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Automated Print Production for the 21st Century
Presented by:
Shawn M. Delemeester
Production Director
Valpak Direct Marketing Systems Inc.
A Quick Company Overview
Project Background
RFP Process and Installation
Power Systems Criticality & Extreme Weather Preparedness
Importance of Maintenance Agreements
Agenda
Valpak Manufacturing Center
St. Petersburg, Florida
Two current plants at capacity, requiring non-value added processes.
Current technology had been in place for some time and expansion was limited.
Process was very manual and not scalable.
Business was booming in terms of more envelopes and number of coupons in each envelope – new business meant new staff, not improved efficiency.
Project Background – Why?
Build a completely new manufacturing process with all new equipment.
Consolidate our production operations at two existing plants into one new facility.
New facility to be built in St. Petersburg, FL to meet the company’s growth needs for next 10 to 20 years.
Project Background – What?
Established dedicated team to work on project
Traveled the world to visit installations of latest technology and equipment options
Developed a detailed product plan (charter)
High-level process design
Created a guiding manufacturing philosophy
Lean Manufacturing Principles
Industry-Proven Technologies
World-Class Partners
Core Manufacturing Concepts
Project Background – How?
1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q
Project Initiation
Technology Research
Project Scope Definition
Project Proposal
Project Approval
Site Selection
Announcement
Equipment Selection
2002 2003 2004
Project Initiation Timeline
Valpak provided a detailed:
• Project overview
• Project scope
• Technical requirements
• RFP description
• Testing requirements prior to shipping
• Installation agreement
– Commissioning & acceptance
Valpak insisted on:
• One vendor per element
• Fulltime dedicated team
– Project manager
– Engineering support
• Very “intense” design integration meetings
• Strong partnerships
– VP of higher level involvement
Why did we chose Caterpillar? They had the coolest hats!
RFP Process
Bidding vendors: Caterpillar, Cummins and Kohler
1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q 1Q 2Q 3Q 4Q
Announcement
Equipment Selection
Equipment Design/Mfg
Building Construction
Systems Development
Equipment Installation
Integration Testing
Work Instrs./Training Matls.
Train the Trainers
Employee Startup Training
Mock Production
2004 2005 2006 2007
Project Installation and Start Up
Timeline
Building was built in 5 stages Based upon timeline for equipment install
Each required power and A/C
Power systems and A/C
Temporary Gensets and A/C in Phase #1
Utility power and Chiller supplied A/C by Phase 2
Testing Show us it will work
Commissioning Show us it will work consistently
Acceptance Show us it will work to specification
Installation Process
Building Completion Sequence
Tampa Bay are is the lighting capital of the United States.
1.5 million strikes per year on avg.
Tampa Bay is ranked in the top ten for the most vulnerable hurricane zones
Collaborated with USF to determine worst case scenario
Cat 5, mouth of Tampa Bay, Lunar high tide with Mars and Venus in alignment
Built the facility to withstand Cat 4 Hurricane
Raised the ground level to 18ft above sea level
Tilt slab construction with maximum structural support
Reinforced roof connections, minimal roof clutter/penetrations
Hurricane Impact glass
Curtain Walls to protect exterior equipment
Invested in redundancy where it made sense
Power, Water, Control systems
Extreme Weather Conditions
Continuous process flow critical 24/6 Production Mon.-Sat.
Maintenance or Make-up on Sun.
All systems are computer controlled 18-20 different vendor systems
1 Middleware package (the router)
SAP our Business management software
Onsite Datacenter supports Valpak operations
Valpak franchise network
Data back up at Cox Atlanta
Business Continuity Plan is nearly impossible
Systems Projection Criticality
Cat 300 Series Flywheel Generator (UPS) 4 - 1200 kVA 2 - 300 kVA
Generator Sets 3 Model 3516B Diesel 2250kW Volts 480 Phase
3 Sound attenuated enclosures
Keeps the neighbors happy Protects the equipment
Paralleling and Switchgear 3 Paralleling Switchgear 2 Automatic Transfer Switches
Caterpillar Power Systems
Equipment “Bumper to Bumper” long-term service agreements on all
equipment
Monthly, Quarterly and Annual maintenance
Annual load bank testing
Genset Fuel (3@7,000 gallon tanks) Electronic fuel usage monitoring
Fuel tested and maintained by Caterpillar
One Throat to Choke!
Importance of Maintenance
Agreements
Questions and Answers
THE END
