Picture Gallery: Repro’s 28 days of quality showcase

Repro India celebrated its Printers’ Quality Month this February. The 28-day extravaganza was aimed to boost better understanding of internal supplier and customer processes and address the pain-points that hindered effective execution of book production workflow

Inaugurating the show, Repro's Rajaram Khose, AGM QA, said, "The objective of Printers Quality Month is to share and enhance knowledge of the employees on the shopfloor and increase the interaction among the people."

Each department was given a stall, and the task was to demonstrate the working of their department and boast about their achievements. The stalls were manned by the respective team under the guidance of their department heads

One of the pillars of this initiative, Repro's AGM-production, Vijay Jadhav inaugurating a stall

The engineering department is the backbone of Repro. In the picture, Mr Gaikar explains automatic reel changer modification project on Pressline Prima 508 press. The result was reduced paper wastage

Mission accomplished: 68mm spine book was perfect bound on Acoro A7. In a process re-engineering project, Acoro A7 was set beyond its maximum book thickness of 62mm for a specialised job

Stores official Pramod Shirke explains stores SOPs to his colleagues from sheetfed and binding divisions. Shirke informed: "We have 2000 tonne paper capacity and 150+ items in other raw materials (ORM) stores. The ORM stores is enhanced with 5S implementation"

The stall of web offset division showcased paperboard dummies of stack press and Harris M1000 press

The operator Jayesh Jagtap at the stall told PrintWeek India about how the team converted Harris M1000 heatset press to cold set, in-house

The web press is enabled with perforation facility before the folder in order to provide customised perforation sizes. The project was entirely handled by Repro's in-house team

The sheetfed stall boasted the record of 100 makereadies in a day (achieved on 16 August 2014) on its ISO 12647-2 (Fogra) certified Ryobi machine. This is perhaps the only one in India with Fogra certification

Repro's perfect binding journey: From 2500 books per day in 1995 to 1,50,000 books per day in 2010 when it installed Muller Martini Acoro

Flaunting the binding prowess - from wiro to spot glue to section sewing to perfect binding

Suresh Wadne told PrintWeek India about Repro's finishing capacity: section sewing capacity four lakh books per day, perfect binding capacity is 1.5 lakh books per day and centre-pinning capcity is two lakh books per day

Step-by-step: Binding process explained in detail

The logistics division is combined with packing and dispatch. It is also capable of kitting and hologram pasting. Pradeep Pansare said: "We ensure right quantity at right place. We also do Out of Box audit to ensure quality of final product

The digital stall showcased working of IBM Infoprint and Kodak Prosper 1000 inkjet press. Hrishikesh from digital division explained difference between toner-based and inkjet process. Lesson learnt: Arial serif fonts tend to fill up on toner-based presses, hence should be avoided

Repro's digital department has embarked on One Book project, which aims to provide as low as one copy of book printed on demand. For this the company is in process of collaborating with publishers and digital book stores

Among the series of tech-talks was the presentation by Mandalekar of National Center for Quality Management (NCQM) titled 'Total Quality Life'. "Correct attitude always leads to deliver excellence in work," said Mandlekar. This session was well appreciated by the staff and it was decided to extend it to all the employees batch-wise

Team Technova gave a crash course on Kaizen - a way of life. TechNova's Neeta Patil shared how TechNova reaps benefits of Kaizen style of working

Bottcher India team presented the intricacies of rubber roller manufacturing. The interactive session by Prabhat Kumar discussed how aromatic solvents are harmful for both human beings and the rollers. Bottcher tip: Use personal protective equipment PPEs while handling pressroom chemicals

Repro team learned print enhancement by screen printing from Mustafa of Colors. Repro has started adding value to its book covers through screen printing

Kiran Upasani of Perfect Graphics spoke about pressroom chemicals and troubleshooting. Take-away: Bharat DK, a sheetfed operator shared that he will now add Isopropyl Alcohol (IPA) while preparing fountain solution once temperature of chilling water reaches to 15 deg Cel. By doing so he will save at least two liters of IPA per day

Godrej Boyce team shared a case study of on Theory of Constraints (TOC) on Supply Chain Management and how the company reduced its inventory but still achieving higher customer satisfaction by providing spares at right time. through TOC

Paritosh Jha of Seigwerk gave profound insights on on ink technology

Men behind the extravaganza:(l-r) Rajaram Khose, AGM-QA; Vijay Jadhav, AGM-production; Dinesh Shah, GM-engineering and Yogesh Manjrekar, HOD-admin and human resources

Recently, Repro had organised a panel discussion amongst global leaders titled 'Your gateway to improved business' at Indian Habitat Centre in New Delhi