EP2457859A1 - Method for manufacturing packages made up of printed products - Google Patents

Abstract

The method involves monitoring and regulating integral production of group of printed product packages. The defective printed product is eliminated during the monitoring and regulating processes. The postproduction of printed product corresponding to number of defective printed product is triggered, when subsequent excretion of defective printed products is performed.

Description

Technical area

The present invention relates to a process for the production of packages consisting of printed products according to the preamble of claim 1.

State of the art

In automated mail-order systems, combinations of a major product (HP) and the associated inserts can not be made correctly because, for example, one or more inserts have not entered the main product or products have passed through the inserter (ESM) a staple transporter have not been transferred exactly in the clip.

There are also cases of faulty clamps in the transporters, which prevent the transfer of the products from the ESM into the transporter. In general, it must be assumed that errors can occur even in the most modern production processes and these have a negative effect on the performance of the plant.

All defective (and missing) products are recorded at a defined balance sheet and reported to the higher-level control device. In this case, the ESM can correct the detected, defective copies themselves. However, if the target print on the HP print is reached, it stops and thus ends a possible correction of the copies to be processed which are still in the ESM and enriched with supplements.

The defective products are discharged from the staple conveyor, which transports the products from the inserter (ESM) to the stacker (STM), then inevitably creates a gap and the package to be formed from the product sequence is incomplete.

The incomplete package (also called partial package or incomplete main package) has been segregated so far after the ESM and before the ramp, the missing products were nachproduziert after the end of the zone or completed by occurring in the mailroom excess copies. The main package was then completed manually, if necessary provided with the associated cover sheet and manually re-introduced into the production process.

This type of post-production is not very problematic in large zones and relatively large distances between the successive zones, since this work process is not repeated very often and thus until now resulted in a justifiable manual effort.

In zones of small print size (fine zoning), however, the manual effort multiplies by a multiple. If, for example, 2000 zone sequences are produced in one week and 3 minutes are calculated for the manual processing, this results in an additional effort of 6000 min. The existing solutions on the market of other providers of VR systems leave each a package to be completed at the end of a zone sequence in a stacking machine and complete this with an additional commissioned zone. However, this method has the great disadvantage that the number of stacking machines also limits the number of packages to be completed.

If zones of small run size are driven, it can happen that x zones are simultaneously in the processing process. Between the zones, there is only a distance of, for example, 2 empty brackets. A post-production with this procedure is only marked at the expense of longer interruptions and waiting times In addition, this method is no longer practicable with manual work and can only be carried out by slowing down the insertion process.

Presentation of the invention

The invention aims to remedy this situation. The invention, as characterized in the claims, the object is based, in a method of the type mentioned, resulting partial packages consistently and continuously without limitation.

The main advantage of the invention is the fact that with the proposal according to the invention no more fluctuations in production output, and it is now possible for all possible zone sizes to produce continuously and consistently with the full system performance, so the manual effort for completing the incomplete packages is completely eliminated.

For this purpose, the superordinate control device provides the essential information such that information is given as to whether the originally intended size of the parcel 1/1 could be completely produced or not.

If production runs smoothly, the stacking machines (STM) are supplied in their entirety and the stacking process is completed when the specified quantity is reached.

If, on the other hand, the production has faulty products, these are eliminated immediately after recognition. At the same time, the process for the subsequent production of the missing package parts, ie the missing products, is started. The missing products are thus reproduced directly after the error detection, ie between (parallel or sequential) of the immediately following zone. This sub-package, consisting of the post-manufactured products, is then sent to the incomplete part of the package, which is parked in the ramp. fed. In such a constellation, it is only necessary that information about the correct assignment of these post-produced subpackets to each other is ensured, so that the definitive stacking on the ramp can be done safely.

Now, however, it may happen that in the production of the post-produced products again errors may occur, which makes a renewed partial excretion necessary. In this case too, the error detection ensures that a new post-production is started immediately. With the delivery and assignment of this second post-produced subpacket, the corresponding incomplete parcel part in the ramp can be completely stacked.

Since the re-production of the products must take place as quickly as possible, it may happen that two sub-packages must be formed in the following zone. This is because, for example, with only one stacking machine, the post-production can only be inserted sequentially and thus the subsequent zone interrupts. This can certainly be done on the basis of a circulation that can be reproduced precisely to the package in the further processing process.

However, in the insertion process, in turn, so-called miscarriages can occur, as a result of which a part of the specimens has to be ejected. Thus, in this case, a partial package of the subsequent zone, which in turn must be completed with a sub-package.

So seen, so the process can be repeated if necessary, for example, as mentioned above, in the post-production of the products for the TP2 again come to a disturbance, another sub-package (TP3) is generated. The goal is thus achieved by a continuous supplementary post-production, which is efficient and product-saving.

If the parcels have arrived at the loading positions of the ramp, the above-mentioned assignment can be detected there immediately on the basis of the package-related information on a cover page of the individual subpackets; these Assignment of the individual sub-packages can also be done by information on optional display elements, where it is displayed which sub-packages belong together.

