International Newspaper Group Pre-Press Operations….A Journey

DOWJONES

International Newspaper Group

Pre-Press Operations….A Journey September 2013

Pre-Press Operations Assessment…A Journey

• A common lament?

– Through acquisition and evolution, our publications have different processes and software applications.

– This has brought challenges:• Too many different processes.• Technology and process was implemented to “do it like we used to”.• Process and technology is ever changing.• HUMAN ERROR; SYSTEM OUTAGES; PROCESS PROBLEMS

2

– Objectives :• Leverage existing assets and minimize technology platforms across the

publications.• Create the most efficient operating model of People, Process and

Technology• Determine what if any processes should be outsourced.

• A work in progress across three companies, – Dow Jones/New York Post: Started with the 9 publications– News UK: Followed with the 17 publications– News Australia: To follow

• Utilize PROCESS ENGINEERING– Applied Lean and Six Sigma Improvement tools

PROCESS– We started by mapping out the current pre-press processes by publication,

to understand: • Who does what and when.• What technology is employed (applications).• What are the opportunities identified throughout the process.

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PRODUCTION OPERATIONS – PAGE FLOW and PROOFING – ALEXA – AS IS /September/October 2012/Jgreer; CGalliard/ M. Bird; J. Moyer; K. Oechsner; M. Carpena; D.O’Callaghan; L. Warshawsky

Glo

bal L

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atio

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dito

rial

Ad

Ops

Sal

es

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Ad Booker EVO Black Magic MethodeGCR QMS OneVision Kraus CTPInDesign

Release Final Pages

Using generic QMS which requires manual setup to match Methode. 1 hr setup daily?

Does QMS Pair Pages for Alexa?

Generate OutputFlatten

transparencies and generate pdf X-1A

Run GCR software

Create “plate” in QMS and transmit to Receive

Site

Site uses QMA to

route

Generate Onsite Proof

Drag PDF EVO RIP (Kodak)

Create Plate

Print

PRINT SITE

Setup QMS To

Pair Pages


Pag

inat

ion

Edi

toria

lG

loba

l Lay

outs

Ad

Ops

Sal

es

1

Layout placementinstructions

supplied

Advise that layout is complete

1-2 weeks before run

2Run EVO RIP

(Kodak)Compose Page

(Editorial and Ad) Compare via visual check

All quality checks OK?

Run GCR software

Render simulation of press quality on

actual stock

Compose Page (Advertising)


3

Flatten transparencies and generate pdf X-1A

Generate proof Output Color?

Run EVO RIP (Kodak)

PDF GEN Server

moves to EVO

N

Y

Print on BW printer

N

4Y

Unable to generate quick proofs with current IT solution for printing. Printing one sheet takes up to 5 min.

16-24 pgs @ 2-3x each page

Legacy system no longer needed. Potential point of failure. Slows

troubleshooting for system problems.

Note: Color printer produces inaccurate representation of colors – ICC needs adjustments - 5 imaging technicians spend 30-45 min per day adjusting ink colors (NYC)

PROOFING


Glo

bal

Layo

uts

Ad

Ops

Pag

inat

ion

Edi

toria

lS

ales Book Ad

Is this in “Ad Booker”? (Jim Riley) Can Ad Watch or Ad Base be used here?5-7 ads/month

Receive Ad Copy (pdf)

Identify when ad is to run

Note: This is a cumbersome task as there is no formal alert before ads are received. Sales may contact Ad Ops or vice versa. Usually Ad Ops will then request for a listing of other ads running in the same issue, along with sold status and the ATC (Ad to Come). The “Special Section” Calendar is not issued regularly to Ad Ops.

Check PDF to WSJ

specifications

Drag PDF into GCR software

Drag PDF post GCR into EVO-3

BM3 (Kodak)

Drag PDF non GCR into EVO-3

BM3 (Kodak)

Compare via visual check


Sales Rep or Client provides new material


actual stock (2 prints)

Post PDF to Pub Server

Post PDF to One Vision Server

Set up NYPost Methode

Page Plan by Run date

Transmit “Methode

ready PDF” to NYPost Methode

1

1-2 days before send to print

Manual

NManual

Auto

Y

Note: Any changes made here have bypassed the QA

process

This is not the same BM as NY Post

Desktop Acrobat may

not be the same and

result in variation

Receive Editorial Copy (pdf)


