BOSTON--Oct. 27, 2005-- Large companies producing millions of printed manuals, mailings, and other documents each year have a new service from Xerox Corporation to help ensure their print operations are running as cost-effectively as possible. Xerox Production Optimization Services comprise assessment services and simulation software that identify inefficiencies in print workflow processes, eliminate wasteful steps, and maximize the use of printing equipment. Production Optimization Services have been shown to reduce in-house print shop costs by as much as 20 percent, increase the productivity of such shops by up to 40 percent, and boost print revenue by 17 percent. First Data Corporation, a $10 billion electronic commerce and payments leader, called on Xerox Global Services to conduct a key component of Production Optimization Services, called Lean Document Production, for its First Data Card Issuing Services business group. Lean Document Production, developed within the Xerox research centers, involves an extensive on-site analysis and assessment of an organization's print operation using Lean Six Sigma tools, which reduce defects and wasted steps in the printing process. After feeding actual First Data print information into a variety of simulation models, Xerox consultants identified a number of areas where First Data could improve efficiency and capacity while cutting costs. As part of its recommended changes, Xerox suggested a redesigned production floor layout that divided the operation into "cells" to use space more efficiently. Xerox also identified an equipment management process that would enable First Data's Output Services card product group to send print jobs to equipment that was normally idle. "Xerox's analysis and recommendations have helped First Data reduce expenses and, more important, improve the quality of service we can provide to our output services clients," said Tim Rosenthal, senior vice president, Output Services, First Data. With Production Optimization Services, Xerox consultants concentrate on two distinct environments: print production areas, where Xerox consultants assess workflow processes to help customers complete print jobs more quickly and at lower costs; and mail and finishing operations, where consultants find ways to automate the workflow so that jobs can be completed and mail delivered at faster speeds. Xerox also offers production print, mailroom and finishing outsourcing services to allow enterprise customers to focus on their core business. "Xerox has applied more than 15 years of technology innovation and consulting expertise within the printing industry to develop these assessment and process methodologies to give customers measurable results," said Howard Holley, vice president, Document Outsourcing and Communication Services, Xerox Global Services. "Our expertise in Lean Six Sigma, which Xerox has used extensively to improve our own internal processes and cost structure, provides a disciplined approach to helping customers do the same."