The higher-level control device ensures adequate information for all persons involved in the further processing process. The plug-in staff is permanently displayed by a suitable visualization of the correction process.

In particular, the truck driver or the palletizer this process must be visualized on a quasi-real-time display device. Thus, it is enabled to schedule that for a particular repository, instead of a package, two or more sub-packages must be accommodated. Of course, the corresponding shipping documents must also be mutated to this effect, i. then that they basically can not be printed in advance. The higher-level control device therefore has a quasi-real-time balance, which also allows the fully automatic printing of the delivery documents.

• Es können Einsteckkombinationen im Kleinstauflagenbereich ohne Effizienzverlust produziert werden.

The main further advantages of the invention are in summary the following:

• Insertion combinations in the smallest edition area can be produced without loss of efficiency.

No manual rework is required for package completion.
The waiting times at the ramp are minimized resp. canceled.
An achievable constant flow of products ensures that machine performance can always be fully managed up to the respective maximum capacities.
An exact representation of the process in the development of the products up to their actual state is always guaranteed, whereby the updated information is fully guaranteed.

A further advantage of the invention results from the system according to the invention, according to which it is not only possible to complete the stacking of the subpackets, but also to the effect that an originally defined order of the printed products within the stacking can be established. For this purpose, it is provided that the sub-packages are collected intermediately and in sections, and then the order is made in the subsequent final stacking targeted. This approach always provides invaluable benefits when the stack contains, for example, printed products that must be queued for personalized criteria within the stack.

Advantageous and expedient developments and variants of the inventive task solution are characterized in the further dependent claims.

Short illustration of the figures

Fig. 1

einen Produktionsablauf nach Stand der Technik,

Fig. 2

einen optimierten Produktionsablauf mit Teilpaketen,

Fig. 3

ein Flussdiagramm über die Vorgehensweise bei der Stapelung von Teilpaketen.

Exemplary embodiments of the method and the device according to the invention will be described in more detail with reference to the following figures. All elements not essential to the instant understanding of the invention have been omitted. In the various figures, the same elements are provided with the same reference numerals. It shows:

Fig. 1

a production process according to the prior art,

Fig. 2

an optimized production process with partial packages,

Fig. 3

a flowchart about the procedure for the stacking of subpackets.

Embodiments of the invention, commercial usability

Fig. 1 FIG. 12 shows the operation of a prior art production flow P2 in which the defective products have been discharged from a first package, as shown by the gap in the package 1. As a result, a gap inevitably arises, and the package 1 to be formed from the product sequence is initially incomplete. This means that the stacking machine STM has an incomplete number, and therefore it can not be released.

It is obvious that this incomplete package, which now only fulfills the qualification of a subpacket, must first be discarded in order to be transferred to a waiting position = WP, as is shown in the waiting position for package 1 = WP-P1 Fig. 1 evident.

The missing products must thus be nachproduziert after the end of the zone (zone change and post-production = Z + N), the number of those of the rejected copies corresponds, as is Fig. 1 is shown well. The package 1 = P1 in waiting position = WP must then be completed manually, if necessary provided with the associated cover sheet, and manually reinserted into the production process.

Further aggravation in the continuous process becomes virulent if the printed products consist of different printed products which have to be joined together in a cycle-related manner. Thus, if the assembly of the individual and different printed products is carried out over several strands, and transport and provision must ensure any combination of inserts, then it becomes obvious which additional manual operations have to be scheduled until the individual packages can be conveyed qualitatively and in the desired quantity , Furthermore, it should not be underestimated that under certain circumstances a visualization the missing products = FP must be provided so that the manual or semi-automatic completion of the finished packages can be done safely. The whole thing then becomes even more difficult and subsequently more labor-intensive when customer-specific containers have to be made available. A production in stock would be possible in itself, but would have the serious disadvantage that a whole infrastructure would have to be provided for an unknown number of defective products. Apart from the fact that the introduction of the post-produced products would still occur.

Fig. 2 shows the process of the production process with partial packages, which has the ultimate goal of no manual rework for the completion of finished packages more perform.

For this purpose, the control unit, which belongs to the production process starting from a package P (3), provides the essential information, so that the information that a particular package could not be completely produced is given priority. At the same time, the control device is able to convey to the surgeon information which type of errors have occurred in the products, resp. available. The process for the formation of sub-packages is, however, started immediately and without delay, as soon as the information has been operational, with which those missing products = FP can be reproduced until parallel to the rest of the process, such that a strict interdependence between error detection and post-production in a direct following zone. The subpackage, consisting mainly of the post-produced products, is stacked in the STM, then provided with the necessary information (TP2 of the XY package) and transported to the ramp. Since the post-production of the products takes place as quickly as possible, it can lead to the fact that in the subsequent zone Z, as required, two sub-packages can be formed. This is easily possible because, for example, only one stacking machine, the post-production can be inserted only sequentially, which is then command then to temporarily interrupt the subsequent zone. This may well be on the Based on a run that can be reproduced precisely to the package in the further processing process.

