: 3,000 extra cases per day 175 BPM: 4,000 extra cases per day
Based on 24 hour operations with 3 labels ( Front, Back and Neck ) with 5,000 label per roll and 30 Change Over
• Non Stop Labeling No Roll Change • No Fixed Leading Edge • Significant Productivity Gains And Flexibility For Bottling.
A Continues Web Perforated Enough To Fold But Not Break
WEBRUNNER Labels a continues web perforated enough to fold but not break
But @ Greater then 250 BPM
Improvement Categories Impact
Purchase Price Improved Pricing
Customer Value No Change
Material Reduction Reduction in Material Loss
Inventory Reduction No Change
Transportation Increased Transportation
Material Quality (Product and Process) Reduced Quality Issues
Delivery Issues & Time Improved Supper Production Flexibility
New Product Development Cycle Time No Change
Overall Equipment Effectiveness (OEE) Improves For Both Printing & Bottling
What is “Lean”???
Lean is keeping lean simple!!