Standard workforce number needed for 3 offset machines

[shamelna]

Hi everybody,


We had a discussion at our factory regarding the optimum number of workforce required to run our three Heidelberg sheet-fed offset printing machines 4/5/6 colors. Currently we have 4 per machine along with a supervisor for the 3 machines. Some of my colleagues claims that the normal number is 2 per machine. So, form you experience, what is the appropriate number to have per machine. The number should cover feeding raw material, changeover, following up the delivered sheets quality.

A quick response is appreciated
Thank you

[Cornishpastythighs]

This could depend on the amount of automation you have on your presses, if they have autoplate loaders,auto wash ups, auto blanket washers etc you can get away with 2 people (feeder/Pressman).You should also have a press helper for each machine or someone who could 'float' who can handle the finished stock and assist with changeovers and makereadies. I think only 2 people on a 6 colour is stretching it a bit thin personally. If you are a shop where training and not shutting the press down due to absenteeism is important that extra guy allows for the feeder to learn to run the press and the helper to learn the feeder. 4 people on a four colour press is not very cost effective.
Just my opinion

[Mike LaForest]

All of our 6/color presses run wih 2 people , our 5 / color half size runs 1 operator and shares a feeder from time to time. These are also a mix of UV and conventional . I could not compete with 3 or 4 guys on a press.

[jbeniston]

Normal manning for such presses in North America is 2 people.
Pressman and Feeder

[Mike Herndon]

2 sm102 6 color+ coater/perfectors
1 sm102 8 color perfector

3 lead pressmen, 2 helpers shared between 3 presses. We run 24 hours a day 7 days a week and will go through 300,000 sheets of paper in a weekend easy. 4 guys on a press???....man, heads would explode.

Mike

[BVulgaris]

Its all about the Print Samurai and Ninjas....
(sorry... daydream...)

[shamelna]

So, how do you manage the make-ready times, we have like 10 changeover(s) /day.


Mike, what is your average production per week(sheets)

Thank you all

[Mike Herndon]

So, how do you manage the make-ready times, we have like 10 changeover(s) /day.


Mike, what is your average production per week(sheets)

Thank you all

hmmm That's tough to say. We're all over the place in run length change overs. We average 60-80 plate changes per 12 hour shift, so roughly 120-160 plates per day. Some days more, some days could be a lot less. Some jobs are 500 sheets others could be 200m sheets.

My schedule for the weekend covers 72 hours, this weekend we had 86 jobs, 700m sheets worth of printing. We'll be finishing up the last of the jobs Monday am. In a 7 day week running 24 hours a day we probably run 2-2.5 million sheets between our 3 sm102s. Sounds like a lot and it is but when you average it out over 7 days its equals around 60m sheets per press over 12 hours.


Mike

[motormount]

Hi Mike!

I saw on your site that you accept native files as well!

Could you please tell me how many people are on the prepress department and which platesetter you use?

Thanks in advance!

[CD102]

So I take it that the presses go down for breaks? For safety's sake I'd want two people on a press at all times and there's no way I can see that happening with 5 people on three machines.