(X)JDF Workflow Automation at an Internet Printer with Rogler Software

Established by Hannes Rogler over three decades ago, Rogler Software has emerged as a prominent name in the field of Management Information Systems (MIS) software solutions. Headquartered in Vienna, Austria, the company remains dedicated to pioneering advancements in MIS technology. But what exactly does MIS entail according to Rogler Software?

The company adopts a comprehensive approach to defining MIS, encompassing far more than mere order calculation and management. Integral to the MIS is the integration of production control, where a sophisticated scheduler strategically plans order sequences, complemented by robust warehousing and materials management systems ensuring a transparent flow of resources. Crucially, the scheduler is fueled by real-time data gleaned from production data acquisition, facilitating decision-making. Moreover, the MIS extends its reach to encompass online solutions, including web-to-print shops and customer platforms, integrated as modules within the system.

The Internet Printer

About six years ago, Rogler Software started an elaborate workflow automation project with a major Internet printing company in Würzburg, Germany. As is common in this sector, the web-to-print shop produces a very large number of jobs per day (around 20,000) with a low average order value. As a result, order creation, production and packaging must be largely automated in order to offer print products at competitive prices and remain cost effective. The range of printed products is extensive, from simple products such as business cards, flyers and brochures to packaging, three-dimensional objects and various textile applications.
Production takes place in a relatively large number of branches and locations. These receive orders from the head office. In most cases, the entire production process is carried out at one of the subsidiariesy, but in some cases partial products are passed on from one branch to another. The subsidiaries also act as a production back-up in the event of a malfunction or overload.
Production is highly automated. Job ganging is standard and the machines, such as the sheet-fed offset presses, are often equipped with the latest automation options. In addition, some machines are dedicated to specific product types. For example, some offset presses always print the same paper with fixed sheet sizes, or folding machines always fold the same type of flyer. This drastically reduces makeready time and therefore costs. Business cards, for example, are produced fully automatically from order entry to packing without any human intervention, with multiple orders ganged on the same press sheet.

 

(X)JDF Integration

But now let’s come to the underlying CIP4 technology behind the applications. The web-to-print system generates a PrintTalk business object that incorporates XJDF. The PrintTalk object defines the process step while XJDF contains the product description. This data is imported by Rogler's MIS and converted into a private data format that is also used by the Rogler internal modules described at the beginning. But as soon as an external order has been placed, the CIP4 data formats come into play again. JDF is sent from the MIS to the production devices, and PrintTalk and XJDF is used to send job orders to the branches, as only the industry standards JDF, XJDF and PrintTalk can communicate with various devices and controllers from different manufacturers. As a result, these standard formats future-proof investments in new equipment.

The Project

The original automation project's goals, defined six years ago, have of course long since been implemented, but there is always a need for additional workflow automation, which is constantly being formulated and worked on. The two project managers - one from Rogler Software and the other from the printing company - meet regularly to define project extensions. For example, communication between head office and the stores has changed over the course of the project. Initially, the central MIS also planned the production steps of the branches, but now a more decentralized approach is being taken. The branches receive orders from head office, but not production specifications. This has proved to be safer and has reduced the need for costly installations such as server mirroring in the head office.