Whereas press and prepress have been networking together for many years, the postpress sector was dozing in a state of hibernation. At least there has been a fast development process since Drupa 2004. The only concern is to optimise work processes so that the business can manufacture faster, better, with more precision and, at the end of the day, cheaper.

Important pioneering role for the CIP4 organisation
As a founding member of the CIP4 (CIP4 = The International Cooperation of the Integration of Process in Prepress, Press and Postpress) organisation, Muller Martini has, from the beginning, been highly involved in this development. A company employee, Markus Schluep, heads a work group on finishing in the CIP4 consortium. He points out, “The JDF (Job Definition Format) and JMF (Job Messaging Format) formats which we designed are now key technologies for an extensive data exchange within graphic companies.”

Workflow specialist Markus Schluep (right) emphasises that JDF and JMF are today’s key technologies for comprehensive data exchange in graphic companies.

According to Markus Schluep, machines which Muller Martini has developed over the past years can be included in a JDF workflow. “We are working on a unified interface which allows direct mutual communication between the customer’s Management-Informations-System (MIS) and finishing. This allows the exchange of not only the ticket but also of important key figures such as the job status, machine status, production speed and current brut and net quantities.”

The following systems at Muller Martini are ready for the JDF network: print, press delivery systems, saddle stitching, adhesive binding, booklines for the production of hardcover books and industrial total solutions for Book on Demand (SigmaLine).

The steps to digital workflow
Before the network can be introduced in business everyone concerned has to understand how the current workflow works. The next step is to define how a future workflow should function and what can be optimised. Networking using JDF is only one method of implementing this optimisation.

It is advisable to implement JDF within a project together with a responsible project manager who keeps a general view over all the process flows. Apart from the willingness and readiness to equip the flows according to customary software’s and machines’ capabilities, a business should comprise:
- modern machinery
- a well installed computer network
- technical workflow systems (in prepress, print and finishing)
- products (machines and software) that can be networked over JDF interfaces

Workflow solutions from Muller Martini in practice
For every business that wants to digitally network its productions systems, Muller Martini has the right solution based on JDF/JMF. Muller Martini’s saddle stitching systems in Germany, Austria, Great Britain, France, Italian, Poland, Belgium, Switzerland, Australia, Japan and the USA have all been successfully integrated into the digital workflow. Several companies have even received awards for innovative use of the process automation, such as Bauer Druck in Austria and Action Printing in the USA – Today all new Muller Martini saddle stitcher models can be integrated in the digital workflow!

Muller Martini is also taking a leading role in digitally networking the perfect binder area. The first JDF integration of a perfect binding line has recently  been installed in the USA. The Acoro, Bolero and Corona (with Corona Commander II) models, as well as the Merit S und Zenith S three-knife trimmers are being digitally networked via the workflow controller.

The first JDF integration of the Corona perfect binder is currently been carried out in the USA.

Muller Martini is also committed to digital workflow in the hardcover area. All machines that can be driven by the tele-commander (Diamant bookline, Ribbon 60 ribbon inserting machine, BLSD 650 book stacker, Vesta jacketing machine) can be integrated into the JDF workflow. In addition, the Ventura thread sewing machine and, over a separate control station, the Collibri gluing-off machine can also be integrated into a JDF workflow.

The SigmaLine, introduced as the first industrial total solution for Book on Demand at the Drupa 2004, can also be integrated in a JDF workflow. The SigmaLine disposes of an integrated and continuous line control with a JDF interface. This combines and coordinates all process, job and performance management functions of the complete system. This allows for fast  job changes with minimal set-up times whilst using the highest automation possible. The most important information, such as line, machine and job status can be shown on a central screen, as well as on individual displays.

Is networking only worthwhile in multistage businesses?
Smaller business often do not have the resources to tackle the idea of networking. What is the situation with single-stage businesses? In this case, is it even worth trusting in machines with JDF interfaces? Does networking make any sense?

As a matter of principle, it can be said that the difference between single-stage and multi-stage businesses is not particularly relevant. In theory, a multistage business can benefit more from networking, however this is only the case when all stages are integrated in the networking process. “The benefits for a single-stage business should not be underestimated,”
Markus Schluep says “it may be necessary to input a bit more information by hand because the data cannot be taken from the preceding level. Otherwise I cannot see any great difference to a multistage connection. A job ticket, the job preparation, and production control are carried out on a JDF basis. Even BDE data can be transferred using JDF/JMF, which is actually the biggest benefit of workflow.”

Practice has shown that networking is a progressing development. “JDF islands” often appear which then gradually grow together until all levels are fully networked.

Internal networking of prepress, plate imagining, press and finishing: saddle stitchers, perfect binders, press delivery systems and other Muller Martini systems can be connected via a single interface.

“We don’t want to forego digital workflow anymore!”

At the beginning of this year Muller Martini conducted a short survey among its saddle stitcher customers in Germany, France, USA, Japan and Australia. Of those asked, 80% have already introduced digital workflow into their businesses. The vast majority of these businesses (> 90%) appreciate the benefits of digital workflow and do not want to forego it anymore. If they were to be asked the same question again, they would most definitely introduce digital workflow again.

The following aspects were most often mentioned as the biggest benefits:
- Process optimisation
- Cost reduction
- Higher productivity
- Higher speed
- Higher process safety
- Noticeable reduction in administrative costs (by up to 25%)

The main negative point was said to be the insufficient consensus amongst manufacturers. This has to be improved in order that, ultimately, in the future all systems can be integrated in digital workflow.
(Source: Muller Martini)