OEE for Printing

MANUFACTURING IMPROVEMENT MADE EASY BY VORNE

Printing

In today’s digital world, printed material is still paramount - often considered more trustworthy and eliciting a greater response to act than digital materials. This advantage, however, requires a significant investment in large-scale, specialized commercial printers to either mass-produce content at a very low cost or print smaller runs with a great deal of flexibility.

Regardless of whether you’re a larger publisher, a custom print shop, or even a converting or packaging company providing printed labels, cartons, or flexible packaging, you will gain valuable insight into your processes, margins, and production losses with the Vorne XL Productivity Appliance. Vorne XL moves printing operations far beyond manual data capture to gain critical insights for effectively driving process improvement and actualizing change with 100+ metrics and 20+ data dimensions.

Other benefits of XL that customers love include no software to install, no servers to maintain, no recurring fees, and no contracts. Instead you get unlimited users, free technical support, a 3-year warranty, and free software updates. All in an inexpensive, off-the-shelf product.

Driving Improvement for the Printing Industry

Our printing customers strive to produce something that is visually impactful and consistent as quickly and accurately as possible. It is critical to be able to optimize the process while maintaining the product quality that their customers expect.

The Vorne XL Productivity Appliance empowers printing manufacturers to monitor their processes in real time, improve throughput, and maximize efficiency, all while preserving the integrity of their products. XL drops onto your existing process, making it a quick and easy solution that requires little to no changes to the print process. This is a unique and critical advantage of Vorne XL.

Screen capture of a report from the Vorne XL OEE software showing the longest changeovers for a label printing facility.

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Key Benefits for the Printing Industry

Vorne XL is completely agnostic to the type of equipment in your printing process. This is a huge advantage as you can easily apply XL to any process and get the same deep wealth of information. XL includes I/O to integrate with your process, a scoreboard for your operators, and built-in reporting for your managers. Even better, it easily and incrementally scales from machine to enterprise. Monitor your litho or flexographic printers, screen or gravure printers, and other equipment with one solution, quickly seeing benefits such as:

1
Reduced Changeover Time Whether you are performing a full plate change or quick change die-cut procedures, Vorne XL will provide you with accurate historical data for each type of changeover - an accurate and comprehensive base of data that you can use effectively to drive improvement.
2
Standardize on Optimal Run Rates Don’t let opinions drive line speeds that vary by operator. Instead, define line speed profiles by analyzing historical cycle times and average speed and run rates by part in XL to optimize the balance between speed and quality.
3
Precise High-Speed Inputs Feel confident that every print is recorded with high-speed inputs capable of tracking hundreds of cycles per second.
4
Multiple Digital I/O and Count Data Convert cycle inputs to your desired unit of measurement, counting in terms of total and good linear feet, meters, pieces, boxes, or rolls, as well as scrap rates.
5
Full OEE and Pareto Analysis Compare assets or process streams by measuring accurate Overall Equipment Effectiveness (OEE) with Availability, Performance, and Quality metrics. Visually display your data however you prefer - column charts, Pareto charts, line charts, heat maps, and many more.

You're In Excellent Company

Vorne XL customers span across 45+ countries and are in virtually every industry - including many in printing. Take a look at a sampling of printing manufacturers that have unlocked the benefits of XL to obtain accurate and actionable data, critical insights, and a foundation for their continuous improvement programs.

View a sampling of Vorne XL users in other industries

Learn More About Vorne XL

We would be happy to show you XL, deep dive into your challenges and your processes, and answer any questions you may have. We also offer free 90-day trials. In fact, we have completed thousands of successful XL trials. Did you know that 91.9% of companies that try XL buy XL?

Metrics, Dimensions, and Dashboards

Vorne XL provides you with an incredible data foundation and an outstanding suite of reporting tools to effectively drive your continuous improvement, lean manufacturing, and digital transformation initiatives. With XL you get immediate access to over 100 highly accurate and actionable metrics and 20 data dimensions - in real time and for deep retrospective analysis through historical reporting. There are dozens of built-in reports, and you can easily create your own reporting dashboards.

Report from Vorne XL showing KPIs important to a label printing facility including OEE, speeds, and rates.

Vorne XL User Success Stories

XL helps manufacturers in almost every industry improve their process productivity. You will love our free support, free software updates, 3-year warranty, transparent pricing, fast implementation, and of course, the wealth of product features. That is why we have so many customers that share their success stories.

G.K. Continuous Improvement Manager Global Food Service ProviderWe purchased a Vorne XL display to help us monitor production rates and apply lean manufacturing tools to one of our many value streams. By efficiently working to takt time, we have been able to eliminate waste and improve productivity, while maintaining our commitment to quality. We have calculated a 30 percent labor savings on our pilot project which yielded a 31 day payback. Since the pilot we have installed another two XL displays. As you can imagine, we will be continuing to add more Vorne displays!

