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Otto Künnecke GmbH
The Smart Bureau Concept
The smart way to increase productivity and save costs in card production and
personalization
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OK - Smart Bureau
Integrated Concept for Intelligent Card Production and Higher Productivity
Otto Künnecke Innovation
...and the Smart way to solve them…
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Job size is getting smaller
5000
3000
7000past
100
15 12 30 8
78 50 20 5
4
today
Production time is shorter
1 week
past today 24 hours or less
day to day delivery time is getting standard
Problems of card issuance today
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New marketing needs
...of different kinds of inserts & envelopes...
...of carriers, cards and folding types...
...of sizes & layout...
...and positioning of cards.
Problems of card issuance today
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Difficult to handle jobs which consist of many different parameters :
9) Envelopes
1) Transport
2) Issuing type
3) Card body
4) Card encoding
5) Tape layer
6) Carrier
7) Carrier layout
8) Enclosuresenclosure
black/silver/gold tape layer
Embossing,
Problems of card issuance today
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Different machines Which are not working together, neither software, nor hardware
After each production step, the magazines have to be emptied and the cards have to be stored in card boxes to handle the cards forward to the next machine… all with different card magazines, therefore the handing-over of card magazines is not possible.
Additional problems
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The necessary production information is stored in different locations and in different data bases
Additional problems
Specific customer personalization data
Card numberIssuing date
Gottlieb Daimler
Rear indent
Product code Address
6.00am
10.00am
3.00pm
5.00pm
Production information data
enclosure
10.00am
Job specific dataProduct code
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enclosure
black silver card carriers 7 different enclosures delivery
Production is creating a lot of small batches for each customer job
2646 Data sets = 1 customer job
Customer input
54 production batches with an average of 49 cards
Production output
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Each variation creates a new batch
Origin Job-Nr
Sub-batch Nr
Batch size Card-ID 1
Tipping Colour Carrier ID 1 Insert ID 1 Insert ID 2 Insert ID 3 Insert ID 4
Envelope ID 1
Dispatch ID 2
Dispatch ID 3
456.345.23 Black 555.003.21 666.987.01 666.786.23 666.045.43 666.098.22 999.001.00 Express Post
BOF 001 BOF 001-01 34 x x x x x x x
BOF 001 BOF 001-02 56 x x x x x x x
BOF 001 BOF 001-03 33 x x x x x x x x
BOF 001 BOF 001-04 88 x x x x x x x
BOF 001 BOF 001-05 45 x x x x x x x
BOF 001 BOF 001-06 38 x x x x x x x
Every variety of products and personalization functions create a new
job.
enclosure
Even same products but different dispatch creates a new job
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1000
400 600
200 200 400 200
90 110 110 90 240 160 150 50
3456606060505040110130 807030208080
Job BOF 001-02: 56 cards
Vault Perso Mailing Dispatch
3 hours 3 hours 3 hours 3 hours
Vault Perso Mailing Dispatch
3 hours 3 hours 3 hours 3 hours
Each of these batches are running though the production:from vault to personalization to mailing to dispatch
Job BOF 001-01: 34 cards
Issuing type
Card body
Carrier
Inserts
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Very often cards have to be sorted by hand either for the next production step or for delivery reasons as assorted cards for
each branch
Cards have to be sorted for different reasons before and after personalization by hand;here for example by regional or branch offices.
Regional or branch office 1A
1A1B1C1D1E
1A1B1C
1D
1A1B1C1D
1E1E
1A1B1C1D1E
1A1B1C
1D
1E
1A1B1C1D1E
VISA blue
VISA silver
VISA goldMasterCard blueMasterCard silver
MasterCard gold
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Between each production step, the cards have to be inspected, sorted and counted. A lot of job instructions accompany each batchthrough the production.
CountingVerifying
Quality control
CountingVerifying
Quality control
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Very often, envelopes have to be sorted by hand for different sorting reasons, like sorting for branches or for mail-order companies
Job 1 Job 3
Input
Output
Job 2
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Actual production circle
Data preparation
1
Personalization
2
Mailing System3
Dispatch
4
Software
Software
Software
Software
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0
200
400
600
800
1000
1200
1400
1600
1 2 5 10 15 20 25 30
Overview of daily job sizes in most of the financial bureaus worldwide
Most of the job are smaller than 50 cards;Average worldwide : ≤ 20 cards
80 % of the daily card volume makes 20 % of daily work.20 % of the daily card volume makes 80 % of daily work .
Jobs
Cards per jobs
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0
2000
4000
6000
8000
Output
Job size
Output/h
Output productivity goes down
Cost per cards are getting higher
00,20,40,60,8
1
costspercard
Output/h
Costs per card
Summarized, the actual work flow in nearly all card personalizationbureaus creates a lot of inefficient small batches followed by a lot of manual work. This leads to:
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Solution?