Create Editorial

Page Units

Post PDF to One Vision

Server (Bldg 1211)

Conduct Preflight Check of

pdf

Create Ad Layout

Create pdfs

Manual process,

automated for NY Post

Transmit “Methode


A

A

2

3

NY proofing workflow not available in SBK. Photo ads for high profile

customers, i.e. Tiffany’s, Ralph Lauren not produced accurately – credits are

applied

One server no backup. Vulnerable – potential failure

“POINT OF INTEREST”Grouped by:

• Proofing• Manual processes• Ad Production• Process Performance• Software/Technology

GROUP PERFORMING THE TASK

PUBLICATION

Alexa

COLOR IDENTIFIES THE APPLICATION USED


5


Glo

bal L

ayou

tsP

agin

atio

nE

dito

rial

Ad

Ops

Sal

es

4


Release Final Pages

Using generic QMS which requires manual setup to match Methode. 1 hr setup daily?

Does QMS Pair Pages for Alexa?

Generate OutputFlatten

transparencies and generate pdf X-1A

Run GCR software

Create “plate” in QMS and transmit to Receive

Site

Site uses QMA to

route

Generate Onsite Proof

Drag PDF EVO RIP (Kodak)

Create Plate

Print

PRINT SITE

Setup QMS To

Pair Pages


Pag

inat

ion

Edi

toria

lG

loba

l Lay

outs

Ad

Ops

Sal

es

1

Layout placementinstructions

supplied

Advise that layout is complete

1-2 weeks before run

2Run EVO RIP

(Kodak)Compose Page

(Editorial and Ad) Compare via visual check


Run GCR software


actual stock

Compose Page (Advertising)


3

Flatten transparencies and generate pdf X-1A

Generate proof Output Color?

Run EVO RIP (Kodak)

PDF GEN Server

moves to EVO

N

Y

Print on BW printer

N

4Y

Unable to generate quick proofs with current IT solution for printing. Printing one sheet takes up to 5 min.

16-24 pgs @ 2-3x each page

Legacy system no longer needed. Potential point of failure. Slows

troubleshooting for system problems.

Note: Color printer produces inaccurate representation of colors – ICC needs adjustments - 5 imaging technicians spend 30-45 min per day adjusting ink colors (NYC)

PROOFING


Glo

bal

Layo

uts

Ad

Ops

Pag

inat

ion

Edi

toria

lS

ales Book Ad

Is this in “Ad Booker”? (Jim Riley) Can Ad Watch or Ad Base be used here?5-7 ads/month

Receive Ad Copy (pdf)

Identify when ad is to run

Note: This is a cumbersome task as there is no formal alert before ads are received. Sales may contact Ad Ops or vice versa. Usually Ad Ops will then request for a listing of other ads running in the same issue, along with sold status and the ATC (Ad to Come). The “Special Section” Calendar is not issued regularly to Ad Ops.

Check PDF to WSJ

specifications

Drag PDF into GCR software

Drag PDF post GCR into EVO-3

BM3 (Kodak)

Drag PDF non GCR into EVO-3

BM3 (Kodak)

Compare via visual check


Sales Rep or Client provides new material


actual stock (2 prints)

Post PDF to Pub Server

Post PDF to One Vision Server

Set up NYPost Methode

Page Plan by Run date

Transmit “Methode


1

1-2 days before send to print

Manual

NManual

Auto

Y

Note: Any changes made here have bypassed the QA

process

This is not the same BM as NY Post

Desktop Acrobat may

not be the same and

result in variation

Receive Editorial Copy (pdf)


Create Editorial

Page Units

Post PDF to One Vision

Server (Bldg 1211)

Conduct Preflight Check of

pdf

Create Ad Layout

Create pdfs

Manual process,

automated for NY Post

Transmit “Methode


A

A

2

3

NY proofing workflow not available in SBK. Photo ads for high profile

customers, i.e. Tiffany’s, Ralph Lauren not produced accurately – credits are

applied

One server no backup. Vulnerable – potential failure

NYC proofing workflow is not available in SBK . This includes color proofing. REC: Investigate why this is not possible and what benefits would be gained by so doing (L,M)

Any changes made here, dropped directly into Méthode, have bypassed the QA processREC: Investigate why changes occur past this point (M,M)

