Speed is the tip of the iceberg it's easy to see. But the real story lies beneath the surface.
Faster speeds are good. But only if accompanied by higher productivity. This simple yet inescapable truth is being lost amid the claims and counter-claims of inserting system vendors as they introduce and promote faster and faster speeds.
There is no doubt that faster cycling speeds can boost performance for virtually any inserting operation. And customer messaging centers everywhere want to lower costs, especially the total cost per mailpiece.
But higher speeds alone are not enough. The real key to superior performance is productivity. After all, what is the advantage of acquiring faster equipment if you can rarely achieve your production goals?
Consistent performance and not just raw speed yields the best productivity. Managers of customer messaging centers in search of better performance should focus less on equipment with just the fastest cycling speeds. Instead, they should look for the best combination of speed, performance and mailpiece quality. That's the best way to insure a consistent high-speed operation along with flawless production.
Rugged Reliability and Easy Operability
How do you determine which inserting systems offer the best value? By looking beneath the surface. The key is to determine whether the faster speeds are the result of simply speeding up an existing process or are accompanied by improvements in engineering and design that are intended to boost productivity as well.
Inserting systems that feature high speeds plus reliable mechanics, smooth paper-handling processes and fast setups and switchovers will yield the best throughput and highest quality. As a guide, here are a few key innovations to look for when evaluating high-speed inserting systems.
Advanced Motion Control Technology
One of the best methods to boost productivity is to replace the traditional mechanical drive mechanisms such as clutches, brakes, solenoids, chains and gears with individually controlled and highly reliable servo motors. These innovative devices provide value in a number of ways.
First, they are extremely durable, which reduces the instance of unscheduled downtime and dramatically extends the interval, or mean time, between regularly scheduled preventative maintenance procedures. They can typically operate without routine service for periods that are two to three times longer than the conventional mechanical technologies. Servo motors are also "instant on" and precise, which eliminates the unproductive ramping-up period.
The new technology also enables tight control and transport of collations using a minimum, yet still accurate, space gap. This unique feature allows the system to boost productivity by compressing the amount of empty space between collations. This increases the density or number of collations processed. In effect, more collations can be accommodated at a slower speed, which results in less stoppages, more productivity and less material spoilage. With fewer stoppages, there's less wear and tear on components due to excessive stopping and starting. And if a stoppage does occur, it is extremely precise.
Lastly, the photo cells and servo motors, which feature a closed-loop processing technology, are self-monitoring and provide operators with an early warning of excessive wear or impending failure.
Flexible and Efficient Enclosure Feeders
The enclosure feeders should also feature an extended bin to accommodate greater volumes of inserts. This added capacity will reduce the time and labor needed to replenish materials. Ideally, the enclosure feeders should also be modular in design so they can be removed and replaced quickly. The ability to make quick change-outs will help keep system uptime high and enable any feeders needing service to be attended to offline, which also helps boost productivity.
File-Based Reporting and Control Capability
Speed will be irrelevant if the mailpiece is misassembled or otherwise inaccurate or defective. Any high-speed inserting system must feature a state-of-the-art tracking, controlling and reporting system. File-based tracking systems provide precise tracking of individual mailpieces and assure mailpiece integrity as well as being are a key element of any closed-loop messaging system.
Inserting systems should also be equipped with a comprehensive on-board self-diagnostic capability, which will alert operators and technicians in advance to possible service needs. Additionally, the control system should enable easy storage and retrieval of all job specifications, to help speed setup and changeovers and fast and full reconciliation of all jobs processed, to provide assurance that every mailpiece was assembled and processed as expected.
Ideally, the control system should be capable of linking with the other inserting systems in the messaging center as well as with other processing sites. This will allow managers to maximize productivity by balancing work loads and shifting volume from equipment or sites that are overloaded to those with available or excess capacity. Such a feature can also interact with a remote monitoring capability to give customers an up-to-the-minute view on the status of jobs in progress.
Simplified Paper-Path Architecture
An open paper-path, coupled with innovations such as an improved envelope feeding technology, can provide smooth, high-speed processing and greatly reduce any possible instances of production flaws. This improved architecture gives operators an unobstructed view of the entire inserting operation.
An Ergonomically Designed Footprint
Like speed, a compact footprint is good. But an ergonomically designed footprint is even better. What's the difference? Plenty, especially if you're the operator and you're working an eight or 10-hour shift.
On the surface, compact should mean less area and fewer steps. But it doesn't in every instance. Some systems are termed "compact" because they occupy a small footprint with fewer square feet of space. But these same systems, under normal operating procedures, also require the operator to walk around the perimeter or outside of the system, instead of remaining in the "cove." These systems are not designed for maximum efficiency.
An inserting system that is ergonomically designed will minimize the number of steps required under normal operating conditions. A good gauge is to measure the number of steps required to reach the most frequently visited areas. Such a yardstick will provide an accurate measure of the human effort actually needed to operate the equipment under typical conditions.
Shahzad Malick is a 14-year veteran with Pitney Bowes. He holds eight patents and is responsible for the development and introduction of the company's Advanced Productivity Inserting System. For more information, please visit www.pb.com.