OK - Smart BureauThe new way of intelligent card
production
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1) higher productivity Productivity %
0
10
20
30
40
50
60
70
80
90
5 10 20 30 40 50 70 100 250 1000
Job size
Target
2) lower costsCosts %
0
10
20
30
40
50
60
70
80
90
5 10 20 30 40 50 70 100 250 1000
Job size
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3) better overview and transparency
JOB ID= Card ID
Delivery data
Mailing-Data
Information for enclosures
one data base
Target
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4) better information all around the production
job-name
personalization 10.00am
mailing 12.00am
2.00pm
Target
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Production Flow without and with sorting
Vault Perso Mailing Dispatch
Vault Perso Mailing Dispatch
Workflow without sorting
Workflow with sorting
3 hours 3 hours 3 hours 3 hours
1 h 1 h 1 h 1 h
12 hours
4 hoursCISS CISS
Cardsorting
EISS EnvelopeSorting
today
tomorrow
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New production circle with intelligent sorting and inspection
Software
Mailing System
Data preparation1
CISS for pre-personalization2
Personalization3
CISS for sorting after personalization
4
5
EISS for envelope sorting
6
Dispatch 78
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1. Data preparation
Data preparation1
Open system for handling of different type of input data. Data acquisition to prepare input data according to production requirements.
Data
Input
Data acquisitionProduction job generation
Input data base-Input checking-Verification
machine data basePersonalization system
Production feed-back
LoggingLog files
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The Card Inspection Sorting System CISS is creating a controlled rainbow-deck by verifying the card body and encoding the magstripe. Each batch is using different card designs only based on the existing personalization modules of the personalization machines.
Embossing 3 lines, black tape layer, magstripe encoding, rear ident
2. Step creating of rainbow-deck cards for personalization
Card ID-No. 1564876
The card is personalized either with the card ID-no. or the complete ISO customer ID
CISS for pre-personalization
2
Customer ID 12345678912354Customer name Max Mustermann
Bank account 6454875
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By reading the magstripe information, the personalization system identifies the card and finishes the complete customarized personalization.
3. Step personalization of rainbow-deck cards
12
10000000022
1000000002410000000023
10000000025
1000000002710000000026
10000000028
1000000003010000000029
10000000021
10000000011
1000000001310000000012
10000000014
1000000001610000000015
10000000017
1000000001910000000018
10000000020
10000000030
1000000000210000000001
10000000003
1000000000510000000004
10000000006
1000000000810000000007
10000000009
Read back00009=045
00007=04500008=045
00006=045
00004=04500005=045
00003=045
00001=04500002=045
00010=045
00020=046
00018=04600019=046
00017=046
00015=04600016=046
00014=046
00012=04600013=046
00011=046
00030=047
00028=04700029=047
00027=047
00025=04700026=047
00024=047
00022=04700023=047
00021=047
20
Personalization3
Max Mustermann255468864
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4. Step after personalization the CISS is optimizing the next production step
Output
Input VISA gold silver blue
4CISS for sorting after
personalization
Test
CountingVerifying
InspectingSorting
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Output
5. The mailing system is using rainbow-decked cards. Due to the card information, the carriers and enclosures are selectivelyincluded in the mailing. Theoretically, each card is a separate job.
Different card position
5Mailing System
Different carriers with different
templates
Different enclosures
enclosure
Envelopes
Cards in rainbow-deck
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6. The Envelope Inspection and Sorting System EISS is identifying, verifying, printing and sorting the envelopes for different sorting criteria.
Conveyor 1 Conveyor 2 Conveyor 3
Job 1 Job 3
Input
Output
Job 2
6EISS for envelope sorting
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7. By using the intelligent functions of the Otto Künnecke Systems, the final sorting and packaging of cards or carriers is done automatically.
Envelopes branches
7Dispatch
Envelopes courierEnvelopes zip-code
San Francisco
New YorkLos Angeles
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The intelligent systems of OK verify, inspect and quality control can be carried out in each production step. Damaged or wrong cards could be identified and rejected before handling to the next production step.
1385921411110785barcode:1385921411110785mag.-stripe:
1385921411110785OCR:1385921411110785chip:
Bank & Insurance Inc.Logo card:
8
Verifying and inspection
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ID 54
The intelligent systems of OK can handle different card magazines, either from OK or other machine producers like Mühlbauer, Datacard, Ruhlamat. Each magazine can be transported from one machine to the next. By using the intelligent virtual inline magazine solution, each magazine stores the card information in the data base.
ID 54
ID 54 ID 54 ID 54
8
Virtual Inline
Virtual Inline Production
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8. Otto Künnecke software connects each machine with a network.
HOST
Input/Output Control for the whole production
8
Software
Rush / Pull
By using the DIALok Data and Logistic Center, card information can be used throughout the production. Rush / Pulls or double cards can be identified and taken out of the production. By storing the audit trail of each production step, a complete production profile of each card can be stored.
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8. By using the card info module of the Otto Künnecke software, all production information is transported via network to each machine.
Card ID: 20060123-3452678job-name: bank of the best 002Data Preparation: 6:32 amVault: 8:21Personalization: DC 9000 9:45 amMailing: Kuennecke 12:55 am
2:00 p.m.
8
Software
The operator is informed by each machine which products have to be used for each production step. The Information about the final layout of each product can be displayed throughout the production.
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Software
Data preparation
PersonalizationDispatch
1
37 8
Otto Künnecke Products
CISS for pre-personalizatio
n
2
CISS for sorting after
personalization
4
Mailing System
5
EISS for envelope sorting
6