Unable to generate quick proofs with current IT solution for printing. Printing one sheet takes up to 5 minutes, 16-24 pages x 2-3x each page. Note: this is between 3 .3 to 6 hours daily (16*5 min*2.5 times to 24*5 min *2.5 times) REC: Investigate replacement of printers for proofing. (H,M)

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9 11

“POINT OF INTEREST”

What Did We Find? Process

6

Combined Benefit/Effort Matrix

Low Medium High

High

Medium

Low

EFFORT

BEN

EFIT

1

2

3

42 3

4

5

6

7

8

9 10

11

1

12

13

14

3

4

5

6 7

9

10

1

13 1514

11 12

2 8

9 108

6

7

1

2 3

4

5

1 xxx

1 zzz

1 yyy

1 vvv


In all, @100 opportunities for improvement were recorded

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• Some Common Trends:

– Several different groups were doing common tasks, distinct by publication.– Some of the tasks were very time-consuming as a result of the technology

limitations.– Applications, even by the same vendor, were not used consistently across the

publications or companies.– Some changes to ad copy made later in the process were not re-checked by an

upstream Quality Control check.– Pre-flight checks of received ads for some publications failed quite often.– Unfamiliarity with editorial copy tools causes delays and rework.

• Many of these are already being corrected.


In all, @100 opportunities for improvement were recorded

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• Companies used different applications to get the same work done.

– One company is using three times the number of applications than another.– One publication alone has eighteen applications strung together, just to perform

pre-press.– A majority of the overall applications are unique to a single publication.

• Why is this important? – Production is being affected by technology breakdowns.– Significant cost and effort to maintain applications.

We need a common solution to handle a common process

What Did We Find? Technology

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The systems/applications used are in a constant state of change, mostly dictated by the needs of business.

This volatility requires that we simplify and standardize processes and supporting applications to prevent increases in cost to maintain and operate.

What Did We Find? Technology

Mer

lin

NYP

-CN

G M

AC

Exte

rnal

FTP

File

& P

rint

NYP-

CNG

File

& P

rint

QM

S

Which applications affect print production the most

6005004003002001000

Median

Mean

2520151050

1st Quartile 0.659Median 1.6363rd Quartile 7.694Maximum 597.392

6.687 26.120

1.144 2.657

52.249 66.096

A-Squared 33.75P-Value < 0.005Mean 16.403StDev 58.358Variance 3405.637Skewness 7.7717Kurtosis 72.1280N 141Minimum -10.889

Anderson-Darling Normality Test

95% Confidence I nterval for Mean

95% Confidence Interval for Median

95% Confidence I nterval for StDev95% Confidence I ntervals

Summary for Elapsed Time (Hours)

Median Elapsed Time –1.6 Hours

Median Elapsed time that the application is down

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• The review noted that “tribal knowledge” (the practice of subject matter experts fully knowledgeable in their areas but largely undocumented) was commonplace.

• An overall lack of reference materials, consistent training and support supplied to the process participants that should be addressed.

• The non-standardized processes (each publication performs similar tasks differently) adds to the general inability to leverage resources in times of need across publications.

What Did We Find? People

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Pre-Press Operations Assessment…Our Next Steps

MINIMIZE VARIATION of the tasks, they should be consistent

SIMPLIFY THE TASKS to reduce complexities and reduce cycle-time

STANDARDIZE THE APPLICATIONS to reduce complexities and cost

CONSIDER CONSOLIDATING IN A SHARED SERVICE OR OUTSOURCING

Common Pre-Press Tasks across all publications

Manage Ads

Create Pages

ContentTransmitProofAssemble

PagesPlan Book

Typeset and Pre-

flight

Create Classified Ad Copy

DJ

NI

NL

Broadsheet; Tabloid;

Magazine


Magazine

“Strawman”Common

NewsCorp

Review proposed plan (DJ;NI;NL; tech and pre-press)


Magazine

Common NewsCorp

AS ISDefine, Measure

AS IS – TO BEAnalyze, Improve

TO BEAnalyze, Improve

TO BEImplement, Control


PRESENT STATE

BENCHMARK, IDENTIFY STANDARDS

ASSESS COSTS, ALTERNATIVES, EFFORT

IMPLEMENTATION

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• Objective:– A standardized process and technology solution to address each type

of publication that can be leveraged for like products across News Corporation.

– Use the least amount of company resources while maintaining or improving product quality and customer service.

– Our PROCESS ENGINEERING approach helped us get here…

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Documents

International Newspaper Group Pre-Press Operations….A Journey