21st Century Presented by: Shawn M. Delemeester Production - PowerPoint PPT Presentation

Automated Print Production for the 21st Century Presented by: Shawn M. Delemeester Production Director Valpak Direct Marketing Systems Inc.

Agenda  A Quick Company Overview  Project Background  RFP Process and Installation  Power Systems Criticality & Extreme Weather Preparedness  Importance of Maintenance Agreements

Valpak Manufacturing Video valpak3.mpg

Valpak Manufacturing Center St. Petersburg, Florida

Project Background – Why?  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 – What?  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 – How?  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 Initiation Timeline 2002 2003 2004 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

RFP Process Bidding vendors: Caterpillar, Cummins and Kohler Valpak provided a detailed: Valpak insisted on: • • Project overview One vendor per element • • Fulltime dedicated team Project scope – Project manager • Technical requirements – Engineering support • RFP description • Very “intense” design integration • Testing requirements prior to meetings shipping • Strong partnerships • Installation agreement – VP of higher level involvement – Commissioning & acceptance Why did we chose Caterpillar? They had the coolest hats!

Project Installation and Start Up Timeline 2004 2005 2006 2007 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

Installation Process  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

Building Completion Sequence

Extreme Weather Conditions   Tampa Bay are is the lighting Built the facility to withstand Cat capital of the United States. 4 Hurricane  Raised the ground level to 18ft  1.5 million strikes per year on above sea level avg.  Tilt slab construction with  Tampa Bay is ranked in the top maximum structural support ten for the most vulnerable  Reinforced roof connections, hurricane zones minimal roof clutter/penetrations  Collaborated with USF to  Hurricane Impact glass determine worst case scenario  Curtain Walls to protect exterior  Cat 5, mouth of Tampa Bay, equipment  Invested in redundancy where it Lunar high tide with Mars and made sense Venus in alignment  Power, Water, Control systems

Systems Projection Criticality  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

Caterpillar Power Systems  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

Importance of Maintenance Agreements  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!

Questions and Answers

For More Information: Speaker: Shawn_Delemeester@Valpak.com Home Page: http://www.coxtarget.com/vmc/index.jsp

THE END