The Optimizer Brings Order to Chaos
As a product manager for workflow solutions, I’m often asked which feature in Connex LineControl impresses me most personally. And each time, my answer is the Optimizer. Not because it runs especially quietly, but because it does exactly what modern production today requires, all in the background: It brings order to chaos – intelligently.
How it all begins: Jobs from the ERP
Many of our customers work with a central ERP system, which generates the production jobs. These jobs come in a wide range of formats, sizes, and variants. And this is where the magic happens: transforming this variety into a smart, efficient workflow.
Production order: Optimized, not improvised
What fascinates me most about the Optimizer is its ability to take sorted jobs and create a truly intelligent sequence. Based on criteria that we define together with the customer – from priorities to machine-specific requirements.
The benefits are immediately noticeable in practice:
- Finishing requires significantly fewer changeovers.
- Downtimes are reduced, as the machine remains in the optimal setup for longer.
- Productive machine uptime increases noticeably.
Important or urgent jobs can be prioritized and automatically moved up in the queue.
For me, that is one moment where software suddenly reduces real stress.
Here’s an example:
1. Sorting by paper type
First, all jobs are grouped by the paper type used. This sounds simple, but saves an enormous amount of changeovers. Once the machine is prepared for one paper type, it can run without requiring constant adjustments
2. Sorting by format
In step two, the jobs are sorted by their format. A4 with A4, A5 with A5. Changing formats especially results in otherwise unnecessary downtime, which is exactly what we are looking to avoid
3. Sorting by product or spine thickness
Finally, the jobs are sorted by the thickness of the end product. This helps ensure that finishing processes, such as binding, run smoothly and without disruptions.
These three steps form the basis for a production sequence that is not only logical, but also measurably more efficient.
Maximized resource utilization
The Optimizer not only groups jobs. It also considers the entire production chain. For example, it optimizes production types such as inline/nearline or softcover and hardcover production on the same line, such as the Antaro Digital perfect binder. It ensures that the cover and content are placed and produced in the correct order, and synchronizes everything with finishing. This prevents waiting times, misprints, and unnecessary paper changes.
Automatic transmission of jobs to the digital printing press
Another feature that I particularly appreciate: In combination with LineControl, the Optimizer can start production automatically as soon as a defined trigger has been reached. This could include:
- A fully prepared roll,
- A defined starting time
- A manual start signal by the operator.
This makes production more predictable and flexible.
Special case: Maximizing the utilization of wide rolls or single sheets
For digital printing presses with wide webs (roll and sheet solutions), we’ve developed quite the clever solution. With the Optimizer, two or more jobs can be placed next to one another on a predefined printing frame. This:
- maximizes the utilization of the paper roll
- minimizes the number of empty pages
- arranges jobs so that the webs (two or more) run optimally.
I admit: This feature is one of my personal highlights. It shows just how much potential lies in intelligent software.
Across the world, numerous customers are already using the Optimizer. And the feedback is clear: It’s an extremely powerful tool for the digital workflow in print production.
Curious? I’d be happy to explain the benefits the Optimizer can bring to your operations.
Best regards,
Fabian Becker
Product Manager Workflow Connex
