Paper Roll OptimizationSystem
How we helped Darwill reduce paper waste by 35% through intelligent job splicing and automated roll optimization for their direct mail printing operations.
CLIENT
Darwill
Full-service direct mail and multi-channel marketing agency
TIMELINE
4 weeks
February 2024
TEAM SIZE
2 specialists
Full-stack specialists
The Challenge
Inefficient Paper Roll Usage
Darwill, a full-service agency offering direct mail and multi-channel marketing services with in-house printing capabilities, faced significant waste in their production process:
- One job per roll leaving significant unused paper
- No automated way to combine multiple jobs efficiently
- Difficulty identifying where one job ends and another begins
- Manual calculations prone to errors and inefficiency
Without automated job splicing capabilities, Darwill was printing one job per roll, leading to substantial paper waste and increased production costs.
Our Solution
An intelligent paper roll optimization and job splicing system
Smart Job Splicing
Automated algorithm that analyzes PDF job lengths in feet and intelligently combines multiple jobs to maximize roll utilization.
Roll Calculation Engine
Precise calculation system that determines optimal job combinations to achieve near-full roll usage while maintaining production efficiency.
Separator Template Generation
Automatic generation of templated separator PDFs that clearly indicate where each customer's job begins and ends on the combined roll.
Production Workflow Integration
Seamless integration with existing printing workflow, providing clear instructions for operators and quality control staff.
Implementation Process
A focused 4-week optimization deployment
Process Analysis
1 weekDetailed analysis of current printing workflow, roll specifications, and job measurement processes to understand optimization opportunities.
Algorithm Development
2 weeksDevelopment of roll calculation algorithms and job splicing logic optimized for Darwill's specific equipment and production requirements.
Integration & Testing
1 weekIntegration with existing systems, comprehensive testing with real production data, and operator training for seamless adoption.
Measurable Results
Significant improvements in material efficiency and cost reduction
Additional Benefits
Environmental Impact
Significant reduction in paper waste contributing to sustainability goals
Improved Quality Control
Clear separator templates eliminated confusion between different customer jobs
Streamlined Operations
Automated calculations reduced manual planning time and human error
Better Resource Planning
More accurate material forecasting and inventory management
Technologies Used
Cutting-edge tools and frameworks powering the solution
Python
JavaScript
PDF Processing
Algorithm Design
Web Interface
GitHub
"The roll calculation system has been a game-changer for our printing operations. We've dramatically reduced waste while improving our production efficiency. It's exactly what we needed to optimize our workflow."
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