Press Editions Lessons Learned

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Press Editions Lessons Learned

• FLORIDA TODAY
• Expands in the center of the Press
• January 2005 November 2005
• Pete Zanmiller
• President and Publisher,
• The Herald-Dispatch
• Huntington, WV

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FLORIDA TODAY Background

• A Gannett Newspaper Located in Brevard County,
  Florida
• Circulation
• Daily 85,322
• Sunday 103,868
• Regional Printer for USA TODAY and Investors
  Business Daily

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Where We Were

• 16 units Goss Headliner Offset with 8 color decks
  installed in 1985.
• FLAT Press - Units 3 through 11
• 40 pgs/16 pgs full color run straight
• USAT Press Units 12 through 18
• 32 pgs/12 pgs full color run straight

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Challenges We Faced

• Increasing color demands beyond our capacity
• Averaged more than 76,000 lost revenue due to
  killed color annually
• Added pre-runs to maximize color capacity
• Ran collect on a regular basis to reduce color
  kills
• Earlier deadlines for Editorial
• Later deliveries for Circulation
• Often on Sundays

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Challenges We Faced

• Increased number of press runs on both presses
• Less time for maintenance
• Increased Overtime
• Fewer openings for new commercial work
• Higher printed waste due to more comic lead runs.

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The Easy Solution

• Add two towers to the USAT press where there was
  expansion room available at end of the press.
• Add one tower to the FLAT press where there was
  expansion room available at the end of the press.

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Our Solution

• Relocate Units 9 through 12 to each end of the
  existing press.
• Install three Goss Uniliner 4/4 towers in center
  of press line.
• Towers will be selectable to either press for
  maximum flexibility.

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Reasons For Placing Towers In Center Of Press

• Maximize usage of towers between both presses
• Any of the towers can be assigned to either press
  depending on color needs
• Each tower can be split into a two web
  configuration to increase page capacity

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Reasons For Placing Towers In Center Of Press

• Maximize usage of towers between both presses
• Increased page capacity to 56 pages for either
  press
• Allowed up to 24 pages of color to be added to
  either press
• Needed to allow for full color classified
  sections daily.

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Moving the Units

• Access holes were cut in pressroom wall at the
  center and end of the press line

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Moving the Units

• Sound enclosure walls were removed at both ends
  and center of press. Will be reinstalled at
  completion of installation.

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Moving the Units

• Units were removed through access hole into paper
  storage area and brought up through access holes
  on both ends
• Tower units were brought through the same access
  hole at the center of the press.

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Phase IFebruary - March

• Relocated Unit 11 to Unit 19 position at North
  end of press.

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Phase I

• Installed Y columns in reel room
• Did not add an additional reel.

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Phase I

• Unit 11 relocated to unit 19 position

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Operational Impact of Phase I

• Full color capacity for FLAT press reduced from
  16 to 12 pages when page count is greater than 32
  pages
• No Impact on USA TODAY press.

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Phase I StackMarch - May

• Relocate Unit 12 to stacked Unit 20 position.
• Had to run unit 19 each night for USA Today

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Unit 19 and 20 Stack

• Units 19 and 20 stacked at North end of press.
• Units controlled at press console
• Dampener unit controls for both units positioned
  on lower unit.

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Unit 19 and 20 Stack
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Operation Impact of Phase I Stack

• No impact to FLAT Press capacity.
• No Impact to USA TODAY press.

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Phase IIMay - June

• Relocate Units 9 and 10 and reel 7 to Units 1 and
  2 position at South end of press.

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Phase II Stacked Units

• Units 9 and 10 from center of press relocated to
  end of FLAT press

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Phase II Stacked Units

• Existing reel relocated to feed stacked units.

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Operational Impact of Phase II

• Page capacity of FLAT press reduced to 24 pages
  with 12 pages of color
• Collect run on daily and some preprints Earlier
  Start times
• Loss of second Back-To-Back Color Lead for comics
  run.

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Phase IIIJuly - November

• Install three Uniliner towers in center of press.

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Operational Impact DuringPhase III

• Color capacity for FLAT press reduced from 16 to
  12 pages when page count is greater than 32 pages
  
• Limited to one back-to-back color lead.

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Tower Installation In Progress

• A level of tower one being skated into place

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Tower Installation

• A and B levels of tower one in place

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Tower Installation

• Electrical distribution cabinets and unit control
  cabinets are all housed in what used to be the
  ink room just behind towers.

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Tower Installation

• Towers set in place

• Towers set in place with covers and platforms

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Project CompletionNovember 2005

• Capacity of New Press
• FLAT Press or USAT Press
• Up to 56 pages with 40 pages full color
• Based on running all three towers to one press

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Anticipated Impact

• Eliminate six pre-runs per week by combining
  runs.
• Increased color Revenue by eliminating color
  kills and launching new color opportunities.
• Increase commercial print revenue by selling more
  color to existing accounts and selling new
  accounts.
• Payroll savings from elimination of pre-runs.

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Lessons Learned

• Develop the press configuration that will
  maximize benefit rather than being the easiest to
  install.
• Work with Advertising to determine needs analysis
  to make sure your getting what is needed.
• Plan, Plan and Plan again.

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Thank You