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Lean Update by Justin Thompson 
In the 1st quarter of 2012, the lean team introduced a new PAR (Preventive Action Request) system open to all Advanced Web employees. This system consists of a board, which visually displays  the person's idea handwritten on an index size card, but has a timeline as to when each idea should be completed. This new system allows each individual to see their PAR in action during the implementation process of their idea. This PAR board system simulates daily continuous improvement from the factory floor to
pre-production (office). Each group has their own board to demonstrate the commitment to improving our processes to exceed our customers' expectations. Within the first two months of 2012, we have exceeded our monthly goals and expectations of PAR's implemented by 150% (goal 10, implemented 25).
Although we use the A3 tool here at Advanced Web for higher level projects, another tool was recently introduced, the Fishbone/5 Why. This cause and effect  diagram helps to drill down to the root causes of defects and identifies possible failure modes. Problem solving training was conducted on how to utilize the Fishbone/5 Why tool, and then teams were formed to attack CAR's (Corrective Action Requests) in our system to better support our customers. This problem solving tool will be used to support day-to-day improvements throughout the organization.
With the unfavorable trends of raw materials in the pressure sensitive label and flexible packaging markets, Advanced Web has renewed our commitment to Lean Manufacturing. During the first quarter of 2012, we focused our attention on one of our key initiatives... scrap. Through a Focus Circle Kaizen event and a scrap reduction program, we have identified our benchmarks and set our goals. With real-time data collection connected to our presses, we will be able to see where we stand on scrap by press so we can make the necessary improvements.
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Kaleidoscope & Digital Color Matching by Jon Bailey
 The days of color matching... I remember them well.
In the past, sometimes we spend hours with a customer to match their approved color standard. Suddenly, the customer pulls out a piece of colored paper, or a swatch of clothing that the artist had envisioned weeks earlier, expecting the label to match the artists expectation. Panic mode can set in and you're asking the ink department to start tweaking the color that has already been color matched and setup for the press. What direction do you go? How long will this take to get right? How quickly will it take to get this approved and running?
Customer requests or expectations will never change and will always be a variable that is in the mix on any color project. Our goal is to set the customers expectation and to print it on time and correctly to make the project as cost efficient as possible.
How do we set ourselves up for successes, especially when we move into the digital world? Better color management and the use of Kaleidoscope.
When printing digitally, we are no longer talking about a jug of ink or a spot color. Its all process colors and how much of that 4-color (CMYK) mix will be needed to create the customers expected color. A tool is needed that will help dial in, create and set a color standard in 4-color process that would match to the customers target.
Kaleidoscope (Color Engine) is that color management created by software company; Esko. It is a software program that can see a color and convert it into digital information. From a color on paper, plastic, fabric or any substrate into a set of values that the software can communicate to the press how best to create the color.
Kaleidoscope is a set of tools to assist prepress, our ink department and the digital printing team to meet customer's expectations! We are able to measure the values of a color to create a 4-color match on press, and the ability to modify the color tolerances to move, tweak or adjust the color further and lock that color down for future press runs for consistency.
The days of customers changing and going in a different direction will never end, but the days of spending hours color matching on press is numbered! Print a label and work with the customer to review against the colored paper or clothing swatch. If we need to modify the color, Kaleidoscope can read and adjust the 4-color mix in a flash. Print a modified label and get the final approval from the customer!
With Kaleidoscope our color matching time is reduced and color adjustments can all be done in a matter of just a few minutes. With the goal of helping cut down the time spent on chasing colors, press time wasted and helps put the control and fun back into having to adjust colors.
Ask your customer service representative or sales executive for more information.
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Quality Management System
by Doreen Praschak
For more than 15 years, the Advanced Web Quality Management System (QMS) has been certified to the ISO 9001:2008 international standard for quality systems.
So you are wondering...what does this mean to me or my company?
This means that throughout our flexographic printing and specialty converting processes, we follow the applicable requirements for the quality of products, process control and continuous improvement. This process assures that our customers receive consistent quality and dependable delivery every time this part is produced.
Critical processes of Advanced Web quality management work together to provide system integrity and longevity. Together, these key processes are identified, documented, and implemented through training and practice.
With the objective of customer satisfaction and continual improvement, our system focuses on eight quality management principles: - Customer Focus to understand current and future needs, requirements, and expectations
- Leadership that establishes unity of purpose and direction
- Employee Involvement at all levels
- Process Approach to achieve desired results due to managed activities and processes
- Systems Approach to identify, understand, and manage interrelated processes as a system
- Continuous Improvement in overall performance as an organization
- Factual Approach to decision making based on analysis of data and information
- Mutually Beneficial Supplier Relationships that create value for all parties
 The Advanced Web quality management system consists of the organizational structure, responsibilities, processes, documentation, resources, and improvement tools that enable us to manage quality and provide customer satisfaction. Additional benefits include:
- Feedback to improve customer satisfaction
- Improvement projects (LEAN, kaizen) with suppliers, our processes, and customers
- Clearly defined roles and responsibilities within each critical process
- Efficient and effective processes - consistent quality for the customer
- Team approach has increased employee motivation
- Prevention of errors
- Reduction of waste: materials, time, talent
Continuous assessment audits of the Advanced Web quality system are performed by our registrar annually. This provides opportunities for improvements and keeps pace with current industry changes and practices.
We welcome system assessments by our customers and will provide the necessary information that demonstrates our ability to provide products and services that constantly meet customer and applicable regulatory requirements.
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March
