As remote operation becomes more widespread we ask manufacturers what they are doing in regards to printer diagnostics and other technological advances to keep devices running and help large-format PSPs operating lights off.
Remote diagnostics, better analytics, and of course automation, are the friends of any PSP wanting to reduce on-site, hands-on production time and expand lights-off operation. There’s a long way to go before that becomes anything like mainstream - if it ever will - but we’ve also come a long way in turning what was once a mere daydream into reality and systems manufacturers continue to build on that.
Rainer Ganter, product development manager at Fujifilm, says the company is currently doing a lot on remote diagnostics for instance, pointing out that “the Acuity Prime and Acuity Ultra R2 presses provide some excellent examples of our progress in this area.” Both have detailed analytics dashboard that splits data into three categories - for the operator, production manager and for Fujifilm. It means performance issues can be identified early and addressed remotely if needs be.
Ganter also points out that “the ability to remotely send and receive data - often through on-press cameras - is key in order to anticipate potential breakdowns, forecast whether any spare parts or inks are required, and be able to know exactly what needs to be addressed by engineers so that up-time is maximised and disruption kept to a minimum.”
“Automation is another critical aspect of lights off operation,” acknowledges Ganter, who believes that the labour requirements of wide-format PSPs and current recruitment challenges across the sector are going to drive even more investment in automation technologies.
“Automatic sheet feeders are one example, and another, which we are seeing more of, is the use of jumbo rolls - up to 800m long - which can be left on the machine to run. Not only does this speed up production, it lowers the carbon footprint, reduces waste and boosts efficiency. Fewer changeovers mean less need for human intervention - and the economies of scale can mean much more profitable work. Automated handling, including the use of robotics for pallet-to-pallet loading and unloading and the lifting of heavy rolls (up to 1 tonne) is speeding up production and reducing the need for human involvement.
“Ink refills ‘on the fly’ are also important here - maintaining constant production and ensuring that every machine is working as long as there is work for it to do. In fact, the seven-litre tanks found within the Acuity range ensure the efficiency of this process.
“Fujifilm is not yet at the point of total unattended lights off printing, but with every advance in remote diagnostics and handling automation, we are getting closer and closer. At Fujifilm we want to make our machines as productive as they can be, and continued development of remote diagnostics, automated two-way systems communication, and automated machine handling will all play a critical role,” says Ganter.
Jane Rixon, business development manager, HP Large Format, continues with the remote diagnostics theme.
“HP PrintOS is a print production operating system built into all modern HP large-format printers. As a free-of-charge software its usefulness might have been underestimated, however PrintOS can be accessed anywhere at any time, via the Web or the dedicated mobile app, making it an essential tool for diagnostics,” she says.
“Service partners can use PrintOS to have a real-time view of any issues on the machine and look at upcoming maintenance tasks. Error notifications are sent straight to users’ phones or computers, meaning users can see where and when materials or ink need replacing.
“With HP PrintOS Print Beat production managers can monitor the status of their machines at any number of sites, without having to physically be there. At a glance, they can see the proportion of the fleet that is printing, preparing to print, disconnected or suffering an error.
“Additionally, the HP Print OS Configuration Centre allows PSPs to easily monitor their printers in case of calibration needs or additional alignment of printheads. It also notifies the product manager if there is a new update for the firmware and has it ready to be installed when available. The printer can also report to the supplies partner to let them know when the inks or media is running low, so they can ship out replacements before they run out.”
Rixon continues: “With each update to our product portfolio, we strive to mitigate issues and ensure the user experience is as seamless as possible. We are heavily investing in improving our applications and tools to optimise and automate print operations with the ultimate goal to grow new business for PSPs. With HP Print OS and HP PrintOS Print Beat, HP Click and HP Smart Stream we make sure to offer PSPs the right tools in order to ensure a seamless printing experience.”
InkTec MD Joey Kim, flags up the company’s work on remote diagnostics too, saying: “Our use of virtual remote diagnostics has become more prevalent as the number of Jetrix printers installed both in the UK and across Europe has increased. As a result, InkTec is considering further investment in a more involved remote support diagnostic tool to enhance the existing remote access we have to the Jetrix GUI software. In addition, the software could enable both parties to review images, documents or print outs that are being discussed and shared as part of a video conference.”
He adds: “Offering remote support for our customers has always been part of our service. However, as we move forwards, the sophistication and depth of detail we now want to offer remotely means we are investing in even more superior technology. To achieve this, we have to expanded our team of Jetrix technicians as it makes no sense to have the infrastructure available without the people to actually offer that support. As a result of reducing the need for non-essential travel, means we can help more customers and contribute towards reduce our carbon emissions too.”
Duncan Smith, production direct sales director, Canon UK and Ireland, says it is also “focused strongly on automation technology through our R&D. This helps us to ensure that we are offering customers technology that will allow them to keep their production workflows running 24/7”. He points out that at Fespa Global earlier in the year Canon launched the Prisma XL Suite to support workflow automation, adding: “Our Prisma remote app enables unattended printing, allowing Colorado customers to run their printers overnight, see the status of their devices and receive alerts about any errors or warnings via their smartphone or tablet.
“Through Prismaservice our engineers are able to remotely collect, analyse and evaluate print data to help maximise uptime at the customer’s site. We also work with One Vision to support large-format PSPs or print factories that receive daily print jobs from multiple sources.
Smith highlights too: “We work closely with technology partners such as Zund and Fotoba so that we’re able to provide complete end-to-end solutions that will help allow 24/7 production 365 days a year - one result of that collaboration being the UVgel Wallpaper Factory, which provides a fully automated solution for print factories that specialise in digital wallpaper production. The entire production process is supported from printing to shipment, offering maximum output whilst maintaining flexibility in finishing options.”
At Roland DG Peter Waelkens, product manager software, acknowledges the increase in remote working seen across many industries over the last couple of years, saying that “print shops have adjusted their processes and workflows and, alongside Teams and Zoom, have also leveraged remote repair, maintenance and printing functionality that - until Covid-19 - was a largely under-utilised feature set. This includes remote VPN logins, hot folders in Rip software as well as tools like Roland DG’s OnSupport which allows users to quickly access machine usage metrics, firmware updates and product information through a PC or smartphone.”
He enthuses: “Within Roland we see great benefits of bringing devices online so have developed a cloud-based service, Roland DG Connect, which allows users to monitor the print status while away from office. When partnered with a compatible device (currently select TrueVis and VersaUV models) Roland DG can help solve or prevent many of technical issues which can slow down or halt production.
“The software, available on mobile or desktop, can monitor printer status and condition - recognising patterns in production and printer state to identify potential problems before they happen. It can also send notification of when key maintenance should be performed and give an overall health status of the connected device. What’s more, through Roland DG Connect users can grant their authorised dealer access to their machine, who can monitor and analyse online the machine’s status and even plan pro-active support based upon the collected information, keeping the machines online for longer.”
Waelkens also points to other features found on Roland printers to aid PSPs aiming for lights off operation, such as the adjustable take-up unit included as standard on the TrueVis VG3, plus an optional new dryer/blower to support media drying for TUC even in high-speed mode, allowing for long runs with a controlled print length to be left unattended. Moreover, when the take up unit is combined with the printers Perfcut and separation cut functions, the post-print finishing process is minimalised.
“In the future, we expect to see more manufacturers offering additional smart device integrations to offer services such as help and support directly from the printing device screen or remotely via an app rather than calling a helpline, prompts to order supplies allowing PSPs to minimise stock and ensure they never run out of key materials even when not on-site - and voice control, which will allow them to talk to their printer like you do with domestic smart devices,” adds Waelkens.