1. Building a World Class Inserting
and Distribution Center
CASE STUDY 1
2. “First Start With Good People”
Need good people and great leadership with project
management expertise
CASE STUDY 2
3. “Create a Organizational Chart”
Get the “right people on the bus” and make sure they
are in the right seats to contribute
CASE STUDY 3
4. “Create…”
Selection Matrix for consistent selection of associates
Conduct Associates Evaluation's with staff input
Outplacement Provided for those not selected
New Job Descriptions for each position
Competitive Wage Scale providing a progression
Standard Operational Procedures (Mimic - ISO 9001)
Work Rules & Policies
Project Plan with Weekly Updates (MS Project)
Contingency Planning (PMBOK)
Layouts (Auto CAD, PDF’s)
CASE STUDY 4
7. “It’s Lonely at the Top”
“Iron is the easy part of a start-up” Operation
CASE STUDY 7
8. “How Much Racking is
Required?”
Installed 4 & 5 High racking with a security cage for High
Value products (Made use of existing 4 high racking)
CASE STUDY 8
10. “What Material Handling
Equipment is Required”
Converted Fleet from LP to New Rapid Charge Batteries – No transfer carts.
All new Safety features included, not shown are new Walker/Riders
CASE STUDY 10
11. “Distribution Requirements
Model”
Total
Pallets
B&Q CTZ ASSIGN 769
STATEN CTZ ASSIGN 97
% Production Pallets Produced Produced % by 4pm Prod by 4PM Available as of 4PM Bal to produce 2nd Pick up Comments
Total 866 Mon 9.6% 83.1 0.0 0 0.0 0.0 0 Start up Monday Night
Tues 24.7% 213.9 0.5 107.0 190.09 107.0 0 Can't deliver until wed (Preload )
Wed 30.2% 261.5 0.5 130.8 237.7 130.8 427.8 Load 150 Pallets at 6AM (Actually 277 on floor)
Thurs 28.8% 249.4 0.5 124.7 255.5 124.7 255.5
Friday 6.6% 57.2 1.0 57.2 181.9 0.0 181.9
99.9% 865.13 420 865.1 865.134
839 865.1
Build Distribution Side for Approximately 277
Can't Deliver Until Wed
Pallet Packing Assumption
Overall Package Size 10" x 12 x .375 Overall Package Size 11 1/2" x 12 x .375 Overall Package Size 11.5" x 12 x .375
Assume 40" x 48" Pallet Assume 40" x 48" Plastic Pallet Assume 45" x 45" Pallet
Assume 25 Packages per Bundle Assume 25 Packages per Bundle Assume 25 Packages per Bundle
This means 16 bundles to a layer This means 12 bundles to a layer This means 16 bundles to a layer
Each Layer will be 9.375 each Each Layer will be 9.375 each Each Layer will be 9.375 each
Assume each CTZ is approximately 2,000 packages Assume each CTZ is approximately 2,000 packages Assume each CTZ is approximately 2,000 packages
Each layer will have approximately 400 packages Each layer will have approximately 225 packages Each layer will have approximately 400 packages
Assume maximum of 5 layers or 46.875" or 2000 Pkgs Assume maximum of 5 layers or 46.875" or 1500 Pkgs Assume maximum of 5 layers or 46.875" or 2000 Pkgs
*If we have to go 6 layers max is still only 56.25" or 2400 Pkgs *If we have to go 6 layers max is still only 56.25" or 1800 Pkgs *If we have to go 6 layers max is still only 56.25" or 2400 Pkgs
This will overhang 3" on one side and 1" on other - Not recommend
Not to Scale: Not to Scale: Not to Scale:
25 25 25 25 25 25 25 25 25 25 25
12" 12" 12"
25 25 25 25 25 25 25 25 25 25 25
12" 12" 12"
25 25 25 25 25 25 25 25 25 25 25
12" 12" 12"
Over by 3"
25 25 25 25 25 25 25 25 25 25 25
12" 12" 12"
10" 10" 10" 10" 11.5 11.5 11.5 11.5" 11.5" 11.5" 11.5
Over by 1"
Conclusion: Unless we have less than 1800pkgs or more then 3600 per CTZ we will assume 2 pallets/CTZ for design purposes!
Modeled actual Trade Zone quantities and converted to
finished pallets to determine receiving required
CASE STUDY 11
12. “Polished Concrete”
Never Seal or Paint over good aged concrete. Repainted Deck,
Joists and Walls, High Efficiency Lighting and New HVAC
CASE STUDY 12
13. “Partner With a World Class
Supplier”
Muller Martini and In-house Installation crew commissioned
equipment on time (Matched capacity with equirements)
CASE STUDY 13
14. “Is it big enough? (150HP)”
New Variable Trim Energy Efficient Quincy Compressor with
Oil/Water Separator, Dryer and Pre-filter (Con Edison Rebate)
CASE STUDY 14
15. “Never Forget Your Training”
One of the many classes we had with Muller Martini –
Key to success is process improvement!
CASE STUDY 15
16. “The Dream Becomes a Reality”
Cleanliness is key to good manufacturing it reflects on
the quality of the operation and products produced
CASE STUDY 16
17. How Fast Will it go?
IFRA CALCULATION
(NO MAKEREADY TIME INCLUDED)
N= P x f1 x f2 x f3 x .96 x f4 x f5 x f6
N = Basic Proformance MM conversion from Inches SI Wrap 11 3/8" x 11 3/4"
P = Main Jacket infeed Speed 9 25.40 228.6 Queens 11 3/16" x 9 1/16"
f1 = Influence of the main product format Enter Inches Result in MM
f2= Influence of the type of the main product
f3= influence of the page count of the end product
f4= Influence of the page counts of the pre-prints A4 = 8.27" x 11.69"
f5= Influence of the page count and size of inserts
f6= The numbers of Hopper Feeders in operation
Staten Island Wrap 18-1
P f1 f2 f3 0.96 f4 f5 f6 N Inserts
8500 1 1 1 0.96 1 0.8 0.74 4830.72 18
8500 1 1 1 0.96 1 0.8 0.75 4896.00 17
8500 1 1 1 0.96 1 0.8 0.76 4961.28 16
8500 1 1 1 0.96 1 0.8 0.77 5026.56 15
8500 1 1 1 0.96 1 0.8 0.78 5091.84 14 7000
8500 1 1 1 0.96 1 0.8 0.79 5157.12 13
6000
8500 1 1 1 0.96 1 0.8 0.80 5222.40 12
8500 1 1 1 0.96 1 0.8 0.81 5287.68 11 5000
8500 1 1 1 0.96 1 0.8 0.82 5352.96 10
8500 1 1 1 0.96 1 0.8 0.83 5418.24 9 4000
8500 1 1 1 0.96 1 0.8 0.84 5483.52 8 N
3000 Inserts
8500 1 1 1 0.96 1 0.8 0.86 5614.08 7
8500 1 1 1 0.96 1 0.8 0.88 5744.64 6
2000
8500 1 1 1 0.96 1 0.8 0.90 5875.20 5
8500 1 1 1 0.96 1 0.8 0.92 6005.76 4 1000
8500 1 1 1 0.96 1 0.8 0.94 6136.32 3
8500 1 1 1 0.96 1 0.8 0.96 6266.88 2 0
8500 1 1 1 0.96 1 0.8 0.98 6397.44 1 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Using a formula provided by (IFRA) the Newspaper
Organization, was able to determine a theoretic output
CASE STUDY 17
18. Return on Investment – Less than one year!
“If we are to achieve results never before
accomplished, we must expect to employ
methods never before attempted”
– Sir Francis Bacon
CASE STUDY 18