 
Background
Operating year round in a print shop below the Corpus Christi Educational Service Center, this in-plant printer produces teachers' training manuals and workshop handbooks for the center's eight educational departments. The in-plant printer also serves 42 other Texas school districts on a project basis, sometimes juggling seven to ten projects simultaneously. Two full-time operators service the print shop eight hours a day. The in-plant printer hires additional temporary employees for special projects or for seasonal production increases, particularly in September when school is back in session.
Challenge
When classes resume for the school year, the in-plant printer experiences a huge spike in demand for documents that contain new class schedules and curriculum information. Although the bulk of the content for these documents is revised during the summer months, due to late-breaking information, the schedules are finalized only a short time before the school year begins.
To meet this periodic surge in demand, the Educational Service Center's in-plant printer wanted to find a binding system that could improve productivity and reliability during periods of heavy, frequent use. It also wanted to improve productivity and reliability year round: the three comb binding machines the in-plant printer used required punching holes in paper before binding a document and then feeding the binder section by section. This process took too much time and labor to complete large-run document finishing projects -and often required more than one attempt, making it unreliable. Losing time and money due to the slow comb binding method increased overtime costs and frustrated customers because of output delays.
Solution
One day in 1999, Sales and Technical Representative Chip Sturchio of PDP Systems' San Antonio office made an unscheduled visit to the in-plant printer. He presented sample books bound on various models of the Fastback® binding system. Unaware that such professional looking documents were achievable with a desktop binder, the in-plant printer agreed to let Chip bring a Fastback Model® 15x into the shop for a demo. Impressed, the in-plant printer asked Chip to leave the Fastback binding system behind for a two-week trial.
The in-plant printer happened to be in the middle of a 250-book (85 sheets each) binding project and convinced the customer to switch from comb binding to the new Fastback binding system with just one look at its superior finishing capabilities. When the project was complete, the in-plant printer decided to keep the Fastback Model 15x. Two years later it upgraded to a Fastback® Model 15xs binder, purchased a second Fastback® Model 15xs and one PowisPrinter®.
The Fastback binding system easily solves the in-plant printer's productivity problems. Says Print Shop Supervisor Roland Perez, Jr., "The Fastback Model 15xs combines faster binding with the quality results assured by a thermal binding process. Its one-button operation, compared to the multi-step, comb binding method, liberates my partner and me. We are free to create a variety of document styles using Fastback binding choices such as wraparound covers bound entirely to a book block's spine or spines that lay flat when open."
The Fastback binding system solves the in-plant printer's need for assured reliability thanks to new features that insure better strip alignment, eliminate misfeeds and improve menu display.
Results
The Fastback binding system minimizes overtime costs and the need for additional staff, even during the high-demand season. Says Roland, "I count on the Fastback binding system to take care of my customers and meet their deadlines. With the tape binding strips, we can produce a large number of books fast with no waste (30-45 seconds per book, depending on size). Before the Fastback binding system, it took us an entire day just to punch holes in 150 sheets."
That's why the in-plant printer auctioned off its three comb binders long ago. Roland says, "It's nice to know that when we get an order for 5,000 bound books that are due in two weeks, my staff and I won't have to spend weekends making sure the job gets done on time. Fortunately, once an educational department or school district agrees to switch from comb binding and start using the Fastback binding system, they never want to go back."
Roland originally wanted to purchase the Fastback binding system for speed. He was surprised that it also turned out to be extraordinarily cost-effective. He cites an example, "Since the Fastback binding system requires no hole punching before binding, we no longer have to stock pre-punched paper for the fast-turnaround jobs. That factor alone frees up money that would otherwise be tied up in labor, inventory and storage space. By reducing production steps - by simply pushing a button - our customers are more satisfied with us; we have not received one complaint since 1999. Cost is always the first priority to our customers in the education field, and those who shop around at various copy shops always choose us."
Crediting the Fastback binding system for improving production 70% and lowering costs 50% every year since it was installed, Roland is also pleased that it allows him to offer customers customized books and documents. One example: the in-plant printer produces the Educational Service Center's bimonthly Board of Education Report which consistently features a teal strip and dark blue vinyl cover with a window to distinguish it and foil titled and dated spines for reference.
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