Quality mindset for the production of personalized print products

RPI is responsible for the print and fulfillment of custom products designed through the platforms of our clients. We print, produce, and ship products of high personal value for consumers. They expect a high-quality product in pristine condition. We take this commitment very seriously and foster a quality mindset across the company.

Philosophy of constant improvement

We work towards operational excellence through a continuous, structured, and global process. Constant improvement defines our goals and day-to-day activities. With KPIs, we track our internal performance and analyze external complaints to identify improvement areas and develop pragmatic lasting solutions.

Philosophy of constant improvement

Open culture

The production process itself prioritizes the quality of our print services, but it depends on the experience and commitment of our employees. Because we rely on them to make the products and take responsibility for the quality of their work, we invest in their training and foster a culture of open communication and trust. We cross-train our employees for all production stages, as we believe that task diversity improves their work experience and results.

Open culture

Batching

Machines tend to run best when uninterrupted. Every change in the settings increases the risk of mistakes or malfunctions. Because we print a range of highly personalized products, we cannot eliminate adjustments in our process, but we keep them to a minimum by batching. We batch unique print products according to shared specifications - dimension, paper, and type of finish - and print them together in one uninterrupted run.

Batching

Barcode Driven Production

Barcodes contain information about the print product itself, the order the product belongs to, and its shipping details. Every production stage corresponds and depends on a proper scan of the correct barcode, so the information in our system is an exact reflection of the production process. Barcodes are essential to match book blocks with covers and complete multi-item orders before shipping. We work with barcodes printed on the cover or removable sticker barcodes.

Barcode Driven Production

Visual management

We make sure that the crucial information about the product is visible and accessible at all times. The order forms or job tickets we use at RPI allow for both system and manual checks. The forms are color-coded by their shipping day. Other information includes the type of order (single or multi-item order), color and location of the end sheets (for hardcover photo books), thumbnails of the cover and first page, and the number of items within an order. All this information allows us to perform a visual quality check every step of the process.

Visual management

Quality checks

Our automated production flow minimizes the room for error. Manual quality checks are an integral part of the process and allow us to detect the remaining mistakes and correct them before shipping. Consequently, we maintain the quality and speed of production regardless of the volume our print facilities receive. Every custom print order leaves our print facility in excellent condition and within the agreed timeframe.

Print quality check Print operators check the batches for color, smudges, lines, and other typical print issues. They also check if the batch is complete, with all the files printed out.
Intermediate quality checks At every stage of the production process, the operator takes responsibility for the quality of their job. They follow the instructions displayed at every workstation and perform a visual inspection of each product after completing their task.
Final product quality control A comprehensive check before shipping ensures that the product has no quality issues. The operator checks the product against the product thumbnail, which shows on the screen with the final scan of the product barcode.
Pre-shipping check Our system ensures that we don't ship incomplete multi-item orders before the barcode on each item is scanned. Additionally, we count all items and enter the amount manually. If the number is correct, the order gets the green light in the system and is ready for shipping.

Final photo book quality check

To ensure the quality of our custom print products we carry out multiple visual quality checks throughout the production flow using our order forms or job tickets. This is the final check of a photo book before shipping.

 

Are you looking for a print partner you can trust?

If your business is looking for a reliable print partner, get in touch. We are always happy to discuss new exciting print-on-demand projects.

Send us a message