Company Overview
4over LLC is one of North America’s largest trade printers, operating nine facilities across the nation. Known for its vast selection of high-quality print products and its commitment to supporting print professionals, 4over operates in a demanding, gang-run, batch-production environment where quick turnaround times are essential to maintaining a competitive advantage.
The Challenge
In the fast-paced world of trade printing, productivity isn’t optional—it’s survival. As Joe Davis, VP Operations at 4over, puts it: “It’s like a big treadmill. It’s just getting tougher and tougher. We’re running faster, and we’ve got to perform on the same level.”
4over identified an important opportunity: gaining clear visibility into shop floor operations. Because production data was difficult to capture consistently, there were gaps in the available information, which Davis described as “a black hole where data didn’t go before.” Without real-time, accurate insights, the team found it challenging to:
- Accurately measure productivity and equipment utilization
- Clearly understand true job costs within their batch-production environment
- Track collective batches within their gang-run workflows
- Confidently make data-driven decisions about capacity and resource planning
- Move from estimates to precise, actionable production metrics
Recognizing this, the company set out to find a solution that would bring greater transparency across all facilities and empower teams with the insights needed to drive continuous improvement.
The Solution
After evaluating multiple systems, 4over selected SpencerMetrics for its strong reputation in the printing industry and recommendations from colleagues. “SpencerMetrics is known in the printing industry. They’ve got a good reputation,” Davis explains. “We looked at a couple of different systems, and this was definitely the one we felt the most comfortable with.”
4over implemented SpencerMetrics’ CONNECT system—a comprehensive shop-floor data-collection and productivity-enhancement platform. The system provides real-time machine data and production information, enabling the company to:
- Capture accurate productivity and utilization metrics
- Analyze equipment performance across facilities
- Conduct a detailed job costing analysis
- Track collective batches in their gang run environment
- Identify specific areas to target for productivity improvements
Implementation
The deployment proved remarkably efficient. From the initial meeting to having sensors installed on production equipment took just a couple of months. Davis credits the smooth rollout to strong collaboration: “The cooperation between Spencer and our IT department was seamless…everything worked really well.”
4over initially deployed CONNECT at two facilities, with plans to expand across its network.
A key component of the implementation was installing monitors throughout the shop floor to display real-time performance data. This visual approach has transformed employee awareness and engagement with productivity metrics.
Results and Benefits
Daily Operational Insights
The CONNECT system has become integral to 4over’s daily operations. “I begin each morning by reviewing the previous day’s productivity reports,” Davis explains. “They give me a clear picture of how each piece of equipment performed, and from there, I follow up on any questions that come up.”
Enhanced Analytics and Planning
Beyond daily monitoring, the system supports strategic decision-making. “Weekly, we run the analytics to see equipment utilization and capacity,” says Davis. “We’ve also been able to get into job costing analysis to understand tracking of a collective batch. It just gives us more data on where to target productivity.”
Shop Floor Visibility and Engagement
One of the most significant outcomes has been the cultural shift on the production floor. “Visibility has been huge for us,” Davis explains. “We’ve put monitors up throughout the shop, so everyone can see what’s happening. Employees are much more tuned in now.”
Data-Driven Decision Making
With CONNECT, 4over has moved from estimates to actual data for costs, consumables, time, materials used, and production efficiency. This shift enables the company to make informed, proactive decisions about shop-floor productivity and to better understand equipment utilization and capacity planning.
As Davis summarizes: “What’s measured is improved.”
Looking Ahead
Building on the success at their initial two facilities, 4over plans to continue expanding the SpencerMetrics CONNECT deployment across their network of nine locations. The partnership demonstrates how data-driven solutions can help trade printers meet the increasing demands of a competitive market while optimizing operations and controlling costs.
“SpencerMetrics’ solutions have provided us with deep, actionable insights into our production data, allowing us to analyze performance from multiple angles. We can now make informed, proactive decisions about shop floor productivity while gaining a clear understanding of equipment utilization and capacity needs. The result has been a significant improvement in how we manage productivity and overall operational efficiency.”
— Joe Davis, VP Operations, 4over LLC
