Houston Chronicle SW Production Plant Transformation and Packaging Project Centralized Packaging for Hearst Media South Texas Newspapers. Houston Chronicle, Beaumont Enterprise, Laredo Morning Times and San Antonio Express-News
Dec 17, 2015
Houston Chronicle SW Production Plant Transformation and Packaging Project
Centralized Packaging for Hearst Media South Texas Newspapers.
Houston Chronicle, Beaumont Enterprise, Laredo Morning Times and San Antonio
Express-News
• We will be a world class service organization that relies on efficient/optimized processes to insure flawless execution
• Our organization is positioned to deliver exceptional value for our audience/readers, advertisers, and is relied on to deliver the bargained for message
• Customer service and process efficiencies are leveraged to unlock incremental value by attracting new customers
Vision
2
Strategies
• Develop a professional management organization & culture
• Ingrain process discipline
• Implement accountability and measurement systems to insure performance
• Ensure effective utilization of assets/tools/staff to create value
• Install financial discipline at all levels in the organization
• GROW Business - Commercial Print Opportunities (Tune in Tomorrow)
Sunday, Direct Mail and SMC Plant - 163,137 Sf.
South West Production Plant Total SF. – 440,730 (118,320 unoccupied)
Harvey Wilson (East) - 78,845 Sf. Newsprint and Distribution with Rail Spur.
Main Business office 801 Texas Ave. - 498,340 Sf. Office Space 278,290 Production/Industrial 220,050 (phased out)
Facilities
Consolidate Kempwood to Southwest / Improve Performance
Background & Business Case
Project Scope: OVERVIEW
Strategy • Convert fixed to variable costs• Lower the overall cost baseInitiative• Close & sell 160,000 square foot offsite, separate
inserting facility• Relocate all inserting to main production facility• Reduce operating costs by $2+ million annually• Relocate all Texas inserting to Houston
San Antonio Laredo
Prior to Project:13 total inserters• Sunday facility: 3 NP 630 ‘s• Main plant: (1) Double out 2299, (5) 1272P• San Antonio: (1) 2299 double out, (1) 1472 and (1) SLS-1000 17 Head inserter
After project:3 total inserters• One 40-1 double out Magnapack• One 32-1 double out NP-632• One double out 2299
Equipment
Southwest 2nd Floor Packaging CenterOne New + One Machine Relocated and One existing 2299
(1) 40-hopper Magnapak + (1) 632 machine relocated. Existing 2299 location shown. All shown as double-out for flexibility in layout.
55’ – 0”
55’ – 0”
55’ – 0”
40’ – 0”
Double-out632 Inserter
40-hopper Magnapak
Existing Press / Operating Level
Pallet out-feed
ROP Stack / TieLines
Existing FourPallet Lift
Existing 2299
Existing (2) SinglePallet Lifts
Pallet staging
632 Inserter under Reconstruction and Reconditioning
NEW MAGNA PACK 40 Head
2nd Floor / First Floor Pallet StoragePallet Storage Racks
2nd Packaging Level 1st Warehouse Level
90’
212’
Wide-aisle Racks
RemainingNewsprint Storage
Pallet Gravity Staging Racks
12
20
12
16
12
20
12
16
12
12
12
12
Pallet / NewsprintStorage Below
Area for lift truckpicking pallets –move to inserter
1
2
1Pallet Gravity Staging Racks
Project Scope Insert Storage and Barcoding Management
Volume Processed
• 34 million (+) inserts per week.• 1,500 pallet storage in Racks• 76 to 80 unique Pressruns Weekly.• Avg. weekly tons 760 (+), up from 641 last year.• Almost 24 thousand M8PP per week.
Products Produced @ SW
• Houston Chronicle• all related Products• Houston LaVOZ Spanish Bi-WeeKly 400K (+)
• USA-Today• Beaumont Enterprise Daily and Commercial• San Antonio Express-News:
• Sun-Comics• Advances Thu-Fri-Sat and other related products requiring inserting
• Laredo Morning Times:• Sun-Comics• Advances Thu-Fri-Sat and other related products requiring inserting.
Distances covered to ship Insert packages
197 mi
314 mi
95 mi
154
mi
Additionally:Houston prints Beaumont Daily 7 daysSan Antonio print Laredo Daily 7 days
• (6) 12 unit Goss Metroliner Presses (12 Folders)
Pressroom Transformation