egsa - electrical generating systems association ... s10...building was built in 5 stages based upon...

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