Pressing on with a LEAN Manufacturing Journey: How Cimlogic helped APS put the Power into Print

1. • APS Group is a marketing solutions provider, established
in 1961.
• Operating from numerous locations across the UK and
Europe, APS is building a strong presence through the
development of on-site services, account management
and fully-equipped creative studios.
• APS is committed to the identification and application
of emerging manufacturing technologies and processes,
in order to add value to its clients and maintaining its
environmental responsibilities.
Pressing on with a LEAN Manufacturing Journey:
“Unlike other OEE Software programs specific
to print manufacturing, TrakSYS gave us the
flexibility of having full site ownership. It was extremely
important that we had the ability to test and control the
data recorded, to develop our OEE initiative.
Cimlogic and TrakSYS was an ideal solution for us, as
they developed a customised package that suited our
production needs, whilst seamlessly integrating with our
existing MIS system.
The system will be further developed to assist us on
our LEAN Manufacturing journey.”
CASE STUDY
How Cimlogic helped APS put the Power into Print
Company Profile
• APS is embarking on a LEAN Manufacturing journey and
sought a solution to measure and improve the efficiency of
its existing manufacturing equipment.
• As part of its LEAN Manufacturing activity, APS adopted
overall equipment efficiency (OEE) as a key performance
metric.
• Previously APS collected data such as average machine
performance, and it was important that the company
expanded this knowledge by measuring and managing OEE
through the information generated in real-time.
• A key requirement was to integrate standardised data
collection on all existing kit and to improve visibility of
performance. Individual reports were available on some
machines, but the same reports could not be generated
on finishing equipment such as gluers and guillotines.
Accurate, real-time reporting was required in order to
drive continuous improvement efforts forward, and to have
maximum impact on the business.
The Business Requirements
Steve Goodall - Production Director, APS Group

2. Cimlogic Ltd, 11 Baildon Mills, Baildon, Shipley, West Yorkshire BD17 6JY
e: enquiries@cimlogic.co.uk t: 01274 599 955 f: 0870 762 5559
www.cimlogic.co.uk
• Cimlogic conducted a trial using its mobile productivity
solution LEANTrak™, to demonstrate the capability of the
complete performance management software, TrakSYS™.
The system was set up and recording data in under 4 hours,
providing instant meaningful data on a 10 colour printing
press.
• Following the trial, Cimlogic deployed a full TrakSYS™
Performance management software solution, initially
encompassing two ManRoland 10 colour printing presses.
Operators had the ability to factually measure downtime
through using the innovative EVENTTrak™ Terminals.
• Operators were presented with real-time information on the
shop floor, giving them the tools to make an instant impact on
the days production and efficiency.
• A Lean Manufacturing team was formed as part of a Six
Sigma programme, which included the development of a new
office dedicated to the recording and visual management of
performance, creating an instant picture of production.
• KPI reports presenting metrics such as OEE, TEEP and MTBF
were instantly accessible to the Lean Manufacturing team,
providing the visibility to make good business decisions such
as using available machinery time in the best possible way and
reducing non value added steps and waste.
• Future built-in capability in the TrakSYS™ system to
collaborate information with APS’ MIS system, and leveraging
the already in-built capabilities of its MIS System.
“TrakSYS was installed quickly, without
disrupting ongoing production and provided
instant real time performance data needed to
record and improve our OEE.
We now have the ability to justify future capital
expenditure of manufacturing equipment, as we
can measure the performance of our machinery
and have the facts be able to identify assets
which are under performing”.
Rick Snelson - Director of Print Services, APS Group
The Cimlogic Solution
• APS saw a 22% improvement in OEE in first 4 months.
• APS can accurately review its top loss reasons in real time.
• Quality and performance issues can now be interrogated
and reviewed against individual suppliers of raw materials.
• Non chargeable, wasteful activities were reduced to just
8.4%, freeing up additional production time.
• Ultimate buy-in from equipment operators in improving
efficiencies was achieved, from top down (the directors’
office to the shop floor).
The Benefits
Outstanding manufacturing solutions