1St Special Focus Symposium on ICSKS: Information and Communication Sciences in the Knowledge

1st Special Focus Symposium on ICSKS: Information and Communication Sciences in the Knowledge Society

Research of Planning Methods in Graphic Production

Klaudio Pap1, PhD; Vladimir Simovic2, PhD; Mario Barišić3, PhD

1University of Zagreb,Faculty of Graphic Arts, Getaldiceva 2, HR-10000 Zagreb, Croatia; ;

2"Baltazar Adam Krcelic" College of Business and Management
3Vjesnik d.d., HR-10000 Zagreb, Croatia;mario.barisic @vjesnik.hr;

Keywords: Planning, graphic production

Abstract:

Production planning in graphic production is one of the most difficult tasks due to the simple reason that one single printing house produces over a hundred different products. One and the same product may be made in many various ways, i.e. on basis of different workflows in the same printing press. However, some of the methods are the optimal ones and some are not. A planner is faced with numerous problems linked with machines and people being occupied. This paper is a report on the research and module development, as well as development of planning methods specific for graphic production. It has been made possible to have autonomous system configuration for the wished planning (machines, production chains, people and crew). The paper shows planning methods especially developed for solving the most difficult situations, functioning in a simple and visual manner allowing the job of planning to be less difficult for the planner.

1. Introduction

Graphic production is specific in respect to the fact that a single printing works can produce a variety of over one hundred different products, from books with all kinds of binding, formats, different sorts of paper to airplane tickets, tickets of all kinds, labels and posters. Planning such production is completely different from planning, for example, in the automobile industry where there are only around ten workflows for several types of cars that the factory is producing for the market. In a printing production there are very many different workflows. Please note that some of the production phases may be used for completely different products. The printing phase on a four-color printing machine of B1 format may be used in printing pages for some book in the same way as it may be used for printing advertising leaflets. The difference is only in the type and the distribution of information on the sheet to be printed.

In previous works we have reported on experimental results acquired on the graphic production modelling and simulating software under the code name WebPoskok (designed by Dr.Sc. Vilko Žiljak and Dr.Sc. Klaudio Pap). Graphic production processes were turned into adequate standards described in XML and stored in the relational database. Resources, operations and process connections described in this manner enabled carrying out electronic calculations and creating workflows in virtual and real printing works. The system thus developed enabled entering into the process of graphic production planning.

The introduction of interactive web technology such as SVG (Scalable Vector Graphics) enabled new approaches to complex processes such as graphic production planning. The main characteristic of this technology is that it is in itself an XML record which is interpreted by t SVG processor installed in the Web browser or some other work environment. This is why it was an ideal choice for developing a module for graphic production planning. The link to the WebPoskok system is relatively simple because there is possibility of direct communication of the workflow XML dictionary from WebPoskok with the dictionary for planning that is being developed and shown in this paper.

2. Time and time segment display

In the process of production planning time as well as time segments that need to be observed should be displayed in a certain set manner. Also there must be a possibility to record the time segments in the relatetional database. The time matrix created in the database is allotted to a certain planning project that occupies time segments with its possibilities, user interventions and algorithms setting them in the wanted states. We have decided to display the basic time segment as a rectangular form. Besides the displayed role it also has the role of an interface between the user and the database. This possibility is derived from the property of the SVG language as an XML derivate.

By altering the data recorded in the XML record, the change of the data display in the SVG coordinate space will be shown interactively through the SVG language. In the same manner the developed planner algorithm will change the appearance of the time segments in case there are certain planner situations arising from newly formed data being analyzed. Possibilities were used within the range of the SVG language for software creating of paths, Bezier curves, grouping and control of different graphic objects, as well as different animation technique for warning the planner during his tactical moves. The SVG DOM (Document Object Mode) was used over these graphic objects as the main software interface through which it was possible to change the SVG vector graphic behavior in real time as well as receive user interaction information.

Display of time and time segments is shown by the time matrix in SVG coordinate space. There is a time matrix for each entity that we wish to plan the time for where days are displayed in columns, and the hours 0-24 are displayed in matrix rows (Fig.1).

Figure 1Time Matrix

It is possible to adapt the matrix dynamically to the wanted display formats. The color, as well as the identification job code, planner's notes and many other properties may be changed by the time segments through the SVGDOM interface. Due to this type of work it is not necessary to use variants of input and editing attributes through different table types that are otherwise usual in the standard modules for planning in the market.

