In-plant Profiles

For in-plants serving religious organizations, printing takes on a much deeper meaning. In her white habit and black veil, Sister Mary Jeremiah blends in well with the other 27 Dominican nuns at the Monastery of the Infant Jesus as they go about their daily routine of work and prayer. But when she throws a coverall apron over her habit and fires up her Multi 1250, one thing becomes instantly clear: She's a printer. Sister Jeremiah has been running the in-plant at her Lufkin, Texas-based monastery for eight years. She's the third printer the monastery has had since it started its in-plant in

California Office Of State Publishing Sacramento, Calif. Annual sales: $61,333,656 Operating budget: $57,996,000 Full-time employees: 456 Part-time employees: 21 Jobs printed per year: 24,380 When the California Office of State Publishing (OSP) installed a new eight-color Heidelberg M-1000B web press recently it was major news in the in-plant world, where such giant webs are rare. Still, for OSP the installation was, in a way, just a continuation of the growth it experienced through much of the 1990s. "We went [from] having some of the most obsolete technology in our greater Sacramento area, to having some of the most current, sophisticated technology, especially in prepress and in our digital print

by Bob Neubauer When the Federal District Court for the District of Columbia prepared to release Judge Thomas P. Jackson's "Findings of Fact" in the Microsoft case in November of 1999, the court contacted the U.S. Government Printing Office. GPO was asked to make advance preparations for the rapid dissemination of the document. GPO, as always, was ready for the challenge. Judge Jackson's decision was announced at 4:30, and the court sent a printed copy and a disk version of the 207-page document to GPO, where print production began immediately. Covers had been produced in advance. By 6:30, when GPO's main bookstore reopened,

Spartan Stores Grand Rapids, Mich. Annual Sales: $16.4 million Operating Budget: $14.1 million Full-time employees: 90 Part-time employees: 4 Jobs printed per year: 9,620 When it started out 35 years ago with just a one-color duplicator for printing company bulletins, the in-plant for Spartan Stores seemed an unlikely candidate to become one of the largest in-house printing facilities in the nation. But as the century nears its end, that is exactly what has happened. For the second consecutive year, Spartan Stores has ranked tenth on the IPG Top 50 list. There have been some drastic changes at this Midwestern grocery wholesaler shop since the single duplicator days. The

North Carolina Correction Enterprise Print Plant/Central Duplicating Raleigh, N.C. Annual sales: $7 million Full-time employees: 186 Jobs printed per year: 13,500 Robert Leon runs an extremely professional, profitable in-plant. Comprising a large offset operation and a separate duplicating facility, his in-plant generates $7 million in annual sales and employs 186 people. But his operation is different from other in-plants in one key way: Nearly all of his employees are prison inmates. Leon is director of printing at North Carolina Correction Enterprises. He oversees the offset print plant, located in Nashville, N.C., and a central duplicating center, in Raleigh. In its 60 years of

USAA San Antonio, Texas Annual Sales/Budget: $38 million Full-time employees: 305 Jobs printed per year: 36,000 For the employees at USAA Publishing Services, an increased workload is to be expected. The customer base, which stands at over 3.5 million people, grows by up to eight percent annually. But with a cap on the number of employees at the shop since 1992, that increase in work must be handled by the current staff. "We expect capacity to increase with our volume growth but expect staffing to remain constant," explains Jack Mondin, executive director of publishing output services. "That means...we cannot continue to do business the way we have

After being recognized as a top digital shop, Unisys revamped its offset operation to make it an on-demand model. In 1995, the in-plant at Unisys was recognized as a leader in the digital realm when it was honored with the CAP Ventures Technology Innovators Award. After adding digital technology, the in-plant had reduced its 200,000-square-foot warehouse to an aisle of less than 10,000 square feet, while raising production and quality. But what could the shop do in the offset area to cut costs and offer faster service? "I said, 'Hey, we have to come up with a better way to do offset than

University of California Printing Services Berkeley, Calif. Annual sales/budget: $15,877,189 Full-time employees: 186 Jobs printed per year: 5,000 To satisfy the printing needs of some 140,000 University of California students attending nine campuses across the state, University of California-Berkeley Printing Services has needed to be flexible. According to George Craig, printing services director, there have been many changes over the years, especially with the emergence of digital technology. Craig recalls bringing in photocomposition and computer business management systems in the '80s, before moving to the direct-to-plate processes and computer-controlled presses of today. Through it all, Craig says, his staff has excelled at adapting to the changes.

Allstate Print Communications Center Wheeling, Ill. Operating Budget: $30 million Full-time employees: 361 Part-time employees: 84 Jobs printed per year: 20,000 To keep a huge operation like the Allstate Print Communications Center productive and cost-effective, its management team must meet the challenges of changing technology and staggering workloads—while keeping costs low and bringing top-notch service to customers. "We are very successful at answering our company's printing needs and providing the most cost-effective solutions," explains Bob Tierney, print communication director. "Our cost-effectiveness is clearly our greatest strength." The Allstate Print Communications Center is not only a leader within its company, but also in the printing industry. It has

Boeing Printing & Output Service Seattle Annual sales/budget: $56 million Full-time employees: 330 Jobs printed per year: 240,000 Bill Walker, senior manager of printing operations at Boeing, has seen a lot of changes in his 33 years—and he knows that as soon as one technology is mastered, it's time to prepare for the next. "We've about maxed out the gains in our printing operation," says Walker of the shift from camera ready art to the digital original. "Ten years ago, it was tough to get an electronic original because customers didn't think that way. Today, 95 percent of our originals come to us digitally." That change