SIX SIGMA & THE LEAN FACTORY

1. SIX SIGMA & THE LEAN FACTORY Approaches for Media Ingest and Processing Jörg Houpert & Rob Poretti Cube-Tec North America

2. Six Sigma & The Lean Factory What is Six Sigma? • A business management strategy employed to improve performance, value and reliability. • It produces these results by focusing on the elimination of defects – errors. • Six Sigma is a statistical term that defines to Six Standard Deviations – is 99.99966% or equating to 3.47 defects per million “opportunities”. • Tangible results: reduces costs through waste reduction, work flow efficiency gains, quality improvement, etc.

3. Six Sigma & The Lean Factory Six Sigma in an Archive… 3.47 defects / million “Opportunities” 100 Opportunities / Object 1,000,000 Objects = 100,000,000 Opportunities

4. Six Sigma & The Lean Factory Six Sigma in an Archive… • A relatively small amount of errors creates an unmanageable number of problems. • A factory approach produces tangible benefits: • Increases man-power efficiencies. • Minimizes the migration costs. • Quality control is improved. • The PrestoSpace project estimated substantial savings over the life-time of the digitization project. 100,000,000 1% = 1,000,000 0.1% = 100,000 0.01% = 10,000

5. Six Sigma & The Lean Factory What is a Lean Factory? • “Lean” is a strategy that focuses on the elimination of waste so that each step in a work flow process has maximum value. • In an archive facility, this optimization is used to • Maximize ingest time • Minimize errors • Automate processes • Supervise workflows • Provide real-time reporting systems

6. Six Sigma & The Lean Factory Lean Six Sigma Methodology in the Archive • “Lean Six Sigma” simply applies Lean Factory strategies in order to extract Six Sigma performance. • Define Workflows: a recursive process of measurement, analysis and then creating fault tolerant processes, is critical to minimizing errors. • Deploy Solutions: Decision support systems, real-time metrics, and automated processing are required.

7. Six Sigma & The Lean Factory Sound & Vision Overview • Sound & Vision – 700,000 hours of television, radio, music and film, Sound & Vision is one of the largest audio-visual archives in Europe. • Different collections / different formats: • Preservation standards. • Metadata requirements. • Storage spaces. • All collections are digitized in parallel.

8. Cube-Tec International – Technical Overview Sound & Vision - Ingest • The largest part of Sound & Vision’s aural heritage is currently stored on analog quarter-inch tapes and R-DAT cassettes. • Cube-Tec delivered 4 QUADRIGA workstations for the parallel ingest of material from 32 tape machines. • 16 Telefunken M15A reel-to-reel machines and 16 Sony DAT-Recorders are used for playback and controlled by four operators. • All the Telefunken machines were modified by Cube-Tec with the new universal Opto-Sensor hardware to detect and document torn tape, bad splices and separation tape with a time-code stamp.

9. Cube-Tec International – Technical Overview Sound & Vision –Automated Post Processing • In addition to the analog archive, there is also a backlog of nearly 30 terabytes of digital files that must be quality checked and missing technical metadata to be inserted. • As DOBBIN runs 24/7, undesignated processing time will be used to inspect the pre-digitized backlog. • Processing the backlog has become an automated job. Process rules are individually defined in the DOBBIN Rendering Farm to classify the technical quality of each file.

10. Cube-Tec International – Technical Overview Sound & Vision – Workflow Management • Cube-Tec and the audio digitizing team at Sound and Vision have developed a highly optimized workgroup solution based on Cube-Workflow. • Cube-Workflow is fully integrated with the existing IT infra-structure, which includes a cataloguing system and an external storage-provider (Technicolor). Cube-Workflow controls the QUADRIGA and DOBBIN audio and metadata process chain. • Cube-Workflow ensures that each member of the archive group has access to all necessary information available throughout the process - ensuring the best possible work. • Cube-Workflow streamlines the flow of work and detects and prevents operating errors. The project leader has a real-time detailed overview of the progress of the work and any special cases that have been flagged.

11. Six Sigma & The Lean Factory Cube-Tec Archiving Suite • Friendly, purpose-built digitization engine. • Import modules for popular legacy media formats. • Multiple stream ingest with integrated monitor. • Emphasis on audio quality and metadata. • Metadata driven workflow management & supervision software. • Import/Export XML metadata - web-service integration with Cube-Tec and 3rd party products. • Employs Business Process Model framework. • Scalable distributed batch processor. • Audio and metadata processing engine. • Simple graphical interface for creating workflow processes. • Powerful decision making. • Reporting • QUADRIGA • DOBBIN • CUBE WORKFLOW

12. Six Sigma & The Lean Factory Integration Legacy Database • QUADRIGA • DOBBIN • AUDIOCUBE • CUBE WORK-FLOW Asset Management System

13. Six Sigma & The Lean Factory Cube-Workflow • Fully integrated into existing IT infra-structures, including cataloguing systems and external storage systems… • A collaboration environment that supports structured/unstructured communication processes for definable roles through ad-hoc messaging. • Ensures that team members have access to all necessary information available throughout the work-process, streamlining workflows and error detection.

14. Six Sigma & The Lean Factory Custom Designed for your Facility • Cube Workflow connects to your DBMS or Asset Management System. • Underlying engine defined by Business Process Modeling. Easy to modify – easy to extend. • User interface uses internet client – easily customizable and updateable. Simplifies deployment and accessible via the internet.

