Workflow mistakes!

[Joe Duffy]

I need some help with alleviating mistakes made in our workflow. We have too many messed up plates being made.

Problems include:

• wrong imposition
• old file being sent instead of new content
etc...

We have nexus, but we don't have the budget to purchase an imposition software right now, so everything is imposed manually.

We just need to make sure that mistakes are at a minimum before someone looses their job![/I

]You have to get a handle on the controllable issues in prepress before you can address the plate and pressroom. Your "workflow" as it is lacks all means of controlled output. Start by creating a checklist that the operator must follow, name conventions, etc so that you can eliminate the mistakes of the "wrong version" of file being used. Establish a Remake Sheet and find the root cause of each issue(who, what, when, where, why) and what you are going to do to stop it. If the same person makes the same mistake over and over again, it is hard to call it a mistake. Once you have Prepress in order, address plate room QC procedures for checking proofs. It was mentioned previously about making sure you fold proof so you have a mock up for press - that can also be unfolded and laid on the plate to check impositions. Then you may find you really have no pressroom issues. Get prepress together and do all of this, then you will find it easier to get $ from the owner to implement a effective impo solution.

 

[DanB]

nothing beats a good case of obsessive-compulsive disorder for making sure all the details are gone over again, and again, and again...

It's hard to find Mr. Monk.

 

[rich apollo]

Currently we don't have anyone proof the plate and i think that is where the problem lies after seeing your posts. We do both a assembled and flat proof of the finished product and a printout of the plates. But then the job jacket is transfered to the pressroom and its in the pressman's hands.

We need someone other than prepress to look at the printouts before they go to the pressroom.

I can guarantee that the owners won't spring for anymore software, so impositioning will be done manually no matter what.

I don't think proofing the plates is an acceptable answer. It appears that there is no reliable blue-line/dylux/digital-dylux procedure in place. The things that should be caught during plating are physical defects in the plates. Correct information must be assured before plating is undertaken.

Having another set of eyes is a good idea, but prepress should be able to catch the errors. Someone is going to have to take responsibility. Prepress is on the hook and must identify the causes of the errors. Then the causes must be rectified - whether that is through personnel realignments, improvements in scheduling, changes in how corrections/alterations are noted, or investment in equipment. Prepress MUST identify the cause of the problems.

Imposition software doesn't cost money - it saves money. Management's resistance to purchasing imposition software is impeding the profitability of the company. Talk to your plate vendor or your paper vendor(s). Depending on your volumes, you should be able to accomplish two things:

1) You should be able to get a trial license to assess the value of the software. ANY software company will grant a trial license.

2) You can probably get the software for no money out of pocket. The cost of the software can be rolled into the price of your consumables for a period of time.

If management still won't budge on the software, then begin your job search. They are keeping the company from being competitive. In your situation, management is bringing a knife to a gun-fight.

 

[Mark Flanders]

Greetings,

I am familiar with Nexus. It's a good workflow. You have two issues. One is workflow, the other wrong imposition.
--
One of the other posters got it right...the first issue is a file managment issue. Once you have sent a file through the workflow to print your proof, it is probably sitting there waiting to be released to plate. If it comes back with changes, it needs to be resent to the hotfolder. If the plate person gets the ticket and runs to release the plates, it is easy to release the earlier version. There needs to be control over the release, and removal of the previous files. We used to have the file prep/imposition person responsible for that, since they would know if there were changes. Also, good clean notes on "new files!" on the job ticket helps. it's essentially a communications issue. REgarding the press vs. prepress responsibilities, the answer is BOTH. Prepress needs a system to check and pressmen should compare the plates to the printouts, and look for relevant notes. If everybody makes the effort to double-check the details, and pas thie information along, you will be good to go.

Impostion: Establish best "file management" practices (write them out and post them on the wall) and follow them.

all the best,

Mark