WORKFLOW SOLUTIONS -- Can't Beat the System

BY MARK SMITH

Technology Editor

"Workflow" used to be an easy, concise way to reference the digital equivalent of conventional prepress. It spanned the processes from when a file came in the door until the plate went out to the pressroom.

Over time, usage of the term has been extended to encompass so much of the print production process that it now is in danger of applying to everything and effectively defining nothing. Workflow already has been—or is in the process of being—extended:

* back to the customer, initially in the form of preflighting and remote proofing solutions, but increasingly including production portals and e-procurement/digital storefronts;

* out to the pressroom and bindery, with presetting of equipment first via PPF/CIP3 and now JDF/JMF (Job Definition Format/Job Messaging Format); and

* across the functional boundary between production and business management, as a rapidly growing number of connections are made between pairings of MIS solutions and digital workflow systems.

In addition, more links are being made between offset and digital workflow systems, which previously had represented largely parallel production paths. Such connectivity accounted for a number of the workflow-related announcements at PRINT 05 (detailed in the "Streamlining the Process" workflow portion of the post-show coverage in Printing Impressions' October issue).

For the most part, the level of connectivity currently being introduced is an interface between the offset workflow solution and the digital printing system's front-end software. Job information is passed along with the file to be output, and color management applied for the target device.

JDF typically is an integral part of such offset/digital workflow connectivity, along with being the foundation for a growing number of bi-directional interfaces between MIS solutions and production systems. Both developments represent steps toward achieving the vision of an interconnected printing workflow touted by early champions of JDF.

All of the talk of big benefits from implementing CIM (computer-integrated manufacturing) in the printing sector has been considered overblown, or at least premature, by much of the market. Skeptics questioned the ROI from this proposed reengineering of the process.

As part of its efforts to spearhead JDF's development, one of the ways CIP4 (The International Cooperation for the Integration of Processes in Prepress, Press and Postpress) has responded to this challenge is by establishing the "CIP4 International Print Production Innovation" (CIPPI) awards. This program highlights tangible results of process automation, with an eye toward JDF-enabled solutions. The 2005 winners in three categories were announced recently.

Action Printing, in Fond du Lac, WI, was honored for the "best cost benefit realization" as a result of process automation implementation. The shop has automated the setup of its Muller Martini Prima saddlestitchers by communicating layout and production specifications from Kodak's Synapse UpFront software to Muller Martini's AMRYS (Automatic Make-Ready System).

Implementing a JDF workflow is said to have reduced the shop's makeready time for a saddlestitcher to 24 minutes from 85 minutes. This gain in productivity enabled it to eliminate a binding line (from three down to two), while producing 17 percent more books than in the previous year.

Kraft Druck und Verlag, of Ettlingen, Germany, was recognized for achieving the "biggest improvement in efficiency and customer responsiveness." It has implemented JDF/JMF to connect its Hiflex MIS to a Creo (now Kodak) Prinergy workflow system and the PECOM control system of its MAN Roland sheetfed presses. An important aspect of this solution is reporting all machine events back to the MIS via JMF for timely and accurate invoicing.

Among the benefits gained by the company are a 9.6 percent increase in productive hours, elimination of a full-time scheduler's position and an estimated savings of 24 man-hours per day in job creation alone.

Druckerei Bauer KG, of Vienna, Austria, was recognized for achieving the "most innovative use of process automation technology." Its implementation combines elements of the other two, linking the shop's Hiflex MIS to a Muller Martini PrimaPlus saddlestitcher with AMRYS and MAN Roland presses equipped with the PECOM system.

The time required for initial setup of eight stations on the saddlestitcher has been reduced from 70 minutes to 20 minutes. Overall, the company has calculated an ROI of 220 percent in the first year of operation. JMF feedback from the machines adds the soft benefits of real-time production status monitoring and accurate data reporting for job costing.

Skeptics have also pointed out that presetting of downstream equipment already is enabled by the PPF/CIP3 functionality available on most presses and some bindery/finishing equipment. What's missing, though, is the capability for that equipment to report back production data as highlighted by two award winners.

More to the point, indications are that vendors are now integrating JDF support as a matter of course. Connectivity will simply be an option, if and when shops decide to capitalize on it.

The Ghent PDF Workgroup (GWG) is another organization looking to improve PDF-based print workflows. The goal is to take unpredictability and variability out of job processing by establishing "best practices" for the dominant applications.

David Zwang currently is serving as GWG vice chairman, in addition to his work as an independent consultant. This past summer, he also served as team leader for the IPA Workflow RoundUP that the group undertook in conjunction with IPA, the Association of Graphic Solutions Providers.

Common Challenges

Workflow test files developed by GWG were processed by system vendors who elected to take part in the roundup. Common workflow challenges—in the areas of default color spaces, image type support, overprints, raster/vector object handling, transparency, font handling and more—have been incorporated into these files.

Printers face challenges such as ever-shorter deadlines, lack of available skilled operators and looming global competition, Zwang points out. Modern workflow tools may promise to save the day through automation, but do they, he asks rhetorically? The degree of automation offered can vary wildly.

"Equally as important as having good tools is the processes and procedures that you employ in your operation," he says. "This includes ensuring you are using the optimal settings on all of your equipment and that your software versions are up to date."

GWG has defined globally acceptable procedures and settings for many of the design and output workflow tools currently used. All of this information is available free of charge at the organization's Website (www.gwg.org), along with the aforementioned test files.

"Through extensive global testing (with those files), it has been found that most of the problems people are having with submitted files is related to older RIP versions," Zwang adds.

