Milwaukee Journal Sentinel Project Plan in Review

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Milwaukee Journal SentinelProject Plan in Review
ING Conference September 21-23, 2004Milwaukee, WI

• Ken Kieck, Sr VP Production
• Royce Miles, VP Manufacturing Operations
• Jeff Goelz, Production Manager
• David Reszel, Advertising Special Sections Manager

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Project Deliverables

• Product Operational Drivers
• Productivity Targets
• Design Efficient Manufacturing Process
• Select Equipment
• Installation Start-Up
• Evaluate Results

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Product Operational Drivers

• Inconsistent Quality High Waste
• Page Count and Color Constraints
• Obsolescence
• Site Selection - Limited downtown dock space
  Satellite Inserting Operations drove off-site
  decision

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I. Inconsistent Quality High Waste

• Letterpress converted to Di-Litho Process
• Dot Gain in Mid-Tones Shadows (Plate to
  Substrate)
• Coarse 75 Line Screen
• Register Drift on Unit to Unit Process Color
  Leads
• High Overall Press Waste - 4.67
• Wide UCL/LCL of Process Causes High Degree of
  Variability

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II. Page Count Color Constraints

• Unit to Unit Process Color Reduced Paging
• Typical Monday - Saturday Product
• 56 Pages in 4 Sections with 12 Pages Process
• Typical Sunday Product
• 56 Pages in 3 Sections with 12 Pages Process
  Color
• Inverse Relationship page count/color Increased
  difficulty of Run
• Forced Additional Sections Handling in Field
• Sunday Main plus 7 Supplement Pieces in Field

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III. Obsolescence / Useful Life

• Presses Approaching 40 Years Service
• Obsolete Electrical Components
• Gear Wear
• Corrosion
• Metal Fatigue
• Fretting

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III. Obsolescence / Useful Life

• Focus on PM Shifting to Emergency Repairs
• Increased Downtime
• Reduced Productivity (32,400 Net CPH)
• Experiencing Larger More Complex Component
  Failure
• Dwindling Source of Mechanical Parts

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III. Obsolescence / Useful Life

• Major Overhaul Consideration Limitations
• Same Page Process Color Constraints
• Same Sectioning Restrictions
• No Improvement in Reproduction Quality
• Continued Level of Newsprint Waste
• Limited increase in Productivity
• Process Remains Labor Intensive

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IV. Site Selection

• Location
• Drive Time to Distribution Centers
• Near Major Bus Lines
• Site
• Minimum 30 Acres with Rail Siding
• Zoning Permitted Use
• 24 hr Operation
• Trucking/Distribution Operations
• Light Manufacturing (M2)
• Access
• Access to Streets, Major Arterials and Freeways

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IV. Site Selection

• Physical Attributes
• Soil Bearing Weight and Water Table
• Utilities
• Dual Substation Feed with Underground Service
• Underground Phone and Data Lines
• Natural Gas
• Adequate Water/Sewer for a 448,750 Sq. Ft.
  Facility
• 4101 W. Burnham St. West Milwaukee, WI
• State of Wisconsins Largest Brownfield
  Reclamation

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Productivity Targets

• Improve Penetration / Increased Zoning
• Improved Print Quality
• Tighter Print UCL/LCL Provides Less Variability
• Finer Screening (85 lpi or 100 lpi)
• Reduced Process Waste
• Process Efficiencies Through Automation
• Faster Make-Ready
• Quicker Change-Over

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Productivity Targets (cont.)

• Increased Net Speeds
• Six Formers More Sections, Less Handling a
  More Consistent Product
• Monday - Friday
• Pre-Run (insert Jacket) Main
• Saturday (Expanded Weekend Package)
• Auto/General Classified Main
• Sunday
• 2 Ad Packs, 3 Larger Advanced Sections Main

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Productivity Targets (cont.)

• Increased Page Color Capacity
• Three Press Operation (Straight Operation)
• 64 Pages - 24 p. Full Color, 32 p. Spot, 8 p.
  Blk.
• Two Press Operation (Straight Operation)
• 96 Pages - 36 p. Full Color, 48 p. Spot, 12 p.
  Blk.
• Improve Packaging Distribution Process
• Less Manual Handling
• Better Accuracy and Tracking of Products

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Productivity Targets (cont.)

