N.K.O.T.P. - New Kids on the Press

BACKSTORY

I've done it again. Moved. Left home. Once again, I'm chasing change.

I am a firm believer that frequent change heightens and diversifies what we know, and how we learn. Spaces and faces change. We emerge from each new experience, changed. Moved.

I beg to be moved, for "The greatest thing in this world is not so much where we stand, but the direction in which we are moving" (Oliver Wendell Holmes, Jr.) Movement breeds opportunity.

I recognized an unlikely opportunity in the printing industry during my final Fall quarter at the University of California, Irvine, where I recently graduated with a major in English, and a minor in Management. The Consolidated Graphics (CGX) approach won me over: the company's Leadership Development Program (LDP) promised to teach me everything about printing from the ground up, expose me to all aspects of the business, and let me choose my career path from there.

And so begins my three-year rotational experience with Consolidated Graphics, specifically at Watermark Press, located in San Francisco, California.

I started on Monday, Martin Luther King Jr. Day, with Ian Shaw, a California Polytechnic State University (Cal Poly San Luis Obispo) graduate in Graphic Communications, which is essentially a printing major. It helps that we're starting along side of each other. I really value his expertise, and his frequently uttered school motto, "learn by doing." Ian, who I affectionately call Twinsy, does his best to help answer some of my printing questions. In addition, he motivates me with his encouragement, and humors me when I tell my lame brand of jokes. Excellent!

We are only the second and third Associates going through Watermark Press' LDP. The first is Herman Kung, a fellow UC Irvine Anteater, who has been here for about one year. We go to him for guidance, as well as the new company president, Jerry Hogan, and Matt Heroux, a graduate of the LDP. We're still feeling the program out, and experimenting with scheduling, giving Ian and myself every opportunity to shape our experience in definitive new ways. Already, we've made efforts to make our first job out of college unique, fun, and personally valuable. In just one week, I've learned so much, as you will soon find out...

Week One at Watermark Press:

MONDAY, January 19th -

• Tour the local area (Potrero Hill manufacturing district) with Matt and Herman.
• Scope out rival print shops and approach with competitive zeal (smile and wave in their outdoor security cameras).
• Uncover hidden food sources in the nearby buildings.
• Tour Watermark Press: Sales, Pressroom, Bindery, Pre-press, Accounting, Planning
  
• Go over scheduling with Herman
• Lunch at Serpentine with Matt, Herman, and Jerry
  
• Introduction to Digital (Pre-)Press with Oscar Canada
• Definitions: gutter, bleed
  
• Spend some quality time getting to know Oscar, who gave me pointers to understanding the craft of printing as a team and communication heavy endeavor, and advice for effective learning (go slow, ask questions, verify, repeat, and gain confidence.)

TUESDAY, January 20th -

• Introduction to Pre-Press and Production Work Flow with Jim Jordan
• The Cycle of Dockets
• Importance of file management with Tim Lindner
• Change Order Process and Trouble Shooting (ghosting, gutter)
• Definitions: Densitometer, Spectrophotometer, Colorometer
• Prinergy Program
• TIF (Raster Graphics) vs. EPS (Vector Graphics)
• RGB, CMYK, LPI (dots/square inch)
• Definitions: #-up, signature, folio, imposition
  
• Resolution/color integrity across different technology
  
• Integris Proofing
• Review color, pagination (folding/page ordering), layout, head-/foot-trims
  
• The overall proofing process (Pre-Press and Imposition Check Lists, Rule Outs)
  
• Pre-Press Suggestions: Redraft the Docket layout, because the sheet and its instructions could stand to be more specific and direct. It is also a bit hard on the eyes to read as it is. Standards as to how to fill it out properly should be re-taught to all affected departments and employees. Another suggestion is that sales be involved in proofing as well.
• Employee paperwork with John Morris
• Spectrum Proofing with Oscar

WEDNESDAY, January 21st -

• Fun Facts of the Day: Ice cream truck music plays when the machines are setting up plates! Presses are frequently referred to as animals or "beasts" (diet: paper and ink).
  
• Introduction to Heidelberg/Kimori Presses
• Definitions: registration, gripper, side guide
• Heidelberg 640: Bare Essentials job
  
• Make Ready Process with Tony Clem and Pavel "Paul" Tartakavskiy (feeder/positioner)
  
• Heidelberg Console/Control Center Overview
  
• Ink Chemical Usage Form tutorial with Paul
• Kimori 840: U.S. Mint job
• Make Ready Process with Craig Davis and David (feeder/positioner)
  
• Definitions: perfecting, skids (wooden crates/pounds)
• Chat with Craig and David about printing histories, and Watermark Press history
  
• Brief introduction to Shipping with Larry Minetti
• Shipping done by Echo, Pioneer Express, Fed Ex, Sam
  
• Build dummy for Judith McKim
• Intro to CGX/LDP with Herman and Matt
• Brief overview of CGX Solutions with Matt

THURSDAY, January 22nd -

• Ask Craig (Kimori) a question about coated paper supposedly drying faster (contrary to a book I borrowed from Ian, which states that uncoated paper dries faster)
  
• Bindery Overview with Larry Bilsky
• Tour of cutter, folders, Roll-em, and saddle-stitcher (Muller Martini)
• Definitions: scores/collars, perfing
  
• "Learn-By-Doing": load stitcher pockets for the Audi job and Chuck Sayavong
  
• Help Accounting with invoice filing: learn major Watermark Press/CGX accounts
• Major Paper Accounts: Spicers, XpedX, and Unisource
  

FRIDAY, January 23rd -

• Introduction to Estimating with Matt Heroux and Herman Kung
  
• Project suggestion: help Herman investigate potential courier options (bike messengers?) who would offer affordable services in the nearby area (and keep costs low!)
  
• Estimating work flow, including price adjustments
  
• Brief introduction to PSI Program
  
• DM - direct manufacturing cost
• AI - all inclusive cost
  
• VA - value added
• FOB - freight on board
• M - 1000, and C - 100
  
• Introduction to Production Planning with Kystine Gauthier
  
• Project flow revisited
• Scheduling and purchasing materials (purchase orders)
  
• Planning a Work and Turn job
• Proofreading business cards
  
• Definitions: parent sheet (paper), wash-up, sheetwise, Dylux (2-sided Integris)
• Finishing options: die/fold/glue (Apex Die and Glue, Nickelson and Foil), imprinting (Murphy's), mass inkjet mailers (Accurate Mailings), perfing and embossing (letter press)
  
• Navigating an estimate print-out with Ian and Herman

That concludes Week One on the job. I'll be moving right along, continuing to learn as thoroughly as I can. I shall resume my copious note-taking, and curious inquiries in the morning.

This week I'll be O.P.P. (yeah, you know me!): On Pre-Press, that is.