Rejected Book Replacement on Binding Line

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Rejected personalized books pose a challenge in the printing industry due to difficulties in regenerating identical pre-personalized books, especially when they contain personalized information or indicia, making it hard to replace them efficiently.

Innovation Solution

A method is introduced to generate a mailing list of recipients, assemble pre-personalized books on a binding line, identify and replace rejected books with alternate pieces, which can be either reprinted pre-personalized items or generic books, maintaining the mailing order and ensuring minimal disruption in the printing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If pre-personalized books are assembled on the binding line, then customization and recipient-specific content are achieved, but rejected books cannot be easily regenerated

Engineering Contradiction:

Improvepersonalization capabilityVSAvoidregeneration difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The system performs preliminary actions by pre-personalizing books before binding and maintaining a record of personalized content. When rejection occurs, the pre-personalized content can be quickly reapplied to a replacement book, avoiding the need to regenerate personalization from scratch

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention creates a copy or duplicate of the rejected book using the stored personalization data. The system retrieves the recipient information and book content specifications, then produces a replacement book that replicates the original personalized book without requiring complete regeneration

Inventive Principle:

Principle #26Copying

2Productivity

If rejected books are replaced with generic books, then mailing order is maintained, but customization is lost

Engineering Contradiction:

Improvemailing efficiencyVSAvoidpersonalization

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

Personalization data is prepared and stored in advance for each recipient in the mailing list. When a book is rejected, the system can immediately retrieve the pre-prepared personalization data and apply it to a replacement book, maintaining both mailing order and customization

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements feedback by tracking which books are rejected and why, then using this information to quickly regenerate appropriate personalized replacements. The feedback loop ensures that replacement books receive the correct personalization data corresponding to their intended recipient

Inventive Principle:

Principle #23Feedback

3Reliability

If rejected books are regenerated with identical personalization, then recipient satisfaction is maintained, but production time increases

Engineering Contradiction:

Improverecipient satisfactionVSAvoidregeneration time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

All personalization information is prepared and stored in advance for each recipient. When regeneration is needed, the system simply retrieves and applies the pre-prepared data rather than creating personalization from scratch, dramatically reducing regeneration time while maintaining identical personalization

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system creates a copy of the original personalized book by retrieving the stored personalization data and applying it to a replacement book. This copying process is much faster than original personalization while ensuring the replacement is identical to what the recipient should receive

Inventive Principle:

Principle #26Copying

Data Source

PatentUS8393843B2Printed product binding method

Publication Date: 2013.03.12 QUAD GRAPHICS INC

AI summary

The invention relates to a method for replacing a rejected book on a binding line.