Late Stage Customization - Business Review Webinars

The Final step in
Operational
Excellence
James
MacKenzie
Hapa AG
10.5.2012

Hapa’s Profile
A Globally Acting Company
_‘Just in time printing’ & ‘Late Stage
Customization’ solution provider
_Approved supplier to all Pharma
Multinationals
_HQ near Zurich, Switzerland
_150 employees worldwide
_Annual sales +/- € 40 Million
_Subsidiaries in US, UK, DE, IN, MX, BR & JP
_Member of the Coesia Group:

Our Core Segments
_Pharma
_Medical
_Consumer

Forms of packaging
Where can We Add Value for You?

Manufacturing & supply chain challenges
_Increased number of packaging variants
_Smaller batch sizes with frequent changeovers
_Lengthy changeover procedures and line clearance
_Packaging reconciliation
_Warehouse stock value reduction
_Minimum order sizes from packaging suppliers
_Fast time to the market with new and existing products
_Marking of unit dose blisters
_Implementation of anti counterfeit measures, like
serialised codes or printed covert security.

Manufacturing & supply chain challenges
_Implementation of Lean principles
_Focus on OEE improvement
_Reduction of costs
_EU directive on packaging waste
_Security and integrity of packaging

Poll 1
Does your organisation have to deal with small
production batches or high packaging complexity?
1. Production is around small volumes and complexity is high
2. Small, medium/large volume production, complexity is mixed
3. Only run large volume production so complexity is low
4. None of the above options fit our production.

On-Line printing increases flexibility
On demand printing technology from Hapa allows
easy addition of unit dose codes, or serialised data
for anti counterfeiting purposes.
Covert features such as RFID printing or invisible
codes are also possible
The trend toward small batch sizes has resulted in
a huge increase in SKU’s making stock control
very difficult to manage. On-line printing
eliminates this complexity since country or market
specific packaging can be printed at the last
moment on blank material. Furthermore, printed
stock is reduced to the minimum.

On-Line printing increases speed
Frequent line changeovers and lengthy line
clearance procedures result in poor utilisation of
production equipment. Hapa technology is able to
customize a product at the last moment ‘late stage
customization’ and add the final flexibility required
for your lean production process.
The internet is driving customers to expect
information and goods on demand. A newly
approved product can benefit greatly from a faster
release. With Hapa technology, you can produce
packaging when required and speed up your time
to market significantly.

On-Line printing reduces complexity
With frequent line changeovers comes the
necessity to reconcile packaging which is both
time consuming and costly. With On-Line printing,
the packaging material is blank and can be used
for multiple presentations. Auditing of suppliers is
also greatly reduced.
Suppliers of packaging materials have minimum
order size requirements. This can result in the
need to stock more material than you need. With
On-Line printing, you print exactly the amount
required. Small runs for marketing purposes are
easily accommodated.

On-Line printing reduces costs
Most businesses today are looking for
opportunities to reduce costs and improve
efficiency. Hapa is the perfect compliment in
helping you reach these targets. Switching from
pre printed to an On-line printed concept can
reduce costs by 80%.
The benefits associated with in line printing and
the low cost of ownership, quickly produce a return
on investment. A detailed ROI calculation can be
made in combination with a short questionnaire.

On-Line printing is secure and better
for the environment
Packaging security requirements are not new, but
with Hapa you take control of your security.
Packaging mix ups due to errors by your suppliers
are eliminated.
Meeting targets to reduce packaging waste is
difficult for companies with high packaging
complexity. With a Hapa, it is easy! Printing
packaging on demand means no inventory
obsolescence and no waste is produced. This is
good for our environment, reduces costs and
pleases shareholders.

Core Technologies
_UV flexo
_UV DOD InkJet
_Material control and handling
_Data processing

Integration Process
Inline or Near-to-line
Top mounted
Roll-to-Roll
Fully integrated printing Module
90 degree connection
Stand alone
Printing and Marking Module

CMYK label printing

Hapa UV Flexo blister foil printing
Hapa 230 T 1 color on Ima Giant

Flat Carton Printing
Flat cartons for use in
open top cartonners
Flat or glued cartons for
use on conventional
cartonner
_Print on blank or partially printed components
_Add braille digitally
_Use in combination with a converting unit

Folded Carton Printing

What is Late stage customization
_Late Stage Customization is the customization of
semi finished goods at the last moment before
shipment.
_In recent years, technology has become available
to print directly onto the packaging and this has
opened up new opportunities for example for
blister packs.

Conventional blister production
versus Late Stage Customization
Production time
Down time
Short runs concentrated one run
Increase capacity and utilisation

Late Stage Customization
Blister production
Storeage via large carton,
or BIB BOB concept
Warehousing of
blisters
‘Call off‘ in response
to orders
Cartoning
Customisation
De boxing

Ferring Switzerland

Hapa Engineering projects
_Hoffmann la Roche, Switzerland
_All packaging printed
on line from blank stock
_Label, carton and leaflet

Poll 2
Has your organisation implemented LEAN or
similar process improvement principals or does it
plan to do so?
1. Yes
2. No

Lean Focus on the elimination of waste in a process
Intellect
Any failure to fully utilize
the time and talents
of people
Overproduction
Producing too much, or
producing too soon
Transportation
Any nonessential
transport is waste
Motion
Any motion that does not
add value e.g. re-entering
same information more
than once
Rework
Correcting any errors or
doing completion steps not
done before
Processing
Over-processing, unnecessary
steps, signatures, reviews
Inventory
Any more than the minimum
to get the job done
Waiting
Waiting for an appointment,
for signatures, for a printer
that has a long queue

Summary of advantages 1/2
_Reduce complexity
_Simplify and streamline the complicated process of packaging
_Eliminate the need to purchase and handle pre printed materials
_Rapid response to orders
_Increase customer satisfaction
_Lower packaging material costs
_Unit cost is reduced and costs associated with minimum order sizes are eliminated
_Reduction of packaging material inventory
_No pre printed material held on stock
_Reduced finished goods inventory
_Produce on demand

Summary of advantages 2/2
_Waste reduction
_Print precise quantities of material according to the customers request and
manage artwork changes with ease
_Reduced obsolescence
_No pre printed material means no obsolescence
_Automatic reconciliation
_On demand printing results in zero reconciliation
_Improved security
_Artwork files and security remain in house
_Improved OEE
_Improved processes that effect the entire supply chain

Thank you
James MacKenzie
Commercial Director – Hapa AG
james.mackenzie@hapa.ch
www.hapa.ch