There is an unlimited time matrix in the relational database for a certain planning project. All planners’ inquiries go towards the database. The goal is to facilitate for the planner the job to resolve complex dilemmas with the help of a dynamic interactive display through the Web media. The SVG technology that is in itself an XML derivate has been used as the ideal choice for achieving the goal of interactivity and vector display in the Web interface.

3. Resources for planning

In graphic technology there is a basic division of production phases into graphic prepress, printing and graphic postpress. The resources that are wished to be planned are also distributed in this manner. Figure 2 shows the module for determining resources for planning. Two things are achieved by this, i.e. the categorization of resources and allotting resources to a certain created type (category). We have defined six basic types of resources: graphic prepress, sheet printing, web printing, graphic postpress, the rest and null.

Figure 2Resources for planning

The once created resource gets its time matrix whose time segment can always be observed through the time interval display as shown in Fig.1. The time matrix for a certain resource is filled with time segments from certain unit jobs, i.e. in the printing works with a concrete phase from the work order.

Loading of the production plan for certain unit resources is made possible in three ways: importing from the Webposkok work order base (Fig.3), loading from the planner template base (Fig.4) and independent loading of a completely new job (Fig. 5).

Figure 3Importing the work order

Importing of production phases from the work order is a semi-automatic process. This has been made possible by the just described resource categorization. The WebPoskok system contains the same production resource and phase categorization as does the planners’ module. When importing of the work order is started in the time matrix, first there is recognition of the production phase types. This may be observed in Figure 3 in the column named Type. To the right of the column one can observe the belonging time period that has been derived from the estimated process, the work of which is based on the standardized database. After starting the «PLAN! » action, certain production phases will enter the planner's time matrix at the wanted starting time and the belonging resource type.

After a certain production phase is transferred into the plan, it changes its status. There is no change of planner status for all production phases that have not been planned yet so that the planner is aware at each moment of the phases that have remained unplanned and of the already planned ones. It has been made possible to remove a phase from a plan so that the planner could later apply a different entrance tactics for this phase.

There are many jobs yet for which we still do not know even the identification code nor under which work order it is going to enter into production, but for which we must plan the occupation of machines, i.e. resources. These jobs are of the weekly type, monthly issues or printed weekly and monthly campaigns for various types of telecommunication or marketing firms. Such jobs are usually contracted a year in advance with a negotiated price. They are so important that the mutual penalties are negotiated in advance in case the contracted time schedules are not fulfilled in respect to handing over the printed product on one hand and the prepared material that must be printed, on the other hand. Figure 4 shows part of the work with planner templates.

Figure 4Planner templates

The authentic quality is in the fact that the planner creates the template job interactively through the SVG interface and that all templates in the belonging color and abbreviated title are shown at the planner’s left side. The template list may be changed through the window with the order of the template jobs. In this way the planner can plan some of the jobs throughout the whole year. With this kind of planning it is recommended to work with maintenance jobs where it is often known when certain machines should be serviced.When one wants to place a certain production phase into a time plan in a completely independent manner, this is done through the New mechanism displayed in Figure 5.

Figure 5Independent planning of a new job

Attributes of a job that are necessary to be fulfilled before the job takes over the matrix time segments of a certain resource are offered in the window interface. Firstly, this is in the time which as a default amounts to one hour. It is necessary to fill in the label under which this job will be displayed within the plan (the shorter, the better). Color plays a major part in the planning process display. Two manners of determining color are offered: the palette manner of visual choice and hexadecimal code in the RGB system with which the color is recorded in the job XML and in the database. Hexadecimal recording is interesting from the planner's side because often the desire is to group the job phases as chains and sub-chains, and therefore to determine the same color for them. In such cases it is very difficult to choose the same color visually, so the color is transferred to other production phases in the same manner as with the copy-paste mechanism system.

