Ways to Reduce Costs

Transcription

1 Ways to Reduce Costs A Collection of Best Practices and Innovative Ideas from Asphalt Mix Producers and Construction Contractors Across the U.S. Dave Newcomb Minnesota Contractors Workshop February 19, 2015 February 19, 2015 Minnesota Contractors Workshop 1

2 QIS 126 QIS 127 February 19, 2015 Minnesota Contractors Workshop 2

3 At the Plant February 19, 2015 Minnesota Contractors Workshop 3

4 At the Plant Burner Efficiency Maintain flights for heat balance Eliminate air leaks Clean burner nozzles often Tune burner at least once per year Adjust production slowly to minimize jumps in mix properties Minimize plant stops and starts, increase efficiency, minimize wear February 19, 2015 Minnesota Contractors Workshop 4

5 At the Plant - Stockpile Pave and slope stockpile foundations Work with quarry to deliver dry material 1% water equals 10% fuel Build stockpiles from the wet side and push material toward the dry side Take material from the south side to maximize exposure to the sun February 19, 2015 Minnesota Contractors Workshop 5

6 February 19, 2015 Minnesota Contractors Workshop 6

7 At the Plant - Hot Oil System Insulate all pipes, elbows, flanges, and valves Add heat recovery system on hot oil heater Install a timer on the valve to the slat system so it heats in the morning and shuts off during production Flush system periodically to maintain efficiency February 19, 2015 Minnesota Contractors Workshop 7

8 At the Plant Other Things Keep silo level above the top of the cone - avoid segregation and cone wear and keep silo as full as possible Adjust batcher settings to fill to maximum and never run completely empty Put wind guards over entire belt scale to minimize weigh bridge fluctuations February 19, 2015 Minnesota Contractors Workshop 8

9 Keep on Truckin February 19, 2015 Minnesota Contractors Workshop 9

10 Minimize time at plant Keep on Truckin Stagger trucks loading first thing in the morning Use automatic truck release agent spray system Use automatic truck tarping Install automatic ticket writer at plant Provide truckers with map to job site Account for predictable traffic patterns in scheduling Install urethane bed liners on trucks to limit sticking and minimize release agent use February 19, 2015 Minnesota Contractors Workshop 10

11 Keep on Truckin Load to the gross weight on company trucks and to net weight for outside sales Maximize your own trucks, minimize the number of trucks, and give the customer what they order. On mill and fill, use delivery trucks to back-haul RAP Block heaters with timers on trucks in cold weather Like you need to be told! Use a larger pump to unload asphalt tanker and minimize time at plant February 19, 2015 Minnesota Contractors Workshop 11

12 Materials and QC February 19, 2015 Minnesota Contractors Workshop 12

13 Use more RAP Materials and QC Encourage customers to bring clean RAP to plant Show agencies the value of RAP Mill different layers separately to allow more flexibility in RAP use The costs of an extra pass and separate stockpiles needs to be evaluated. Fractionate RAP to optimize use Allows more flexibility in its use February 19, 2015 Minnesota Contractors Workshop 13

14 Materials and QC Use waste products responsibly in mix. Foundry sand can be used as part of fine aggregate Roofing shingles have a high asphalt content Tear-offs require more processing and testing Take advantage of excess quarry materials for certain sizes (like No. 11) Look for opportunities to use excess materials (low cost) from quarries in mixes to reduce costs. February 19, 2015 Minnesota Contractors Workshop 14

15 Materials and QC Put the QC manager in charge of smoothness and density bonuses with the proper authority QC separate from production to assure quality. Check aggregate and RAP moisture frequently Improves consistency of binder content - higher pay. Very important when calibrating the plant. February 19, 2015 Minnesota Contractors Workshop 15

16 Paving Site February 19, 2015 Minnesota Contractors Workshop 16

17 Paving Site Check tire pressures on pneumatic rollers often Calibrate electronics on distributor truck every day Install plate at the end of distributor spray bar to avoid overspray of curb and gutter Purchase vibe tachometer for each vibratory roller to ensure proper frequency Always stop roller on cool pavement at angle February 19, 2015 Minnesota Contractors Workshop 17

