Printing, pre-press, publishing and photography services – yesterday, today and tomorrow

As an employer of 2,000 people, Blue Cross and Blue Shield of North Carolina provides a healthy working environment. It also takes extra care in making solid capital expenditures. The insurer recently took each of these interests into account when upgrading its in-house publishing capabilities.

A key part of the operation is print production. Through the years, computer operations has attempted to keep pace with increasing demands, especially for its most important subscriber document--policy booklets.

In 1987, the insurer began to realize the advantages of electronic publishing through the purchase of a Xerox 701 (publishing) system. Documents had been printed on a Xerox 4135 laser printer and finished as 5 1/2-inch by 8-inch saddle-stitched benefit booklets on a Macy binder located in the Blues' print shop across town. This process proved to be both time- and labor-intensive. Another issue was quality, since transporting the booklets presented potential risks. But perhaps the greatest concern was that the binder had to be hand-fed, one booklet at a time. Because of this repetitive motion, two employees developed carpal tunnel syndrome.

In 1992, Blue Cross and Blue Shield faced a double challenge: improving the booklet-making production while taking measures to help prevent employees from developing carpal tunnel syndrome. The insurer began investigating options for more advanced print finishing, seeking a flexible, state of-the-art system. It needed to enhance the production of saddle-stitched booklets, but was also considering future applications, such as corner- and side-stitching with taping.

After learning about a new integrated system used around-the-clock at Travelers Insurance in Hartford, Conn., the purchasing team went to observe the Standard Gunther IFS 2000 in action. Based on Travelers' experience, team members were impressed.

After much research and testing, Blue Cross and Blue Shield decided on the IFS 2000, the industry's first integrated print finishing system for post-laser processing. For the insurer, the system--with a combination of highspeed feeding, advanced document tracking and automated document finishing--would accept the precollated output of four high-speed laser printers (two Xerox 4135s and two 9790s). For optimum productivity, the IFS 2000 was set up as a stand-alone system. In its first six months of operation, the IFS 2000 produced 370,000 benefit booklets. This includes monthly averages of 70,000 benefit booklets and about 10,000 side-stitched and taped "preferred care doctor" books. There is capability for increased production, as well. The IFS 2000 can feed up to 30,000 sheets per hour and produce up to 2,400 finished documents per hour, regardless of the format. Although the insurer has not run it for maximum throughput, it has performed at about 98% efficiency.

According to Blue Cross and Blue Shield, the Data Center operates on three shifts, with nine people on each shift rotating various functions. With the new equipment, repetitive motions have been eliminated, reducing the chance an employee will develop carpal tunnel syndrome from work-related activities. A total of 27 people operate the machine, and the transition has been smooth. The insurer noted that operation of the sophisticated machine has been very simple. It requires only one operator at a time, and he or she is prepared to handle minor adjustments, if needed.

Accuracy is another advantage of the IFS 2000, an especially important feature for the insurance industry. The IFS 2000 maintains 100% document integrity through its patented bar code scanning technology, in which sequencing errors are identified before the documents are finished.

Thus far, the insurer has relied on the system's Optimal Mark Reading to verify cover checks and ensure that papers do not get out of sync. Soon, the insurer will begin to use bar code scanning. Additionally, the data center plans to increase its production of flat books and internal printing for corner stitching. According to the carrier, the system should double its present capacity by year's end.

Blue Cross and Blue Shield said its insureds are receiving documents with greater speed and efficiency than ever before, although the ultimate benefit of the IFS 2000 has yet to be realized.

The system is capable of multiple applications and long-run performance, and the insurer plans to enjoy the benefits of this healthy investment for years to come.

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