9.0   Collating

9.1 Collating Example:   Collate a booklet with Cover and Inside Pages using a 10-pocket collator. 

Specifications: Collate 1 cover signature and 6 inside pages signatures using a 10-pocket collator. Setup time is 30 minutes overall and 5 minutes per pocket. Running rate is 3000 collated signatures per hour with a 2% slowdown per pocket.

9.1A Shop Standards (Collator Example)

Figure 9.1-1

Collator Example, Standards, Postpress Process

Comments (Fig. 9.1-1):

1.  Costing Method: Finished Sheets.  Program will not recognize signatures if set to Final Product.

2.  10 pockets, 2% slowdown per pocket.

3.  30 minutes setup + 5 minutes per pocket

9.1B Estimating/Order Entry (Collator Example)

Figure 9.1-2

Collator Example, Estimating/Order Entry, Cover Layout

Figure 9.1-3

Collator Example, Estimating/Order Entry, Inside Pages Layout

Figure 9.1-4

Collator Example, Estimating/Order Entry, Postpress Process

Comment (Fig. 9.1-4):

Select Bind All Components option.

9.1C Estimating/Order Entry (Collator Example) – Analysis

Figure 9.1-5

Collator Example, Estimating/Order Entry, Analysis Report

Comments (Fig. 9.1-5):

1.  Production Qty = 10,000/100 x 7 sigs = 70,000.

3.  Run rate = 3000 x (100% - 7 pockets x 2% slowdown each) = 3000 x (86%) = 2580 collated booklets per hour.

4.  Setup time: 30 minutes + 7 x 5 minutes/pocket = 65 minutes = 1.0833 hours.

5.  Total time: 10,000/2580 = 3.8760 + 1.0833 = 4.9593 hours = 4.96 hrs.