J.N. Web Press Manager Commercial Printing CompanyInitially we did not know how much of a difference XL would make… It has raised production undoubtedly and we plan to use the display in all of our hot spots this year… Great product, it paid for itself in a month.

R.H. Engineer Large Print Advertising CompanyWe saw an immediate 29% improvement in production efficiencies just by adding Vorne displays! The project has been so successful that we've now outfitted two complete plants with XLs and are working on another. Corporate is so excited about the project that they've approved the budget to do every plant we have in the next year.

G.D. Bindery Manager High Volume Catalog PrinterHaving the data collected from the Vorne displays allows my supervisors to focus on machines that are running bad and to leave the good ones alone. The bottom line for us is that we cannot effectively react to what was done yesterday. Now, people on the line are always looking to see if their line is number one and do what it takes to make their line perform. No doubt we would not have the efficiency gains that we've achieved without the visuals. It used to take our supervisors 35 minutes to collect the count data for their 9 machines now they have it in 10 seconds!

D.S. Manufacturing Engineer International Printing GroupI have been very impressed with the displays from Vorne. I have worked with them since we installed them several years ago. Operating 24 hours a day seven days a week, we have never had a problem. We are used to dealing with machinery issues, but the displays from Vorne have NEVER failed. Day in day out they just work. We never hesitate to use Vorne in our plant. We don't mess around with quality here, and it's obvious Vorne shares our focus on producing a quality product.

D.G. Operations Manager Grain Milling and Packaging CompanyAfter we installed and deployed the Vorne XL Productivity Appliances we analyzed the data, and started understanding our underlying issues. We benchmarked our primary line and recorded an OEE Score of 45%. When we felt we had a good idea of what was going on, we started working to improve our productivity. We use OEE as the primary metric to gauge our progress. XL gave us the tools to track and eliminate our downtime, and improve our productivity. 10 weeks later we are hitting 60% OEE and still making improvements! Of our 10 best shifts of all time, 5 occurred in the last 30 days. Vorne XLs have been key to improving our productivity.

J.C. Engineering Manager Wheel and Drive ManufacturerI read every customer comment on your web site before I decided to try XL and have to admit that I simply didn't believe them. I never imagined that a product, company or support could be as good as people were saying. I am now a true believer and customer. You not only delivered all that you promised but even more. XL is simply an outstanding product. Not only is XL an outstanding product but your technical support is the best I've ever encountered!

R.K. Maintenance Supervisor Decorative Can and Tin ManufacturerThe results are amazing! We went from about eight thousand units a day to just over eleven thousand just by putting the displays up. That's an almost 30 percent increase in production and we've been able to sustain our gains. Everybody in the plant just loves the displays. Supervisors, managers and operators now have a great tool for monitoring the progress of the lines in real-time.

A.C. Manufacturing Consultant Manufacturing Consulting FirmWhen we installed Vorne displays showing target and actual production rates, the target rate for one of the lines was inadvertently set higher than was planned. One of the engineers set the target rate to 180 pcs/min for a part that was scheduled for 140 pcs/min. A few hours later when the plant manager glanced at the display, he was amazed to see the actual performance at 178 pcs/min. The line was running at 127% of plan simply because the goal was there! The Vorne displays showed us that our team members can outperform our own expectations. After we started visual management using the Vorne displays, the lines are showing record productivity numbers.

L.C. Manufacturing Engineer Global Auto Parts SupplierTwo years ago we brought in the Vorne XLs as part of our lean program. We wanted to measure and improve efficiency on seven lines. OEE gave us a reliable way to measure our progress and also a tool for identifying areas where we can improve. Over this time we have increased our OEE by an average of 20 points and our downtime is down by 15 to 20%. Vorne has been with us every step of the way. We are proud that we have improved and also that we are maintaining our gains. Vorne has been a trusted partner in our journey, providing us the tools and support to help us improve our productivity.

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Printing Specialties

Our XL Productivity Appliance, with its fully integrated OEE reporting system, works well across an extremely broad range of printing industry specialties. Here are some of the more common specialty areas where XL is used:

Battery Component Printing
Ceramic Tile Printing
Flexible Packaging Printing
Functional Printing
Industrial Label Printing
Label Printing
Large Format Printing
Medical Device Printing
Membrane Switch Printing

Metal Printing
Packaging Printing
Pharmaceutical Packaging Printing
Point-of-Purchase Display Printing
Promotional Product Printing
RFID Tag Printing
Security Printing
Textile Printing
Wood Printing

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What's included in your 90-day free trial?

VORNE XL | Works with any machine, any process, right out of the boxEasy, quick self-install | Accurate, real-time KPIs immediatelyTry XL for FREE today

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