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Largest single site installation for Heidelberg Australia & New Zealand

Thursday, 14 September 2006
By Print21

From the onset, the installation of new equipment and relocation of Blue Star Print Group Australia’s primary offset division to a new 8,200 square metre purpose built facility within the Clayton Business Park was to be a major project for Heidelberg.

Plans to install all new equipment concurrently in June 2006 with the relocation from the Craftsman Press facility (Blue Star’s “retired” Melbourne location) to the new, state of the art, print production facility were first brought to the table by Blue Star during negotiations for new press and bindery equipment.

This was to be the largest single site installation ever carried out by Heidelberg Australia & New Zealand, utilising resources from our Customer Support and Service departments to an extent never before adopted for the one project, and our involvement in such an exciting project was highly anticipated.

Planning began in the final months of 2005, over six months in advance of the scheduled commencement date, as it was imperative Heidelberg had the structure in place to effectively deliver a successful installation. Both Business Development and the Victorian Service teams worked very closely to ensure the project was given the attention it required.

After several meetings, the enormity of the installation soon became evident and it was clear that Heidelberg needed to appoint a Project Leader; one person to be the point of contact for communications between the customer and Heidelberg, as well as manage the project as a whole from start to finish. Sam Casa, Team Leader of Electrical/Prepress for Heidelberg was identified as the ideal person for this role. From the customer’s side, Mike Shannon, Chief Operating Officer for the Blue Star Print Group was to be Heidelberg’s point of contact. Many meetings were held with Mike in preparation for installation and to define project timelines.

The project consisted of installation of a new XL105-6+LX, SM102-10-P, SM102-8-P, PM74-2-P, ST350, TH82, TD94 and Ecoclean system, and the relocation of 4 x Folders, 4 x Guillotines, Muller Prima Stitcher, 2 x QM46, SM52-2-P and 3 x SBB Cylinders. Also required was the decommissioning, repair and relocation of SM102-10-P from the Craftsman facility to Link Printing in Sydney. The following equipment was also required to be decommissioned as they were traded in by Heidelberg. This included 102SP, Komori 628, Komori 540, MOZP, GTOZP, ST300 and TF78.

During the initial planning stages, a potential acquisition by the Blue Star Print Group was notified however only ever referred to under its codename ‘Paris’. Towards the end of June when it hit the press that the Blue Star Group had acquired Print in Vision, the relocation of CD74-5-C from Print In Vision across to the new Clayton premises was incorporated into the project plan. It was revealed that ‘Paris’ referred to a certain hotel heiress who it was hoped would be available to officially open the new Clayton premises.

Many weeks went into the planning and allocation of resources required for this project. Victorian Field Service Representatives (FSRs) (Pictured right is Marty Kelders–Field Service Rep, Mechanical) were advised that leave entitlements during the proposed installation period would not be possible as all hands were required on deck. Planning proved difficult in that access dates to the building changed several times which meant plans for resources had to change also. Finally, a start date of May 30 was confirmed and all plans in place. Prior to the installation commencing, all support staff were briefed on the schedule and the impact each person’s role had on ensuring the project was delivered successfully.

During installation, daily site meetings were held to discuss plans for the day and requirements for the days ahead. These meetings were very effective in ensuring installations remained on track as the Heidelberg team worked very closely with Twin Electrics, the electrical and plumbing contractors.

Upon completion, the project will have utilised more than 5,000 man hours of labour contributed to by more than 40 individual FSRs from within HAN, spanning over a 16 week period. It is expected that the project will be completed by mid September.
Projects such as this show the strength of Heidelberg working together and set us apart from the competition, creating greater opportunities for us as a company in the future.
So far it’s been a huge team effort and a lot of hard work, however at the same time an enjoyable experience for those involved. Thanks to all those who have contributed in some way for your efforts and commitment.

Further Information
Sam Casa – Team Leader – Electrical / Prepress
PH: +61 3 9205 4148

Email: Sam.Casa@heidelberg.com

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