The job time deadline is the fourth attribute that must be fulfilled. If the planner does not know yet what the deadline is, he can adopt a default value that is set for 48 hours or he can annul the deadline. The deadline for fulfilling the job is an important planner attribute because the best planned resource is the worst planned resource if the deadlines are not met, because there will be nothing to plan afterwards. The input may be done numerically or through the calendar interface. Input through the calendar interface is more secure because it displays the designation for the current day within the month, as well as the desired hour. Thus the user does not think about the date and time format of the record that must be heeded because of the XML record and the record in the database. The deadline animation is built into the SVG matrix. When the mouse key is held down longer over the random job, there is starting of the animation that blinks the deadline. In the same manner when the planner shifts, i.e. makes new plans for certain segments of the job, it might happen that the deadline is not met. When there is such a situation, the algorithm stops the desired resource re-planning and informs the planner that the move he is making is not allowed. These mechanisms and resolving of such situations resemble games, and this is what the planning process is in a certain way. If the planner wishes to make the newly entered job become a template for future planning, then he activates the template attribute through the check box.

4. Daily planning and the Gantagram

This paper describes the introduction of a new daily planning method. Its main characteristic is the instant parallel display of all resources being taken up for each day (Fig. 6). This may not be mixed up with the Gant display that is developed in a different way (Fig. 7).

Figure 6Daily planning

In daily planning it is allowed to shift jobs from one resource to the other. Jobs may be planned in a simple manner on several parallel machines if it proves to be the only way in which to resolve a bottleneck problem caused by a slower machine.

Figure 7Gant display

In the Gant display (Fig. 7) the planner is enabled to choose those jobs and resources that he wants to see and analyze. In this display it is possible to build in links, i.e. determine the border conditions for starting and finishing certain job phases. A trap mechanism has been built in as well that does not allow the planner to re-plan certain phases without control.

5. Conclusion

This paper is on the research of advanced methods for graphic production planning that are further development linked with new possibilities of interactive Web vector graphics such as SVG (Scalable Vector Graphics). The time matrix is shown in a completely different way, resembling a chess game of the planner against time on certain resources. The interactive manner of work and visual display through SVG DOM (Document Object Mode) frees the user completely of planner attribute input through table types of editing and setting of plans. The plan for unit resources is described in XML format, and later is recorded in the XML Data field of the relative database with the possibility of hybrid inquiries with SQL and Xquery types. As the SVG record is an XML derivate, these technologies fully complement one another with stressed content disengagement from its display.

The paper shows the method of creating resources with a standardization that later on makes possible semi-automatic planning in accordance with the phase type and resource. Three manners of importing jobs for planning are enabled: import from the WebPoskok work order base, loading from the planner template base and independent loading of a completely new job. Daily planning enables parallel display and work with all jobs and resources within one day with the possibility of resolving the bottlenecks created. In the Gant display the planner interactively and without strain builds in trap mechanisms for the job start and ending. The display is created dynamically from the software analysis of all the jobs in the database for the required time interval. These approaches are fully new in the planning process in general, and are developed primarily for the graphics industry where there are a great number of parallel workflows for completely different end products.

6. Reference

1. V. Žiljak, V. Šimovic, K. Pap:"Simulation of Stohastic System of Printing Procedures",The International Conference on Modeling and Simulating of Complex System, ICMSCS 2002, Chengdu, Sichuan, China

2. V. Žiljak, K. Pap, D. Agić, I. Žiljak:"Modelling and Simulation of Integration of Web system, Digital and Conventional Printing", 29th International Research Conference of IARIGAI, Lake of Lucerne, Switzerland, 2002

3. V. Žiljak, K. Pap, V. Šimovic:"The Simulation of Integrated Convencional and Digital Enterpreneurship System Models with The Financial Patameters ", 15th International Conference on Systems Research, Informatics and Cybernetics- INTERSYMP - best paper award, Baden-Baden, Germany, 2003, ISBN 953-99326-0-2

4. Žiljak, Vilko; Šimovic, Vladimir; Pap, Klaudio: ENTREPRENEURSHIP MODEL: PRINTING PROCESSES SIMULATION WITH TIMES AND PRICES IN THE BASE FOR NORMATIVE PROVISIONS,Announcing InterSymp2004,Baden-Baden,16th International Conference on Systems Research, Informatics and Cybernetics,Baden-Baden , Njemacka, 2004

5. Žiljak, Vilko; Šimovic, Vladimir; Pap, Klaudio: ORGANIZING DIGITAL NORMATIVE PROVISIONS AS THE BASE FOR SIMULATION OF THE POST-PRESS,5th EUROSIM Congress on Modelling and Simulation, Paris,2004