Quality Assurance of personalized print products and digital print services

As a global print partner, RPI is responsible for the fulfillment and shipping of the custom print products that consumers design through the platforms of our clients. The print products that we make and ship are personal objects. The consumers expect them on time and in pristine condition. We take this commitment very seriously and handle every product with care.

The procedures and measures we have developed and implemented in our production flow minimize the room for error and allow us to detect and correct errors before the product is shipped. Consequently, we maintain the quality and speed regardless of the volume our print facilities receive.

Every custom print product leaves our print facility for delivery in excellent condition and is shipped directly to the customer within the agreed time.

A production process that ensures consistent quality

Our facilities produce and ship thousands of photo books, cards, invitations, and wall decor daily. The production process itself prioritizes the quality of our print services. The data we analyze and the KPIs we set focus on continuous improvement. We carry out preventive maintenance to increase the reliability of our printers and machines. We make sure our employees are cross-trained for all the production stages, as we believe diversifying their work improves concentration.

Philosophy of constant improvement

Operational excellence is the goal we strive for. The philosophy of constant improvement is ingrained in our culture and defines our goals. We keep track and analyze our internal performance as well as external complaints to identify points of improvement and come up with practical and efficient solutions. As our product portfolio expands, we make sure that every product and every flow meets RPI standards. It is not something we do ad hoc but in a structured, systematic, and global process.

Batching

Batching is crucial to keep production efficient, but, at the same time, it reduces the risk of print errors. Every change of printer settings creates an opportunity for problems. By keeping the manual adjustments and changes to the necessary minimum, we print faster, better, and more efficiently.

Barcode Driven Production

A scan of a barcode corresponds to a stage of production, so the information in our system is an exact reflection of the production process. All irregularities are registered in the system, which allows us to take immediate action.

Barcodes contain information about the print product itself, the order the product belongs to, and its shipping details. Barcodes are essential to match book blocks with the correct covers, and to complete multi-item orders before shipping.

Optionally, we use removable sticker barcodes that leave no trace of the production process on the final product sent to the consumer.

Visual management

We make sure that the crucial information is visible and accessible at all times. The order forms we use at RPI are a reflection of how we apply visual checks and ensure both system and manual checks. Our orders are color-coded by their shipping day. This way we can actually see if all the orders for the day have been shipped.
Other information includes the type of order, color and location of the end sheets, thumbnails of the cover and first page, the number of books within an order, and much more. All this information allows us to keep track of the quality at every step of the process.

Visual management

Quality checks

While barcode plays a crucial role in quality assurance, we supplement and reinforce the process with visual checks. Quality control is implemented in our production flow, which means that every single product that we make undergoes multiple quality checks.

Print quality check Print operators check the batches they print for color, smudges, lines, and other typical issues. They also check if all the files from the batch are printed.
Intermediate quality checks At every stage within the flow, the operator takes responsibility and checks the quality of their job. As we are a print company, our procedures and quality standards are printed out and available at every stage of the production.
Final product quality control A comprehensive check before shipping ensures that the product has no quality issues. With the final scan of the barcode before shipping, a thumbnail of the product is displayed on the screen. It allows us to make sure that the order data corresponds to the actual product.
Pre-shipping check To prevent shipping incomplete orders that consist of multiple items, the barcode on each item of the order has to be scanned into the system. Additionally, all items have to be counted manually and the number entered into the system. If the number is correct, the order can be shipped.

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. This is the final check of a product before shipping.

 

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