Printing industry manufacturing system in the era of micro-profit
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In recent years, as the printing industry has become a fully competitive industry, the printing industry has begun to enter its own meager profit era. The so-called printing industry in the era of micro-profits means that with the full development of the market economy, the seller's market has become the buyer's market, and the printing market in China and the world is facing tremendous bargaining pressure and entering the era of low profit. On the other hand, the full competition of the printing industry itself has greatly weakened its bargaining power and naturally entered the era of low profit.
First, the printing industry response strategy in the era of low profit
Printing enterprises should develop in this meager profit era. Strategically speaking, they can select a target market in the market segmentation, avoid the mainstream packaging market, realize differentiated production, develop leading technologies, improve the quality of printed products, and undertake a large number of foreign trade. Orders, avoiding the contradiction between domestic supply and demand; the printing factory and the design company allied, take the road to design and drive the printing; open up new markets and develop new demands. However, for most of our existing printing companies, most of them are homogenized. For companies that compete for homogenization, the necessary equipment size and cost control are the only viable options.
So we are faced with two important questions: how to make our equipment scale really function, and how to effectively control costs.
First of all, for the scale of equipment, on the one hand, it involves not only the quality and quantity of equipment, but also whether the integration between them is an organic integration.
At present, in order to improve the quality of a printing production process, our company often purchases the most advanced equipment at that time to improve the quality of printed products. At the same time, in order to enhance competitiveness, it purchases a large number of printing equipment and realizes large-scale operation. But we must realize that advanced unit technology can help solve the technical bottleneck of the enterprise and improve the competitiveness of the enterprise. But the most advanced unit technology does not necessarily achieve the overall goal of the system. Conversely, not the most advanced unit technology can achieve the overall goal of the system. In addition, as the number of printing equipment increases, whether it can complete the process from quantitative change to qualitative change becomes "large machine production." The process is to make these unit machines coordinate with each other, become an organic whole, and realize value-added integration (1+1>2) with additional benefits between units, instead of a simple “platform” one-off without additional benefits. Linear integration (1+1=2 or even <2).
Secondly, for the cost control of printing enterprises, it is a system engineering, from production cost control to cost control of non-productive management, human resource cost control, raw material procurement and outsourcing processing cost control, etc., the most difficult of which is the production process. Cost control. An effective form of cost control for the production process is digital and standardized production. It involves the high degree of dataization and standardization of printing equipment. In addition, the management model and management ideas of the company must have corresponding innovations. Because the organizational model of production and production management are to be coordinated, and management's impact on the business is crucial.
Second, the future manufacturing system of the printing industry
1. CIMS in the printing industry manufacturing system
The modern integrated manufacturing system CIMS (Contemporary Integrated Manufacturing System) is a comprehensive technology for improving the competitiveness of enterprises in the information age. It applies to all phases of the enterprise product life cycle, from market demand analysis to ultimate waste disposal. Through information integration, process optimization and resource optimization, the integration and optimization of logistics, information flow and capital flow are realized, and the integration of human (organization, management), operation and technology is achieved to shorten the development of new products (P). Time (T), improve product quality (Q), reduce cost (C), improve service (S), and benefit the environment (E), thereby improving the market resilience and competitiveness of the company. The modern features of CIMS: digital, networked, virtualized, integrated and green.
At present, the printing market is facing a trend of increased short-run activities of printed jobs, increased complexity of jobs, and increased management costs. The main characteristics of this versatile market are: shortened life cycle of printed products, accelerated product update, increased variety of printed products, and reduced batch size; the quality, price and delivery time of printed products have become the three decisive factors for enhancing the competitiveness of enterprises. Therefore, we are eager to see a flexible, agile, integrated, transparent, and collaborative workflow solution.
Because CIMS is an integrated production model, it covers the entire manufacturing activities of market analysis, business decision-making, new product development, engineering design, manufacturing, inventory supply, quality assurance, after-sales service, etc., and strives to achieve three-stream integration. It can be seen that CIMS allows us to get the expected production process and realize the organic integration of equipment.
CIMS also optimizes production management, reduces work-in-progress, reduces inventory, and reduces liquidity to achieve cost control for printing companies.