18 Paving Site Stagger start times for crews on long days to avoid loss of momentum Not all employees need to start at same time. Paving crew needs wooden level to check the screed (daily), transverse joints, and mat behind the screed Attach a magnetic grade gauge on the back of the paver Provides check of cross-slope control Provide crew and with daily feedback on smoothness and density Allows the team to know the score. February 19, 2015 Minnesota Contractors Workshop 18

19 Paving Site Have a printed daily maintenance check list for equipment operators and truck drivers Have parts uptime kits for pavers and rollers Have high wear and repair parts on site so they can be available Inspect scrapers, wipers, and cocoa mats on rollers and have spares available Keep drums and tires clean Install small rubber bumpers on all perimeter frame rollers Protects the sheet metal from damage February 19, 2015 Minnesota Contractors Workshop 19

20 Paving Site Install pre-cleaners on air filters on rollers and pavers Sort milling teeth by the amount of wear to reuse less worn teeth Set start time for operations and meet it Should not wait for mix to arrive. Lag for paver warm-up (20-30 min). Install hooks, buckets, and bins on pavers for all tools Keep biodegradable release agent on board paver for tool and paver clean up February 19, 2015 Minnesota Contractors Workshop 20

21 Paving Site Outline tools on tool racks in utility trucks so they are kept in the same place all the time Tape a list of tools contained in toolboxes and periodically inventory Have auger and tunnel extensions available on site Install common key locks on all equipment to avoid waiting for lost keys February 19, 2015 Minnesota Contractors Workshop 21

22 Paving Site Assign one crew member to the electronics Install a bumper in back of the spray bar on distributor truck Fill roller water tanks and check spray system at start of each shift Have welder wire to clean roller water spray nozzles and have extra nozzles available February 19, 2015 Minnesota Contractors Workshop 22

23 Paving Site Install infrared sensors on rollers or equip operator with infrared gun and set temperature targets Check into GPS to track roller passes Select rollers to match paver and planned production rates Equip operators and dump person with radio headsets (one ear phone, not voice activated) Minimize water spray during milling to keep RAP dryer February 19, 2015 Minnesota Contractors Workshop 23

24 Paving Site February 19, 2015 Minnesota Contractors Workshop 24

25 Customers February 19, 2015 Minnesota Contractors Workshop 25

26 Customers Train customers to order early and show up on time - Educate how to help with product delivery. Order early, have job sites ready, understand what you can do Dedicate silo to outside customers Establish a training program for paving company customers Reduce number of bad jobs/conflicts. Educate about future changes in company and industry, emphasize best practices. Call on customers - Increase customer satisfaction and help maintain repeat customers. February 19, 2015 Minnesota Contractors Workshop 26

27 Customers Have customer appreciation day Be open when customers need mix Provide small incentives to bring customers in (coffee, food, etc.) - Make them feel welcome at your plant Develop a common mix for outside sales - Consolidate number of mixes Provide training for end-use customers and specifiers February 19, 2015 Minnesota Contractors Workshop 27

28 Employees February 19, 2015 Minnesota Contractors Workshop 28

29 Employees Have a regular training program for employees Examples: toolbox talks, regular training sessions, online training, equipment manufacturers schools, and professional trainers to work on jobs. Provide train the trainer classes for superintendents Provide an incentive plan for employees for safety, quality and cleanliness February 19, 2015 Minnesota Contractors Workshop 29

30 Employees Install ice machines for employees at each yard Keep cooler of water and electrolyte drinks with drinking cups on paver at all times Put paving crews in uniforms so they look and act professional Have a person responsible for site clean-up throughout the day Have an employee appreciation day at least once a year February 19, 2015 Minnesota Contractors Workshop 30

31 Summary Best practices make for the best projects Keep things simple Communication Repetition Keep things organized Communication Fewer distractions Better production Customers Communication Expectations Yours and Theirs Employees Can make or break you Communication Expectations Yours and Theirs February 19, 2015 Minnesota Contractors Workshop 31