Benefits

Metrix is an exciting new tool that directly complements the average commercial printer's primary cost minimization strategies:

1. maximizing utilization of the most expensive equipment in the plant - the presses, and
   
   
2. reducing raw materials consumption - that is, reducing stock wastage.

Ganging

Every job ganged up with another saves one or more makereadies and sets of plates, plus wash-ups. This is especially relevant as average sheetfed run lengths are shortening - the shorter the press runs, the more press runs there are, therefore the more makereadies. Also, for short run work each press makeready saved also means significant stock savings, as makeready stock spoilage is a significant portion of the total stock used for a short run job.

Simple Ganging ROI Calculation

Because ganging directly affects major equipment utilization, if Metrix facilitates even humble improvements in the number of jobs ganged the return on investment is staggering. A simple calculation of the savings to be experienced with just one extra sheetwise job ganged per week on a large format press, looks like this:

For the sake of simplicity, this example assumes the same total stock cost as, although the makeready spoils for one job were saved, ganging can sometimes use stock less efficiently due to incompatible run lengths of the different products.

Where return on investment calculations are based on recuperating capital expenses over one year, for this simple scenario, Metrix promises an ROI greater than a factor of twenty. More aggressive implementations, and ones that also utilize the further benefits of computer integrated manufacturing (utilizing the CIP3, JDF, and Preps template data Metrix exports), can substantially increase the ROI experienced.

These are significant numbers considering our industry's poor net profit average. Printing companies considering purchasing a new press worth millions of dollars should consider the option of a much smaller investment in Metrix, to help utilize their existing equipment more efficiently.

Reducing Stock Wastage

Metrix's foremost return on investment is in how it assists ganging, with the huge associated savings in press makeready time and plates. However, a less obvious advantage is the unprecedented waste reduction made possible by considering all job specific bleed requirements.

Our sophisticated industry specific algorithms look for ways to place as much product onto a press sheet as possible, considering the press's image area capabilities and product specifications. Where possible, due to grain direction and other constraints, Metrix will rotate products to share common bleed gutters or to butt non-bleeding edges together. This of course, reduces the number of postpress cuts required, and therefore execution time downstream in the finishing department.

The following links contain examples of how product bleeds alone can make a significant difference in the number of products that fit on a sheet. In an extreme example, twice as many products can fit on a sheet when they bleed only three edges, not four. With stock accounting for one quarter to one third the cost of the average job, eliminating wastage significantly benefits a company's bottom-line.

All examples show a "before" shot - the best layout if the product simply bleeds all four edges, and an "after" shot - the layout possible if the product only bleeds three edges.

•  Example 1 - 50% stock saving
•  Example 2 - 20% stock saving
•  Example 3 - 16.7% stock saving
•  Example 4 - 12.5% stock saving

Skilled Labor

In the current competitive marketplace, skilled workers are becoming increasingly difficult to find and retain. Metrix saves many valuable hours of skilled labor across multiple company departments:

1.  estimating - by instantly calculating optimized layouts Metrix enables estimators to pass competitive prices back to customers, stimulating new business.
   
   
2.  production planning - as planners and production managers look for ganging opportunities based on common stocks and inks, and approved art availability, Metrix will instantly calculate the best layout. This potentially saves employees days of frustrating trial-and-error work per week, enabling companies to capitalize on otherwise lost opportunities for huge cost savings in production.
   
   
3.  prepress - by exporting independent page Preps® templates complete with custom bleed settings, or better still, complete JDF imposition data with PDF content files, Metrix will save prepress operators hours a day duplicating layouts that were calculated upstream, while reducing the risk of expensive errors. Also, because every ganged job saves one or more sets of plates, Metrix saves film setting or plate setting time and materials.
   
   
4.  press room - every job that can be gang printed saves one or more makereadies and sets of plates. This more efficient utilization of existing capital assets quickly adds up to surprising savings.
   
   
5.  finishing, cutting - plants that have CIP3 or JDF capable cutters can save significant equipment setup time because Metrix exports the data necessary to automatically program even complex cutting patterns. Metrix's industry specific layout calculator also reduces the number of cuts by rotating and butting non-bleeding product edges where possible.
   
   
6.  finishing, folding - Metrix also exports CIP3 and JDF folding data so plants with capable folders can further eliminate setup time and save skilled labor costs.

New Sales Opportunities

By considering product bleeds, Metrix enables estimators to instantly find new production efficiencies that can be passed back to customers to generate new business.

It's not uncommon for estimators to quote on the basis of specified job bleeds - one price if the job bleeds all edges, another if there are no bleeds. However, at some point during design if it becomes known that a job actually bleeds just one, two, or three edges, these are simply thrown into the "bleeds" category and the full bled price is charged.

Imagine a new customer's surprise and delight when you come back with a revised price 5-10% under the expected price based on the product bleeding only three edges. How much new business could Metrix routinely generate, as your sales people convince customers of the savings associated with accurately specifying job bleeds?

Summary

Considering the potential savings by ganging just one extra job per week, the reduction in wastage by optimizing layouts based on product bleed, and the considerable skilled labor savings across multiple departments, Metrix promises compelling returns.