1. Stockbridge, Georgia pipe plant

2. A LITTLE HISTORY about the plant….
CONSTRUCTED IN 1981
THE PACKERHEAD UTILIZES OVERHEAD CRANE STRIP
ONE AUTOMATED WIRE ROLLER CAGE DEPARTMENT DESIGN
NARROW LAYOUT

3. CHALLENGE #1 – better loading process
THERE WAS A NEED FOR LESS WEAR AND TEAR ON THE MACHINE AND BUILDING.
PLACE ON TABLE CORRECTLY, THE FIRST TIME.
MAKE IT EASY!

4. CHALLENGE #2 - TIME ROLLING STOCK
WHAT COULD EVERY PLANT USE MORE OF???
ROLLING STOCK
CONSERVATIVE ESTIMATE – 1 HOUR/DAY WASTED TRACKING DOWN A FORKLIFT TO LOAD THE WIRE ROLLER.

5. CHALLENGE #3 – Safer way to cut SPLICES and bands
A NEED FOR BETTER ERGONOMICS

6. PLANNING
A NORMAL DAY OF PRODUCTION CALLS FOR 3 ROLLS OF WIRE MESH FOR THE BIDI-48
DESIGN A TABLE THAT HOLDS A DAY’S PRODUCTION.

7. PLANNING ELIMINATE THE NEED FOR A FORKLIFT (ONCE THE ROLLS ARE LOADED)
DESIGN A SYSTEM THAT ADVANCES THE ROLLS SAFELY.

8. PLANNING ALLOW THE OPERATOR TO SAFELY WORK AS ONE WITH THE SYSTEM
LOCK ROLLS IN PLACE WHEN “ON DECK”
GUARD SYSTEM FOR POTENTIAL SLIPS AND FALLS

9. Final product – “MESH WIRE ROLL CLIP”

10. Allows for cutting towards the top of the roll

11. Cutting platform – less than 4 feet

12. Swing gate for cutting platform access

13. Stops – lever release system

14. AIR ASSIST JACK

15. Foot Pedal

16. Improvement idea from employee’s – guard for potential slips

17. Costs ~$2300
SCRAP MATERIAL FROM A DECOMMISSIONED BRIDGE CANE, ” I-BEAM, (2) 16’ SECTIONS ($0)
AIR ASSIST JACK AND PUMP ($1,100)
EXPANDED METAL AND ANGLE ($700)
MISC MATERIALS ($500)

18. INTANGABLE COSTS SAFER AND MORE EFFICIENT EMPLOYEE SATISFACTION
PRIDE - TEAM ACCOMPLISHMENT
FUTURE SAVINGS – TWO MORE PLANNED FOR THE DRY CAST DEPT.

19. SPECIAL THANKS REGGIE ELKINS (PLANT MANAGER)
JASON HARRIS (YARD SUPERVISOR)
ALFREDO FLORES (MAINTENANCE MANAGER)
GABE JACKSON (MAINTENANCE ASSIST.)
CAGE DEPT. – TITO RIVIERA & CHRIS CARTER