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Implementing production excellence routines

Implementing production excellence routines


Vivian Cohen-Leisorek


This is the second post in a series about using checklists to improve maintenance of digital presses. Read the first post here.


HP Indigo maintenance checklists are designed for maximum utility by all operators. Even those with only Level 1 training can do all the tasks specified in the maintenance checklists.


Two checklist versions: hard copy and software-based

Different maintenance tasks need to be performed on a daily, weekly or monthly basis; and there are some tasks that are counter-based, required according to the number of clicks rather than time passed.


The checklists are available in hard copy and in the press software, accessed via HP Indigo Print Care



 From the Daily and Weekly maintenance checklist folder


While hard copy checklists can have a high density of information on the printed sheet, that’s not possible on screen. For this reason, in the software version, the checklist prompts are shorter, but there is always an easy way to click for more information or guidance, such as a video that teaches the operator the steps to follow. The digital version is dynamic in that it reflects real-time press status. For example, when the press is on stand-by it will not display tasks that must be done when the press is off.




Implementing the maintenance best practices according to the checklists for maintenance routines, can bring significant pay-offs on several fronts:

  • Increased output with same asset
  • Reduced need for capital investment
  • Lower maintenance cost
  • Lower Total Cost of Ownership (TCO)
  • Improved press performance and safety
  • Increased competitiveness and market share


A study of 65 HP Indigo 7X00 Digital Presses on which the routines were followed, showed that on average, non-productive time decreased by around 20% in the first nine months.


Pureprint, in the UK, implemented the maintenance routines on its three HP Indigo 7500 Digital Presses as part of its participation in the HP Indigo Customer Excellence Program. As a result, the 72 hours of weekly unplanned downtime it had typically experienced across its three presses were replaced by weekly scheduled maintenance of 10-12 hours, netting about 50-60 extra production hours a week.




Pureprint has benefitted in numerous ways, some of them not exactly measurable. As Steve Frost, Pureprint’s digital pressroom manager, explains: “We have far fewer mechanical breakdowns. Things get replaced before they break down because we notice when things are getting worn out. We have a much happier press room because there is far less frustration. We’ve seen a massive improvement in our printed quality, particularly in our color consistency, because the machines are running better. I now have more confidence to print jobs and we now take on more color critical jobs.”


Get the full story of Pureprint’s experience with maintenance routines and checklists. 


And join us next month at the Dscoop EMEA 2015 Conference where a panel of customers will share their experience implementing new routines - including the key benefits, the challenges they encountered, and their first-hand tips for maximizing the benefits of these best practices. 




What’s your takeaway?


If I were a press operator or production manager, I'm sure I would already be converted to using checklists for maintenance routines. But since I’m a marketing person, I’ve at least started using checklists in some of my own routines, including this blog.


I’d like to hear your thoughts on how checklists can help – with press maintenance, and with anything else.


Labels: Technical
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About the Author
  • I sit at the crossroads of the HP Indigo technology development team and our customers, sharing knowledge and tools that help printing companies continue growing their business. I’ve been immersed in the world of digital printing since 2006, when I joined HP Indigo. In work and life, I’m passionate about old and new media, and the joys of raising four children.
  • I am a word addict. For both business and pleasure writing is my thing. I am a marketing and communications expert and I am here to let you, our reader, know about all things Indigo. From new product launches to how to make the most of your press and inspiring stories and applications from around the world, I'll write it all here, for you to enjoy.
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