15. Six Sigma & The Lean Factory Driven by Metadata • Cube Workflow automatically generates work-order processes for QUADRIGA and Dobbin systems. • Exchanges process service information with Dobbin and QUADRIGA. Process chains can be dynamic. • Supervises scheduled jobs and traces production issues using a bi-directional messaging system. • Time-line based statistical information can be viewed in the Cube-Workflow Dashboard.

16. Six Sigma & The Lean Factory QUADRIGA • Efficient, purpose-built ingest system. • One workstation can provide up to eight parallel ingest streams simultaneously. • Audio stream supervision and complete quality analysis. • Sophisticated transport and monitoring systems built for various media formats • Integrated workflows with Cube-Workflows and Dobbin.

17. Six Sigma & The Lean Factory QUADRIGA: State-of-the-Art Ingest Multi-Machine Recording Multi-Speed Recording Multi-Channel Recording Dual-Direction Multi-format Observation Integration File Security Automated Reports and Self Logging Scalable

18. Six Sigma & The Lean Factory Operator Managing 8 Parallel Ingest Streams

19. 64x Six Sigma & The Lean Factory Single Operator up to 64 Ingest Streams 16 Tape Decks under one operator control… 2x Speed + Simultaneous FWD/REV =

20. Six Sigma & The Lean Factory Dobbin: Automate. Anything. • Dobbin is a master of audio file and metadata automation. • A suite of software tools that allow for the creation of dynamic, adaptive, and automated processes. • Delegates processes to a powerful distributed processing engine. Easily scalable. • Generates metadata rich reports with live links to media assets. • Easy to use tools and the ultimate in flexibility. Drag n’ drop your workflows to connect processes using virtual audio, logic or metadata wiring. • Trigger jobs from file creation, file movement, metadata criteria, statistical analysis, external applications or manually.

21. Six Sigma & The Lean Factory The Dobbin Tool Set Content Analysis Automatic quality analysis for Analog and Digital errors. Complete logging. Processing Comprehensive re-mastering restoration and re-formatting tools. File Conversion Convert any PCM format. Integrate metadata for any supported format. File Security FSC , MD5, and SHA integrity tools. File-based & Psycho-Acoustic Correlators. Media File Encoding mp2/3, AAC, DD, DTS, AC3, WMA, etc. MXF, MPEG-2, MPEG-4, MPEG TS & PS. Utilities & Tools Complete logic tools. Integrates 3rd party applications and scripts. New Product Announcement: JPEG 2000 lossy and lossless profiles.

22. Six Sigma & The Lean Factory Create Powerful Workflows …Simply The Job Designer • Drag and drop your workflows. Connect processes using virtual audio, logic or metadata wiring. • Performs syntactic wiring check. Test newly created jobs with a single file. • Trigger jobs from file creation, file movement, metadata criteria, statistical analysis, external applications or manually.

23. Six Sigma & The Lean Factory Supervise Concurrent Jobs The Job Manager: • Real- time status of each job progress. • Re-prioritize job queue on-the-fly. Accurate job-time estimates. • Sorting and filtering of job list by any criteria. • Complete logging of all workflow processes. • Messaging service to Cube-Workflow for on-line updates

24. Six Sigma & The Lean Factory Automated Drill-Down Reporting The Result Viewer: • Complete reporting with drill-down capability and integrated waveform displays. • Sorting and intelligent filtering of all events. Events displayed on graphical timeline along with audio image. • Uses web technologies – available at any connected PC. Exchanges process service information with other Cube-Tec products.

25. Six Sigma & The Lean Factory View Your Results… and then Listen to Them! The Event Player: • Launch the BWF player from your web-page with integrated event list and waveform graphical display. • List can re-populate with any event-type and each item can be used to locate with pre-roll. • Built in sample-rate converter provides audio playback on any computer sound card.

26. Six Sigma & The Lean Factory Transform Your Data Report System: • XML reports are styled using XSLT. Templates are provided for viewing and printing. Easily customizable. • Reports can display a wide range of information and can include connection to external data. • Can be stored as intranet resource for archive group stakeholders. • Result Viewer, Event Player and Reports can be installed on any PC.

27. Six Sigma & The Lean Factory Build In Your Intelligence The Rule Editor: • A utility for creating rules used by modules performing decisions. • Completely integrates meta-data schema from the BWF and the complete Cube-Tec software suite. • Drag-and-Drop interface facilitates simple and error-free rule creation. • Rules are loaded and stored into a module from Job Designer. • Rules are the intelligence that drive dynamic and adaptive workflows.

28. Six Sigma & The Lean Factory Summary • There are to many opportunities for errors in a large archive • As we increase throughput by employing factory-type strategies – example: parallel ingest – the error opportunities are increased. • Supervision, automation, real-time reporting systems and clearly defined workflows are all required to minimize errors and improve quality control. • Cube-Tec Tools have been carefully developed to meet the challenges of Six Sigma Lean Factory preservation. • Lillyputtansversus workflow management systems.

29. Six Sigma & The Lean Factory • In a joint effort, Grass Valley and Cube-Tec have developed an interface between the K2 AppServer and the Dobbin Audio Rendering Farm. • This interface provides direct access to the audio tracks stored on K2, without the need to unwrap the MXF container first. • Result: a highly efficient read / write exchange for the audio essence. • Benefits: Dobbin’s rich set of audio processes are available Grass Valley customers.

30. Six Sigma & The Lean Factory Dobbin Video Dobbin Tools: • Encoders and decoders • Wrapping tools such as MXF • Video Analysis • Video Restoration

31. ? Thank-you! Jörg Houpert & Rob Poretti Cube-Tec North America

32. Jörg Houpert & Rob Poretti Cube-Tec North America