He agrees that JDF is becoming an integral, underlying technology for many, if not most, of today's workflow tools and believes much of the skepticism stems from the mistaken belief that a significant capital expense is required to take advantage of JDF. Even though it can seem like the only people who really get excited about JDF compliance are those selling systems with that capability, Zwang contends it's one of the features printers should be looking for when investing in new workflow tools.

In this age of increasing demand for collaborative production, they should also make adoption of industry standards a guiding principle to ensure that their work will have the flexibility to be picked up and reused in different ways and in different places, he advises.

Along with increasing integration of JDF/JMF and connectivity to digital printing systems, recent upgrades to "traditional" workflow systems have centered around three main areas—interfacing with customers, remote proofing and enhanced screening options. A less universal, but still prevalent trend, is the introduction of entry-level versions of the more sophisticated systems. It's a given that all workflow solutions implement PDF.

Agfa has touched on each of these areas in its workflow product developments, which are now being marketed as Digital Solution Suites of software and hardware. Its ApogeeX workflow (in Commercial and entry-level Prime versions) can be combined with Delano Web-based product management for automated job submission and StreamProof soft proofing. Arcadia adds digital asset management to the workflow, which can be powered by Salient hardware solutions.

Even though it can provide all of the components, Heidelberg still stresses open connectivity via JDF in its Prinect workflow product family. Printready 2.1 with MetaDimension is the prepress core, with added functionality provided by Signa Station 1.5 for impositioning based on separate folded and print sheets.

The formerly Creo product lineup is still too recent of an addition to Kodak's Graphic Communications Group to expect any major moves. So far, the company continues to list Prinergy, Brisque, DirectWorks (from KPG) and PS/M among its workflow solutions, as well as the Synapse product family of customer-facing modules (PDF creation, proofing, etc.) and MIS connectivity.

Kodak also continues to offer the products originally acquired from ScenicSoft, which include Preps imposition software and, with version 4.0, the now-named Synapse Upfront job planning software. In addition, the Kodak Enterprise Management Solution for comprehensive business management is due to be released in 2006.

Screen (USA) and Enovation Graphic Systems report they have joined forces to create the next generation of Screen's Trueflow 3 PDF-based workflow system, the core of its Trueflownet operating environment. This version incorporates Fujifilm technology for dot control, screening and eight-bit TIFF export for color proofing.

New Introduction

Independently, Screen is introducing a new color separation technology in Trueflow 3.1 that it says cuts production time and costs associated with using multiple colors, such as in packaging applications. It has also partnered with Enfocus Software to incorporate Certified PDF capabilities into the Screen Riteportal 2.0 and Riteonline V3 Portal Edition customer-facing solutions.

Enovation continues to offer the Rampage JVX workflow from Rampage Systems, as well. The latest version introduced what the company terms a "self-serve" workflow for print customers with job submission, preflighting and low-res proofing via the Pathway client software. It is JDF compliant to enable data sharing with several third-party MIS solutions and template-driven impositions.

Packaging capabilities continue to be a strength of Artwork Systems' product offerings, evidenced by the fact that key upgrades in Nexus 8.1 include exporting of native PDF files optimized for Adobe Illustrator, a JDF-based step-and-repeat function and broader functionality for versioning of packaging. The workflow implements Certified PDF technology from its sister company, Enfocus.

With the less demanding workflows of small- to medium-size printers in mind, Global Graphics has launched Harlequin Print Production Manager as an adjunct for Harlequin RIPs. It provides Web-based monitoring and management of jobs submitted to the RIP in a SOOM (submit once, output many) workflow with Roam job previewing. Presstek, ECRM and Polkadots are among the companies planning to offer the technology.

Presstek has also announced a strategic alliance with EFI to develop a range of workflow products scaled for smaller printing operations. Presstek Facet RIP, available exclusively from ABDick, is the first to be launched. It adapts the EFI Fiery RIP's Command Workstation interface to provide a ROOM (RIP once, output many), ICC-based, color managed front end for driving all Presstek- and ABDick-branded output devices.

EFI continues to offer its OneFlow software for offset and digital printing, but its recent workflow releases have extended the functionality of its MIS solutions and Fiery servers. A new "Foundation" version of its PrinterSite Web submission add-on is now a standard feature of the Hagen, Logic and PSI management systems.

Another system for small printers is OpenRIP Symphony Workflow from RIPit Computer Corp. Enhancements include simplified color management, improved preflighting, TIFF input, an expanded set of PerfectBlend AM/FM hybrid screening and new features for flexographic printing applications.

Making Some Moves

Recent business moves by Esko-Graphics seem to indicate it is focusing on the packaging market, but its top execs say the company is still committed to offering the Scope workflow as a solution for commercial printing applications. This is despite the product being one of the "packaging-related activities" included in a transfer of ownership to Axcel, a private equity firm, while Kirkbi seeks a "safe harbor" for what remains of Esko-Graphics' commercial printing product line.

Further development of Scope reportedly will be done by one team focusing on all applications, and will include greater integration of JDF functionality.

Dalim Software overhauled its entire workflow product line late last year with its port to the Mac OS X operating system. Products impacted include the Swing and Twist workflow solutions, Mistral customer-facing communication system, Dialogue soft proofing, and Printtempo Web-based imposition and job management, all of which are JDF enabled.

Set apart from the other systems is a developing class of products that, for lack of a better term, can be considered "pre-workflow" or publishing automation solutions. They are geared toward automating the generation, submission and initial processing of PDF files.

Some—like Gradual Software's CaslonFlow, Enfocus PitStop Automate and Markzware FlightCheck Workflow—provide a visual interface for building simple to complex workflows that can incorporate third-party applications via use of hot folders. Others—including Apago Cluster Workflow, Lucid Dream's TaskForce—are designed to be self-contained solutions.