🇦🇺Australia

Production Downtime During Press Make-Ready

4 verified sources

Definition

Make-ready process requires clamping plates, adjusting ink density, aligning cylinders, and printing test sheets for quality inspection. This is non-revenue-generating machine time. At typical Australian print shop rates (AUD 200-400/hour per press), a single 1-hour make-ready represents AUD 200-400 in lost billable capacity.

Key Findings

  • Financial Impact: AUD 200-400 per make-ready cycle; typical shop with 5 presses and 8-12 job changeovers daily = AUD 8,000-48,000 weekly capacity loss
  • Frequency: Every job changeover; average 8-12 changeovers per press per day in commercial printing
  • Root Cause: Manual setup process inherent to offset lithography; lack of standardized quick-changeover methodology in most Australian printers

Why This Matters

The Pitch: Australian printing services waste 30-120 minutes per job on unproductive make-ready downtime. Modern automated systems (Edale CartonLine, Canon LabelStream) reduce setup time significantly, recovering 5-10 production hours per week per press.

Affected Stakeholders

Press operators, Print technicians, Production managers, Accountants (costing)

Deep Analysis (Premium)

Financial Impact

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Current Workarounds

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Methodology & Sources

Data collected via OSINT from regulatory filings, industry audits, and verified case studies.

Evidence Sources:

Related Business Risks

Material Waste in Make-Ready Sheets and Ink Setup

AUD 50-200 per make-ready cycle in scrap materials; 8-12 changeovers daily across 5-printer shop = AUD 2,000-9,600 weekly material waste

Underpriced or Unbilled Make-Ready Services

Estimated 2-5% revenue leakage on 30-50% of jobs; typical AUD 500k-2M print shop loses AUD 10,000-100,000 annually in underpriced make-ready

Approval Delay Bottleneck

AUD 40,000–80,000 annually per mid-size print operation (estimated 15-20% capacity loss on AUD 300K-500K monthly production revenue).

Rework and Reprint Costs from Unclear Revision Scope

AUD 15,000–35,000 annually per operation (5-8% of typical AUD 300K–500K monthly revenue; estimated 2–3 reprints per week at AUD 500–1,500 each).

Unbilled Proof and Revision Services

AUD 8,000–15,000 annually (estimated 2–4 unbilled revision rounds per week × AUD 150–300 labor cost per revision).

Customer Dissatisfaction from Manual Proof Workflows

AUD 20,000–45,000 annually in lost customer lifetime value (estimated 2–4% customer churn × AUD 5K–10K average customer lifetime value per print customer).

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