This paper reports work done at Star Tribune, a leading metropolitan daily newspaper in Minnesota, to improve integration among pressroom, mailroom and distribution operations. This work is subsequent to that already reported in IIE Transactions, which was focused on improving press operations only during the live-runs. An improved size-forecasting model is offered which allows preparation of more precise work-force schedules sufficiently in advance. Several system variabilities have been reduced by identifying homogeneous subclasses, and designing tailored operations for each subclass individually, and eliminating over-design to absorb between-class variabilities. Installation of flow sensors on presses has eliminated unnecessary over-production, and also allowed a better co-ordination between the press and the distribution operations. Installation of status sensors in equipment has allowed for collection of more reliable statistics on equipment utilizations, downtimes and so forth. They also have improved many aspects of capacity and operational planning.
