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Effective Plant Operations. Introduction. Erik Varnadoe Rinker Materials Florida Operations Manager David Medina Rinker Materials Orlando Plant Manager. 3. Agenda and Schedule . 9:05 to 10:05 Effective Operations 10:05 to 10:20 Break 10:20 to 11:50 Supply Chain Exercise
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Effective Plant Operations www.concretepipe.org
Introduction • Erik Varnadoe • Rinker Materials • Florida Operations Manager • David Medina • Rinker Materials • Orlando Plant Manager www.concrete-pipe.org
3 Agenda and Schedule • 9:05 to 10:05 Effective Operations • 10:05 to 10:20 Break • 10:20 to 11:50 Supply Chain Exercise • 11:50 to 12:50 Lunch • 12:50 to 1:45 Exercise Debrief • 1:45 to 1:50 Break • 1:50 to 2:45 Review and Test www.concretepipe.org
What is and Effective Plant? • Miriam-Webster • Full Definition of EFFECTIVE • producing a decided, decisive, or desired effect <an effective policy> • Definition to Dave and Erik • Meeting customer expectations while producing spec materials safely and efficiently and meeting/exceeding budgeted goals. www.concretepipe.org
5 Section One Pipe Plant Specifics www.concretepipe.org
Production Meetings • Who Should Attend? • How Often? • Meeting Agenda www.concrete-pipe.org
Prod Meeting Attendees Plant Manager Production Managers Supervisors Maintenance Leadmen/Foremen Quality Control/Yard Foreman Sales or Dispatcher (weekly) www.concrete-pipe.org
Meeting Agenda • Begin with issues that effect everyone. • Personnel • Corp Directives • Ask each area to give a brief report • What they are making • Issues they are having www.concrete-pipe.org
Meeting Agenda (cont.) • Maintenance Issues • Parts • Service • Quality Control Issues • Strength • Testing Required • Spec Issues www.concrete-pipe.org
What should we keep in stock. • How much to run so you do not run out by next changeover? • What runs the best on my machine, and what will I have problems with. www.concrete-pipe.org
Know Your Product Specs • DOT’s • Counties and Municipalities • QCAST • ASTM • AASHTO www.concrete-pipe.org
Know Your Machine • Cycle Times • Mixer cycle time and capacity • Machine cycle time by size/class • Crane cycle time by drop off position • Curing Time • Tipout Time • Finishing Time • Changeover Time www.concrete-pipe.org
Know Your Crew • People • Supervisors • Quality Control • Lead Men • Operators • Maintenance www.concrete-pipe.org
Cross Training • Key Positions • Crane • Machine • Preventive Maintenance • Patching • Loading • Welding www.concrete-pipe.org
Raw Materials • Know your sales rep • Maximize their lead time • Know rough estimates of your needs www.concrete-pipe.org
Maintenance Looking for tools?? www.concrete-pipe.org
Efficiency Killers Excessive Changeovers Design Changes Poor Quality Daily Clean up**** Lack of Preventive Maintenance www.concrete-pipe.org
Section 2 Setting Attainable and Sustainable Goals www.concrete-pipe.org
Know Your Strengths and Weaknesses www.concrete-pipe.org
Establish Accountability • Take a picture of the plant in a clean, orderly or freshly painted state • Blow up the picture and hang it in the area • Use it to periodically inspect the housekeeping in the plant www.concrete-pipe.org
Establish Accountability • Publish your daily and monthly results to the crew. • Man Hours vs Tons Produced • Controllable Costs • Scrap • Maintenance • Does Your Operator Know Their Cycle Times? www.concrete-pipe.org
Try to beat those results incrimentally www.concrete-pipe.org
Setting Goals www.concrete-pipe.org
Success and Failure are Team Functions www.concrete-pipe.org
Be approachable, most of the best ideas will come from your crew www.concrete-pipe.org
Coach Your Team To Success www.concrete-pipe.org
Questions? www.concrete-pipe.org
Section 3 Beer Game www.concrete-pipe.org
Beer Game The purpose of the Beer Game is experience the need for supply chain management How single parts in a system influence each other. How individual thinking differs from systemic thinking. www.concrete-pipe.org
