Watkins Printing Company

Columbus, Ohio
Watkins Printing boosts bindery productivity 300%
Watkins in line for productivity boost: Watkins Printing's plant manager Bob Smith (left) and controller John Logan are happy to see 300% and 400% productivity gains with their new Best Osako 368AS saddle stitcher in-line system.

To Bob Morton, President, Best Graphics, Inc.--

I'm happy to provide a bit of background on the Best Osako 368AS we purchased from you.

As you know, we are a web and sheetfed printer. Our primary business is running short-run periodicals and publications, everything from 16-pagers to 96-pagers, usually magazine size.

We came into the market for a new stitcher because I felt the time was right to completely streamline my bindery operation and enhance both speed and productivity. With the blessing of our owners, I began the process of acquiring a new stitcher, along with a number of peripherals to really help automate the entire collating/stitching/ink-jetting/packaging process for us.

As a starting point, I surveyed several machines at other plants. My search included traveling out-of-state (PA, S.C., as well as Ohio) and also visiting Graph Expo.

In my opinion, the Osako 368AS and Best Graphics gave us the best combination of performance, value and service. We opted for the Osako 368AS with 7 pockets plus the cover feeder.

With our old machine, I felt we were using twice as much labor and running at half the speed I felt we could achieve with the new stitcher and total in-line system. Our goal was to do efficient in-line ink-jetting, speed production and get away from numerous labor-intensive hand operations.

The stitcher and Feuiltault stream feeders have really saved labor and increased production speed. We used to have several people standing and hand-feeding pockets -- now one person can run the machine and feed all 7 pockets. An assistant can load large bundles onto the stream feeder in minimal time. Once the collated and stitched forms come out of the 368AS, they move to the in-line Video-Jet mailing section and are then shrink-wrapped by the Arpac we added in-line. They come out bundled in zip-sorted packs, ready for palletization or go into mail bags.

The amazing thing is that we're doing it with just three people on the whole production line. They're doing the work it used to take five or six to do, and they're accomplishing it twice as fast. Overall, it's a 300%-400% increase in productivity for our magazine production! With very few rejects on the mailing end, we've basically quadrupled production.

I like the 368AS's ability to make adjustments on the fly without holding up production. Also, the 7-pocket configuration is very flexible. I can load 3 pockets for one job, then load the other 3 or 4 for the next job while the first one is running. It's another time-saver, another gain in productivity.

I also like the cover feeder extremely well. It's just an excellent unit and will handle just about anything we throw at it... everything from lightweight 40-LB. text to heavyweight cover.

It was great working with you in putting together this high-productivity in-line system. I feel you went out of your way to help coordinate the acquisition of all the needed components -- ink jetting equipment, shrink-wrapping and all the rest -- and integrate them beautifully with the 368AS.

Best Graphics is truly a quality-conscious company. Your support has been excellent. Even though we haven't had any major problems, you've always responded quickly to anything we've needed. Also, your follow-up training six months after installation showed first-rate professionalism.

Thanks for all your help and advice. I look forward to working with you again.

Sincerely,
Bob Smith, Plant Manager
Watkins Printing Company


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