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Moquin Press Breaks Its Own Printing World Record
Moquin Press printed 464,303 net sheets in 24 hours on a Heidelberg Speedmaster XL 106. A 90-day Lean program raised OEE from 42.8% to 48.8% without new equipment.
Moquin Press printed 464,303 net sheets in 24 hours on 60-lb. C1S label stock, setting a new production record on our Heidelberg Speedmaster XL 106.
We didn't get there with new equipment. We got there through a Lean Manufacturing overhaul of our pressroom: Kaizen (continuous improvement), SMED (faster changeovers), standardized work, visual management and real-time OEE (Overall Equipment Effectiveness) tracking. The goal was simple: eliminate micro-stoppages and variability, and turn shop-floor discipline directly into sheets per hour.
Breaking a record you already hold takes more than the equipment that got you there the first time. For us, "quality first, speed second" isn't a title to defend. It's something we re-earn every run.
Key facts at a glance
Record: 464,303 net sheets in 24 hours
Press: Heidelberg Speedmaster XL 106
Substrate: 60-lb. C1S label stock
Method: 90-day Lean program, no capital expenditure
Verifiedby: Heidelberg Performance Portal audit, and documented in an independent Kaizen Institute case study
What changed on the pressroom floor?
In 90 days (December 2025 to March 2026), the program raised OEE on our XL 106 from 42.8% to 48.8% and cut average makeready from 23 to 17 minutes, without buying new equipment or adding labor.
How did Lean Manufacturing increase our press output?
We ran about 12 changeovers a day across two 8-hour shifts,so makeready was our biggest opportunity to win back press time. A six-person team worked through five levers:
1. Kaizen(continuous improvement). We diagnosed losses with A3 problem solving, Ishikawa diagrams and 5 Whys. The root causes were micro-stoppages, long makereadies and inconsistent processes. We ranked fixes with a GUT matrix and tracked them in PDCA cycles with named owners and deadlines.
2. SMED(Single-Minute Exchange of Die). We video-timed full changeovers and moved 11 tasks off the press, including plate staging, ink-key presetting and wash-up kit prep. A pre-kitting station beside the delivery stages the next job's plates and color targets while the current job runs. That alone removed about 4 minutes of downtime per changeover.
3. Standardizedwork. Every changeover now follows the same 14-step sequence, so operator know-how lives in a documented standard instead of in individual heads.
4. Visualmanagement. A color-coded, laminated work standard is mounted on the press console, and 5S keeps tools and materials where crews expect them.
5. Real-timeOEE tracking. OEE moved from a separate report into the daily routine, reviewed in 15-minute stand ups, so the team sees availability, performance and quality losses as they happen.
What is OEE? OEE(Overall Equipment Effectiveness) measures how much of a machine's planned time produces good output. It multiplies availability × performance × quality. A higher OEE means fewer stops, faster running and less waste.
Independently audited and recognized
The record was verified through the Heidelberg Performance Portal in April 2026: the XL 106 ran at 99.45% of its nominal capacity with no critical failures recorded.
The Kaizen Institute documented the full program in its case study, Operational excellence in printing and packaging: the Moquin Press Lean case. The project was also recognized at the KAIZEN™ Awards North America 2026 in the Operational Breakthrough category.
The case study frames why this matters beyond our plant. Printing and packaging buyers want smaller, more varied orders, shorter lead times and more customization, all of which squeeze efficiency and margins. In that market, getting more from existing equipment, without capital investment, is a real competitive advantage.
What does a faster press mean for our customers?
More capacity on the same press means shorter lead times and more room for smaller, customized runs, with the same quality standard on every sheet.
Moquin Press has printed packaging, labels and commercial print since 1985 from Belmont, California, serving beauty, food, beverage and CPG brands across North America. Our managers are Six Sigma Yellow Belt certified and working toward Lean Practitioner certification, because this record is a baseline, not a finish line.
Quality first, speed second. We'll keep re-earning both.
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Frequently asked questions
How many sheets can a Heidelberg Speedmaster XL 106 print in 24 hours?
Moquin Press printed 464,303 net sheets in 24 hours on a Heidelberg Speedmaster XL 106 using 60-lb. C1S label stock.
What is SMED in printing?
SMED (Single-Minute Exchange of Die) is a Lean method that shortens changeovers by moving setup tasks off the press so they happen while the current job runs. At Moquin Press, SMED and standard work cut average makeready from 23 to 17 minutes.
How do you improve OEE on a printing press?
Reduce changeover time, eliminate micro-stoppages, standardize work and track OEE daily. Moquin Press raised OEE from 42.8% to 48.8% in 90 days with these steps.
Can a print shop increase capacity without buying new equipment?
Yes. Moquin Press reclaimed 312 press hours a year and added an estimated $1.69M in annualized revenue through Lean improvements, with no capital expenditure.
Where is Moquin Press located?
Moquin Press is headquartered in Belmont, California, and prints labels, packaging and commercial print for brands across North America.
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