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.

• A Quick Company Overview
• Project Background
• RFP Process and Installation
• Power Systems Criticality & Extreme Weather

Preparedness

• Importance of Maintenance Agreements

Agenda

Valpak Manufacturing Video

valpak3.mpg

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

For More Information:

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

THE END