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Aggressively ImprovingMaterial ProcessingOperations Key to SuccessBy John Lombard / President & CEO / Bowe Systec North America

In spite of numerous cost reduction initiatives takenover the past several years, the search continues tofind innovative ways to gain further improvements inmaterial processing operations. The initiatives areneeded to offset increases in postage costs, postalregulations and labor rates as some states implementminimum wage requirements. Companies are

discovering that many Automation Solutions are yet to beimplemented and are recognizing the many benefits ofaggressively pursuing these cost saving strategies.

An area of increasing interest isMaterial Handling for tasks such asprocessing, loading and unloading,machine feeding and material movementacross production facilities.

The creation of a mailpiece or packageneeds to be done efficiently andaccurately, utilizing equipment with thebroadest application range. In addition,production facilities manage enormousquantities of finished material requiringstaff to each lift, carry and transportthousands of pounds of material in asingle day. Herein lies significantopportunity for efficiency gains.

Process Flow evaluation often revealsinefficiencies in material flow, machineoperator working habits, inventorymanagement and shipping preparation.Flow improvement itself can increaseefficiencies but when combined withautomation it results in a win-winsituation.Automation Solutions Opportunities:

Single Machine Type Strategy (SMTS)More output can be produced with

fewer systems when adopting oneflexible, state of the art platform to

process all applications combined withfully automated machine changeover.Companies have demonstrated that asingle multifunction system can replace aminimum of two legacy systems,resulting in significant cost reductions,better space utilization, and greatercapability.

Small Batch SoftwareSmall Batch software enables multiple

jobs to be processed successively on HighSpeed Inserting Platforms allowingcompanies to eliminate the processinginefficiencies of smaller jobs.

Operations utilize the software toconsolidate jobs, minimizing thedowntime that is typical of jobchangeovers.

Optimizing Blank Paper ProcessingThe adoption of high-speed full color

printing often results in large quantities ofblank waste paper between jobs. Themost progressive production mailfacilities have embraced newly availablereading software to detect, minimize, anddivert excess blank pages, thus increasingefficiencies while reducing costs andenvironmental impact.

Envelope Printing on Demand – EPODThe ability to dynamically print

envelopes with full color addresses,messages and logos during the productionmail process allows companies to extendthe white paper factory concept tomailing envelopes. This not only reducescost, but also maximizes the possibilitiesof using the outside finished envelope asa low cost, customizable marketingvehicle.

Increasing the Value of Direct MailDirect Mail volumes have remained

steady for years as marketers recognizethe continued effectiveness of thismedium. The USPS has introducedincentives to encourage the use of DirectMail, resulting in innovative styles,shapes and printing. Modern mailingequipment is not only designed to handlethe variety of mail pieces, but also tominimize labor while achieving higherlevels of output.

Bulk Envelope Feeding, AutomaticTraying & Tagging and Enhanced

Enclosure LoadingProduction facilities manage enormous

quantities of material that requireoperators to move thousands of pounds ofmaterial daily.

This physical handling can beeliminated or reduced with automationsolutions such as Mailing Envelopes on aroll, Bulk Enclosure Feeding, AutomaticEnvelope Traying and conveying.

Robotics and AGVsMaterial handling robots can automate

many repetitive tasks in any productionprocess. Robots can automate many ofthese tasks and can enhance theefficiency of production processes withautomated loading and unloading,palletizing and the use of AutomaticGuided Vehicles (AGVs) for the movingof material.

AUGUST/SEPTEMBER 2017 / MAIL: The Journal of Communication Distribution / www.mail-magazine.com

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Package and Parcel HandlingThe parcel and logistics sector requires

advanced material handling automationfor the weighing, scanning, dimensioning,print/application of labeling and sortingsolutions for a variety of industries.

This technology is used byWarehousing and Distribution, Postal andParcel, e-Commerce, Retail andInbound/Outbound logistics organizationsto reduce their costs and translate into animmediate return on investment by savinglabor, saving time and increasingaccuracy.

Now parcel distribution centers caninduct packages into Sorting Solutionsthat automatically prepare packages forshipping and sorting into any number ofDistribution Point destinations. This

eliminates numerous manual processes,dramatically decreases handling time,reduces manpower and justifies theinvestment in well under a two-yearperiod. These solutions can be sized toany number of requirements and areapplied to any manual fulfillmentapplication, including e-Commerce,Retail and Inbound/Outbound logistics

Financial Plastic and ID CardsHigh security plastic card production,

including Credit/Debit, Healthcare andGovernment Identification cards presentunique challenges that hinder automationby requiring Dual Control oversight andstringent manual processes. The ability toautomate the exchange of flawed ordamaged plastics during thepersonalization and inserting process is

one way that technology can streamlineproduction.

Dramatic efficiencies are gained byeliminating the need for vault personnel’sinvolvement by utilizing a secureautomatic Kiosk to exchange individualcards and streamline small batchprocessing.

In summary the ongoing developmentof faster, flexible, and accurateprocessing equipment is helping toincrease operational efficiencies. Whiletrends may be shifting, for example fromphysical to digital and from bricks andmortar to e-commerce, the need for suchequipment continues.

BÖWE SYSTEC, headquartered inAugsburg/Germany, is a leading supplierof high-speed inserting systems,card-mailing, sorting solutions andinnovative software, and is one of theworld’s leading solution providers formodern print, mail and logisticsproduction centers.

BÖWE SYSTEC has grown to become aglobal supplier of comprehensivemailroom and logistics solutions. With 20subsidiaries in Germany, throughoutEurope, Japan and North America, plusgeneral agencies in over 50 additionalcountries, BÖWE SYSTEC meets marketrequirements on a global and yet, highlypersonalized local basis.

BÖWE SYSTEC GmbH is owned by thePossehl Group, which generates annualsales of more than $4.0 billion with aglobal workforce of over 12,000.

More information is available atwww.bowesystecinc.com andwww.possehl.de . Inquiries for BÖWESYSTEC North America can be directedto generalinquires@bowesystecinc.com.

AUGUST/SEPTEMBER 2017 / MAIL: The Journal of Communication Distribution / www.mail-magazine.com

An area of increasinginterest is Material

Handling for tasks such asprocessing, loading and

unloading, machine feedingand material movement

across production facilities.Herein lies significant

opportunity forefficiency gains.

A step aheadwith BÖWE SYSTEC Mailing Solutions

Inserting Solutions for Direct and Transactional Mail

Card Mailing Solutions

Software Solutions

Mail and Parcel Sorting

24/7

Service andTraining

Fusion Cross, the only newly developed, State-of-the-Art, multi format automated changeover inserter on the market that meets the challenging needs of Direct and Transactional Mail on a single platform. Direct Mailer maximizes production capacity with high flexibility and minimal service and maintenance requirements providing low operating costs for service providers. Optimus Sorters provide fully automated space saving and efficient parcel sortation solutions for a broad range of package sizes utilizing a modular design that can accommodate all facility size and shape constraints. Plastic Card Systems provide the highest speed card attaching and mailing with full integrity for financial, prepaid and identification cards.

Orbiter Software offers a full suite of intuitive and easy to use solutions for mailroom automation. Service provides 24/7 support with factory trained engineers and OEM parts to ensure optimal system uptime.