The Denver Newspaper Agency (DNA), which publishes The Denver Post and Rocky Mountain News in Colorado under a joint operating agreement, decided to consolidate operations to save money. But blending the two facilities raised issues that required a new end-to-end supply chain answer.

Key to DNA's success was closing the dated Denver plant and moving all production to the Rocky Mountain site. The merge involved a significant expansion of the 400,000-square-foot facility as well as two new presses.

To support these presses, DNA needed to address materials flow challenges regarding free standing advertising inserts (FSIs). They needed to minimize floor space for inventory, reduce materials handling labor, eliminate lift trucks in the mailroom, provide accountability and control to support zoning requirements, increase production and delivery accuracy, minimize damage to FSIs, and provide real-time visibility for production staff.

The solution? Free up floor space in the mailroom and increase production, they integrated a software system, a high-density automated storage and retrieval system (AS/RS), and a new FSI receiving dock adjacent to the existing building.

The solution also includes seamless integration between the industry's standard BURT production planning system and the new software system. Both software systems coordinate to run the AS/RS and to direct lift truck operators. And the proof of delivery capability verifies that pallets were delivered to the correct distribution facilities.

To minimize space, reduce labor, increase pallet selectivity and maximize throughput, a high-density rack-supported storage facility with 3,432 load positions was added. The configuration ensures maximum density while balancing selectivity requirements for today's mix of FSIs.

With complete end-to-end newsprint and FSI materials handling solutions, the move to one location has provided DNA with savings and increased efficiencies.

HK Systems 800-HKSYSTEMS www.hksystems.com