Above: The actual window sticker itself
During October 2003 we were approached to give estimates for a quantity of window stickers, which were required to be produced to a high standard, and to a controlled budget. The sticker itself was relatively simple, being produced with only a single solid line colour throughout, and with a fairly bold artwork content (not like the usual stuff then!). During the estimating process, various ideas for method of manufacture were investigated and either accepted or rejected on their individual strengths or weaknesses, until finally, the preferred method of production was decided upon.
This was ultimately to take the form of screen printing directly onto a clear self-cling window PVC, which would allow the design to be reproduced faithfully across the entire run. Our equipment allows us to plan works orders to take the utmost advantage of their size and speed capabilities, and in this case, that's exactly what we had to do! Using a full out sheet measuring 914 x 610mm, the pre-production department planned this enquiry to fill a sheet with a maximum of 112 images to view.
However, as the enquiry was taking shape, the quantity was beginning to grow like topsy. From the original amount required of some 25,000 pieces, the volume started to grow daily, until it had reached the magical 1 million mark. With price always an issue, we set about ensuring that our estimate was accurate, and would hold water if required to. It did, and within days we were in receipt of an order to produce the 1,000,000 window stickers required to fulfill the client's order.
With the amount of pre-planning that had gone into this enquiry, it was then only a matter of securing the necessary materials, making sure that there was space on the machines to be involved, and get it started! The entire order was completed in under two working weeks, with everything being produced to a very satisfactory standard. The longest part of the job for us? Packing the million pieces into the cartons when they had been finished to size.... this seemed to take an age, probably due to the fact that 1 million "somethings" is an awful lot to pack up when you have made them in multiple up fashion, and then have to pack them once they are in single format.
Overall, the end client was very happy, and we notched that job up as a successful 1 million parts produced on time and on budget!
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