• Improved Deadlines
• Flexibility and Capacity to Respond to New Market
  Opportunities
• Utilize Excess Capacity
• Sunday Comics
• TV Book
• We-Prints Commercial Cold-Set Printing
• Alternative Weekly Newspapers

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Old Plant inefficiencies

• Multiple production floors
• Limited press speeds of 56,000 cph
• Limited inserting speeds of 12,000 cph
• Limited number of inserting heads
• Manual skidding of insert jackets
• Limited storage space for inserts
• Manual loading of Cannon Carts

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New Plant Improved EfficienciesPressroom

• Warehouse located onsite and the same level as
  the reel floor
• Automatic guided vehicles for delivering
  newsprint to the press
• Reel Stands equipped with automatic roll loading
• Automatic blanket washers
• Press speeds of 85,000 cph
• Shaft-less press allows max. page counts of 96
  pages (straight)

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New Plant Improved EfficienciesPackaging and
Distribution

• All insert jackets wound on Flexi-rolls
• Three tie lines per press delivery
• Eight station Flexi-roll buffer system used for
  inserting jackets along with backing up ROP runs
• Bundles are identified with a bar code label
• Bundle distribution system utilizes the bundle
  bar codes for sorting
• Automatic cart loaders / bar code readers
• Automatic waste conveyor

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New Plant Improved EfficienciesPlate Making

• Three computer to plate lines
• Two optical plate benders
• Individual plates are bar coded for sorting
• Plates are sorted by printing tower within the
  plate stackers

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Equipment Selection Process

• Implement project teams
• Press
• Controls
• Packaging and Distribution
• Newsprint handling / Waste handling
• Warehousing
• Platemaking
• Members of project teams
• Middle management
• Supervisors
• Most important Operators

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Equipment Selection Process

• Strong Project Management Methodology
• Vendor Presentations
• Developed Request for Information form (RFI)
• Developed a weighting system for RFI
• Individually Evaluated Responses to RFI
• Averaged The Results
• Presented Recommendation to Executive Committee

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Request for InformationTopics

• Overall Design
• Ease of Performing reactive as well as
  preventative maintenance
• Reliability
• Training
• Support
• Parts Accessibility
• Documentation
• Warranties
• Project Management

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Request for Information Weighting of Each Topic

• Overall Design 200 points
• Ease of Performing maintenance 200 points
• Reliability 75 points
• Training 150 points
• Support 150 points
• Parts Accessibility 100 points
• Documentation 50 points
• Warranties 50 points
• Project Management 25 points
• Perfect Score 1000 points

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Equipment Installation

• November 2001 first SLS 2000 inserter operational
• Started installing the first press in March 2002
• On October 29, 2002 - TV Book was the first
  product
• April 2003 all products produced at the new
  facility
• Key to a successful installation COMMUNICATION

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Project Deliverables Discussed

• Product Operational Drivers
• Productivity Targets
• Design Efficient Manufacturing Process
• Select Equipment
• Installation

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Whats Next

• New Start Up
• Evaluate Results

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Journal Sentinel Print Strategic Plan - 2004

• Mission Statement
• Printing, Packaging and Distribution at its
  Best
• Primary excellence Goals
• Operational Excellence
• Sales Excellence and Superior Customer Service
• Effective Product Development and Innovation
• A Culture of Pride and Accountability

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Organizational Sustainability
Jan 2002-Present
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Process Flow

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Easy as 123!!
STEP 1
PLANNING
STEP 2
Start Up/ Installation
STEP 3
 ROI
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Plate making
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Pressroom
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Packaging
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New Initiatives

• Complete Lean Manufacturing
• Complete Managerial Education
• ISO 14001
• VPP
• Hispanic VIP Program
• Begin Six Sigma
• Continue to look for Commercial Printing
  Opportunities

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• Refresher Training and Assessments
• Contracts expire in 05
• Quarterly Semi Annually Vendor Review Meetings
• Employee Committees (Invlovement,Safety,Building,e
  tc)

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Awards/Recognition

• 2003 Governors Awards
• 2003 Wisconsin Business
• 2003 Wisconsin Partners
• Members of the International Newspaper Color
  Quality Club 2004
• NAA Best Practices
• SNAP
• ISO

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A Colorful StoryIn Advertising
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Color Ad Comparison
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Reproduction Adjustments

• First six months 2003 27,470
• First six months 2004 Under 2,500
• An over 90 reduction in reproduction
  adjustments!!

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Dreaming in Color