Automating order and job processing to optimise on-demand book production

After seeing a significant increase in the number of requests for shorter book production runs, Otava Book Printing Ltd moved to exploit the trend. Its first action was to shift part of its traditionally offset to digital print production by investing in two Canon high-speed, web fed inkjet presses, a ColorStream 6000 Chroma and a ProStream 1000, both managed by the workflow and output management platform PRISMAproduction. The digital presses were seamlessly integrated with a high-performance book block finishing solution from technology partner Hunkeler.

Once the inkjet solutions were up and running, Otava embarked on the next step of the digital transformation plan it had developed with Canon’s support – the automation of order and job processing. In the past, an automated workflow had not been a priority for the company as annual production had been limited only to offset print jobs with long runs, which were easily manageable for the staff. However, to be able to efficiently manage with the same number of staff, the substantial increase in short runs to date as well as the further increase expected — a fully automated workflow would be crucial to operational performance.

The automation project for more efficient book production and improved book lifecyle management was split into three entirely separate phases to minimise risk and was rolled out over 24 months.

First, internal reprints automation was implemented, followed by the automation of quality assurance checks, and as a third step the automated asset processing for uploaded new titles from external publishers.

By automating workflows, specific challenges such as the increase in short-run titles, information transfer dependent on manual intervention, error-prone manual order and prepress workflow, and the lack of communication between workflow software applications were successfully resolved.

In addition, the automation project has ensured that digital and offset applications are linked for faster and more streamlined production, there is a web interface for easier order placement and faster processing for external customers, and all assets in the archive are now error-free and ready to print.

Overall, more orders can now be handled error-free and more efficiently with the same number of employees.

According to Marko Silventoinen, Managing Director, Otava Book Printing Ltd, the benefits of automating their order and job processing have certainly justified the investment.