However, because the production organization of the printing enterprise has the characteristics of process-oriented, final product indeterminate, product structure and process parameters changing with the order requirements, we cannot adopt the CIMS model of other industries one-sidedly in the research and implementation of information integration of printing enterprises. It is necessary to study and discuss the CIMS model suitable for printing enterprises in combination with the characteristics of printing enterprises.
2. The basis of CIMS in the printing industry - JDF
In the printing industry, the use of equipment and technical instructions is becoming more and more complicated, leading to a large number of "automation islands" in prepress design, printing, postpress processing and enterprise management. Solving the correct and efficient sharing and exchange of information between them is the first step to improve the technical and management level of the printing enterprise and to establish an ideal CIMS.
The printing company as a whole is a heterogeneous environment, because the entire enterprise system contains different operating software, control systems, databases and application software. To achieve smooth exchange of data in such a complex environment requires a unified data exchange format across the enterprise system. To this end, CIP4 (International Cooperation for the Integration of Prepress, Press, Postpress and Process) defines a unified, production-independent data format for the printing industry, including the JDF (Job Definition Format). Its purpose is to get the business flow and production flow to be joined; there is a standard and smooth data format throughout the production process; smooth production scheduling that is not subject to the enterprise; production through the recording of important data in the production process High transparency of the process; the use of JDF communication to achieve the availability of important production data.
JDF is based on XML (Extensible Markup Language). Under certain data security technologies, the network can be transmitted securely. JDF is defined by a complex information technology structure and very rich parameters for different production processes in order to cover all production possibilities and accidents as flexibly as possible. But for now, JDF is not perfect enough, there are still many places that can't be covered, and it needs to be constantly improved. To temporarily overcome the defined vulnerabilities in the existing JDF definition standards, use "private plugins" to make up for it. On September 30, 2005, the CIP4 organization has launched the JDF1.3 version.
But JDF is not accessible to any device, only those devices that support the JDF standard can perform smooth data exchange. More than 190 manufacturers, organizations, and printing equipment vendors in CIP4 members are fully capable of manufacturing equipment throughout the JDF-enabled process. Therefore, a benchmark for JDF compatibility of test equipment is needed. The JDF 1.2 release introduces the new concept "Interoperability Conformance Specification" (ICS). ICS provides collaboration standards for different levels of devices, including JDF specifications that devices must support, and how devices handle JDF or JMF data. It will be the basis for JDF certification testing.
3. Future printing industry manufacturing system model
Portable Document Format (PDF) is the most important electronic file format that Adobe introduced in 1993 after PostScript. With the continuous development of the PDF/X family, PDF has been able to meet the needs of high-end printing and become the de facto industry standard for printing and publishing. JDF will be the standard for describing and controlling individual processes and the entire workflow in the printing industry, becoming the norm for the future printing industry.
Therefore, in the era of low profit in the printing industry, the future manufacturing system model is: JDF+PDF mode. In the future, the digital workflow of the JDF+PDF model will be able to define in detail, clearly and without error what to print and how to print. This print quality will be independent of the operator, while printing logistics, management and financial accounting will be more efficient and low cost.
4. Establishment of integrated manufacturing system based on JDF
If a company wants to implement the JDF workflow, the following hard and soft conditions must be available: all data of enterprise resources, various devices and application software have a good JDF interface, a safe and smooth network data transmission environment, a suitable MIS (Management Information System) system, optimized JDF process management system, excellent technical support, leadership that can continuously improve management mode and management ideas, and the spirit of continuous innovation of all employees.
However, these implementation processes are large and complex systems engineering. Therefore, the implementation process of the enterprise must be gradual, and the construction of soft and hard conditions should be given equal attention, starting from the bottleneck of the maximum processing capacity and productivity of the enterprise. Only in this way can enterprises grasp the investment projects of equipment and technology, and they can continue to make profits in the implementation process of JDF, in order to have a good corporate innovation atmosphere and the courage and motivation of continuous innovation.
Third, the conclusion
After the printing industry enters the era of low profit, our printing industry manufacturing system should respond positively. The printing industry CIMS described in this paper is a long-term goal of the enterprise, because not only does JDF have a well-developed process, but CIMS is based on the digitization of all processes in the enterprise system, and requires a gradual process, which cannot be accomplished overnight. Companies are advised to start with the toughest problems they face in order to achieve the best results.