Next Level Push to Stop: Heidelberg Systematically Unlocks OEE Potential with Intelligent Digitization
Tuesday, March 24, 2020
Press release from the issuing company
The new Intellirun function on the Wallscreen XL ensures continuous navigation during printing and automatically provides the operator with important, context-specific indications and pointers about what activities and information are required to avoid time losses.
In a global survey of over 1,000 customers, Heidelberger Druckmaschinen AG (Heidelberg) identified four key areas that sum up the challenges in the print industry: increasing complexity, skills shortages, competitive pressure, and the expansion of the value chain to include digital platforms. Heidelberg has comprehensive responses for all of these areas. In the area of printing presses, Heidelberg will be presenting the most intelligent and most highly automated Speedmaster yet with the new Speedmaster generation – a smart product that integrates seamlessly into a digitized smart print shop and even into a smart organized printing industry. With the new Heidelberg User Experience (UX) on the Speedmaster, it offers a modern and attractive workstation. In addition, other intelligent assistants ensure that the machine’s productivity potential is unlocked. All models in the new generation also include Push to Stop functionalities and an interface to the Prinect Cloud as standard. This enables more comprehensive navigated and autonomous printing, which increases productivity, process reliability, and profitability. The new Speedmaster generation will go into series production from April 2020.
Next-level Push to Stop addresses the “yellow bar” in a systematic way
New Intellirun software organizes print production on the Speedmaster using an integrated approach
However, the new Intellirun function on the Wallscreen XL now goes a step further. While Intellistart focuses on the makeready process, Intellirun ensures continuous digitally controlled navigation during printing and automatically provides the operator with important, context-specific indications and pointers about what activities and information are required to avoid time losses.
“Everyone is familiar with the navigation system in their car. When you leave the freeway, the traffic situation is automatically visualized. Thirty minutes earlier, this information would have been of no use to you,” explains Jürgen Mittmann, the project manager responsible for machine operation. “Intellirun works in a similar way. For example, Intellirun shows the mask for preparing the next job in good time before the current run is completed. The operator can see at a glance whether anything is missing and can intervene if necessary in good time. A lot of time losses can be eliminated or at least minimized through timely preparation.” With the new Press Center Mobile app, the operator can call up all key control station information, such as the current job status, the job queue with the change overview as well as the status of the consumables, from all connected machines on a tablet or smartphone. This optimizes the processes to do with the printing press, reduces downtimes and manual interventions, and ensures that consumables, paper, and plates are always available in the right place at the right time.
As another highlight, Intelliline also brings navigation to the individual printing and coating units. Color-controlled LED elements make it possible to see the machine status from afar. The LEDs light up blue when the press is printing good sheets and light up green when the press is carrying out automatic makeready processes. The color on the printing and coating unit changes to yellow whenever manual interventions are required.
Intelligent digital assistants leverage additional potential
Another example of intelligent digital assistants is the new Wash Assistant. Evaluations show that operators tend to use washup programs that are too long as a way of ensuring good washing results. The Wash Assistant selects the right washup program based on relevant job and machine parameters. Apart from saving time, this also saves washing fluid and washup cloths. When washing ink rollers, the Wash Assistant can, for example, identify when switching from a dark color to a light one, and initiate a deep clean automatically.
Settings that are too high are often also used in the powder area for safety’s sake. Excessive powder soiling in the delivery will result in increased downtimes for cleaning, and too much powder is also a problem in postpress. The new Powder Assistant gives its recommendation for the necessary powder setting based on the substrate and area coverage. Initial tests at customers have already brought about significant improvements.
The Quality Assist launched in 2016, which starts the production of good sheets automatically when the inking quality is achieved with Prinect Inpress Control 3, has been extended and can now also display the results of the sheet inspection and the PDF comparison performed by Inspection Control 3. As a result, Prinect Inspection Control 3 is also optimally integrated into the Push to Stop workflow. The learning function of Color Assistant Pro for optimizing ink presetting has been automated and enables fully automatic learning of the ink presetting in combination with a Prinect color measurement system. With the self-learning Color Assistant Pro, the Speedmaster automatically optimizes ink presetting and in this way saves time and above all paper waste during setup. All Prinect color measurement systems are now integrated into the Prinect workflow via a central color database and also support the importing and exporting of CxF data. This offers greater flexibility in production, since reference values can be swapped between the printing presses without any problems.
New Press Center offers a modern, attractive workstation
“Minimizing the yellow bar in the long term requires intelligently networked, coordinated processes that help the operator go beyond their physical limits. This is less about a sprint, in other words for a top productivity hour or top shift, and more about a marathon with continuous top productivity over a month, a year, the life of a machine. This is the added value we want to offer our customers with digital integration, outstanding machine technology, modern service concepts, and new, output-oriented business models. We want to do this with a partnership-based approach that pursues common goals, and from which everyone benefits,” summarizes Rainer Wolf.
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