The production process according to Fig. 2 is clearly visible to the skilled person, so that further explanations are no longer necessary per se. Clearly recognizable here is the procedure how the missing products are integrated into the incomplete subpackage TP1 (1) before they are loaded. The number of these missing products FP corresponds to that quantity TP3 (1), which has caused a splitting between the subsidized subpackets TP4 (2) and TP2 (2) in the production process. It is then clear that an intermediate equivalent zone change Z must be provided upstream of the subpacket TP1 (1).

If necessary, the process can be repeated, if, for example, the post-production of the products for the subpackage TP2 (2) again leads to a disruption, another subpackage is produced according to the procedure described above.

• Es können Einsteckkombinationen im Kleinstauflagenbereich ohne Effizienzverlust produziert werden
• Es ist keine manuelle Nacharbeit mehr für die Paketkomplettierung erforderlich;
• Wartezeiten an der Rampe werden verringert;
• Ein konstanter Produktenfluss ist gewährleistet, womit immer eine volle Maschinenleistung möglich ist;
• Eine exakte Verfolgung der Produkte innerhalb des ganzen Produktionsablaufs ist som it garantiert.

The higher-level control device also ensures that all relevant information is immediately available, for example for the plug-in personnel, which is indicated by a suitable visualization of the correction process, which arrangements have been made. At the same time, the truck driver or the palletizer (manually and automatically) on a quasi-real-time display device this process is displayed. If there should be production-related advantages, the loading ramp for a particular shelf instead of a package receives two partial packages, but which are marked exactly. The higher-level control device emits the new delivery documents fully automatically in a quasi-real-time comparison. Thus, the following advantages can be recognized sustainably:

• Insertion combinations in the smallest edition area can be produced without loss of efficiency
• No manual rework is required for package completion;
• Waiting times at the ramp are reduced;
• Constant product flow is guaranteed, which always allows full machine performance;
• An exact tracking of the products within the whole production process is guaranteed.

Fig. 3 shows a flow chart from which the loading processes emerge. First, the incoming packets are routed to the ramp R 100 via the station 10. Since this is an integral, non-defective production, the delivery is 100%. The process is then completed, and further measures are no longer required.

If, however, defective products occur during this production, then the control device LT (not shown in more detail) comes into operation, which ensures that the defective products are reproduced simultaneously. About the station 20, the reduced original partial packet 1/1-X is first forwarded, at the same time issued command to the station 30 nachzuproduzieren the missing amount X. The two subpackages (1/1-X) and X are then merged into a single set in ramp R 100. The stacking happens here conventionally, since it depends only on the completeness.

If now happens that from the post-produced subset X again comes to a faulty production, then a next station 40 takes over the remaining subset (XY), which is therefore smaller than the subset X. In this initial situation, command is given to the station 50 to initiate simultaneous production of a subset Y. At the same time, a command is issued to the next downstream station 60 to retrieve the remainder of the waiting subset (1/1-XY). The three subsets then form again The total amount in ramp R 100. Again, it is sufficient if the stacking of the three sub-packages (1/1-XY) and (XY) and Y conventionally done, since in turn depends solely on the completeness of the main package.

If, however, the default is to restore the originally desired order in the case of just described fragmentation in the final packet, the individual partial STMs 40, 50, 60 must be merged individually and partially packet-related so that the desired sequence can be recreated. It is clear that for this purpose further sub-STM must be activated, such that the fragmentation of the sub-packets always forms a measure of the sequence within the desired sequence, with which all sub-packets can then be seamlessly merged. Such an example emerges from ramp R 200. The subpacket (1/1-X-Y) is in turn divided into two subset packets a and b at the location of the faulty production that has occurred. The same happens with the subpackage (X-Y), which is also divided into two subpart packages c and d. Finally, there remains the sub-package Y, which forms the only sub-package e, since a further defective production has not occurred. If this should be the case, however, two subpart packages would have to be formed here instead of the faulty production that has occurred. This procedure is only applicable if the faulty production forms the integral boundary zone of a subpacket. R 200 now shows how the individual subpart packages a-e come to the final stacking. This stacking then corresponds to the original underlying order of the main package.

Claims (5)

Process for the production of packages consisting of printed products, which consist of uniformly or individually compiled printed products and / or are composed of at least one jacket product and at least one supplement, characterized in that a higher-level control device monitors and controls the integral production of the packages consisting of the printed products in such a way that a first precipitation of defective printed products taking place in the course of the production of a main package as well as any further subsequent separation of further defective printed products triggers an immediate simultaneous simultaneous or quasi-simultaneous postproduction of these defective printed products, so that each subsequent production results in at least one formation Partial package leads, which is integrated into the incomplete main package. A method according to claim 1, characterized in that the sub-package is integrated at the appropriate location in the incomplete main package. A method according to claim 1, characterized in that to form a predetermined order of the printed products in the main package, the resulting post-produced printed products are divided into individual sub-packages so that their combination simultaneously forms the predetermined order of the printed products in the main package. Method according to one of claims 1 to 3, characterized in that the association of all partial packets to each other or of at least one partial packet to an incomplete main packet is determined by visual information. A method according to claim 4, characterized in that the visual information allows at least one manual stacking to a main package.

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