Makeready

Makeready is the setup work before a press run — washing units, hanging plates, registering colours, ramping ink, and pulling test sheets until the job runs to specification. Makeready is non-billable time on the press, so reducing it per job is a direct margin lever.

Also called: press setup · make-ready · press makeready · job setup waste · makeready time

In depth

On a sheet-fed offset press, makeready typically takes 15 to 40 minutes depending on the number of colours, the stock change, and the operator. The press runs at a fraction of running speed while colour bars, density, and registration are dialled in against a target proof. Several hundred sheets of paper are pulled and discarded as "make-ready waste" before the job is declared on-colour.

Modern presses with closed-loop colour control (e.g. Heidelberg Prinect Inpress Control) cut makeready dramatically by measuring the printed sheet in real time and adjusting ink keys without operator intervention. JDF tickets pre-load the press with the job's ink profile, plate set, and run length, so the operator presses one button to start the makeready sequence.

In an MIS that costs jobs properly, makeready is captured as a separate cost line on the estimate — typically a fixed per-job charge that accounts for the time plus the wasted sheets. PeakSpitz AIERP exposes this as an editable setup-cost field per press, so the estimator can tune it to match what your shop actually experiences instead of trusting a vendor's default.

Common questions

How do I reduce makeready time?+
Three levers, in order of impact: (1) gang-run compatible jobs so one makeready covers multiple paying jobs; (2) standardise on a few stocks so the press isn't cleaned and re-inked between every job; (3) invest in closed-loop colour and JDF-driven setup so the operator dial-in is shortened.
Should makeready waste come out of margin or be billed?+
Best practice is to bill makeready explicitly as a setup fee, with the waste sheets included. Hiding it in run cost looks competitive on the quote but loses money on short runs. PeakSpitz AIERP defaults to an itemised setup line that the customer sees as part of a transparent price.

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