1. ACPA Spring Short Course School
Scheduling the Plant
Presented by
Erik Varnadoe
ACPA Spring Short Course School
Houston February 11-14, 2014

2. We all have different plants with different machines and layouts
Basic Opening Page
We all have different plants with different machines and layouts
No one here knows your plant like you so we won’t be covering specific items to one machine or another
We are going to cover some broad topics that affect us all
And those topics are . . .

3. How do we go from this?

4. To This

5. Agenda Supply and Demand Communication Open Discussion
Supply and Demand: What do we need to produce and when does it need to ship
Communication: With Prod Sups and Leadmen, QC, Sales, and Dispatch
Open Discussion: Let’s learn from each other

6. Supply Raw Materials Plant Capabilities Plant Limitations

7. Raw Materials Know your sales rep Maximize their lead time
Know rough estimates of your needs
Raw Materials
Raise your hand if you have ever lost production because you have ran out of a raw material
How often do you speak with your suppliers, do they know your demand, how much lead time do you give them

8. What is your plant capable of?
Product Variation (size, wall, and class)
How much can you produce of each size per day
Tip: Keep an on hand equipment list on your wall in your office

9. Capabilities Kiln Capacity Tip Out Time Back Up Plans
Kiln Capacity: What can you hold and how long does it need to be in there
Discussion: What is the best way to know minimum curing times?
Tip: Break cylinders to find tipout strength, make an extra each day and test if prior to tipping out in the cold months.
Can I tip out and produce at the same time?
If I have an equipment issue can I store cages and changeover to another size?
What parts should I keep in inventory

10. What are your plants limitations?
Equipment Capacity
Raw Material Availability
Finished Product Storage Space
Equipment: How many headers and pallets do you have
Storage: Where do I put it and how long will it sit there
Tip: Store fast moving as close to tipout as possible

11. Efficiency Killers Excessive Changeovers Design Changes Poor Quality
Daily Clean up****
Lack of Preventive Maintenance
Changeover: How long do they take? How many issues with the first day of production
Tip: Keep a settings log at the machine (handwritten) track changes in the machine through out a run and start back where you left off.
Design Changes: Have an approved drawing before you start
Daily Clean up: Get everyone working on a schedule, make sure there is a lead man coordinating the effort.
Tip: If you have the capacity run 4 10’s instead of 5 8’s to save a day of clean up
Maintenance: How much time is required, who is performing it and when?
Tip: Have your machine operators document their preshift inspections, read them and ask questions, let them know it is important to you and they will take them seriously

12. Man Power Do you have the right people in the right places
Take the time to develop your employees

13. Maintenance Looking for tools??
Looking for tools is a huge time waster, have a cart with the basics for each machine and paint them. I have found that no one ever steels the pink tools!

14. Demand What are some ways to get to know your market History Backlog
Lift operator (Right Now)
Dispatcher (Coming Soon)
Sales Meetings (Future Planning)

15. Communication

16. Production Meetings Who Should Attend? How Often? Meeting Agenda

17. Prod Meeting Attendees
Plant Manager
Production Managers
Supervisors
Maintenance
Leadmen/Foremen
Quality Control/Yard Foreman
Sales or Dispatcher (weekly)

18. How Often? How busy are you? How many changeovers will be performing?

19. What Time of the Day? All depends on availability of your people?
Usually after tipout and first few pipe are produced.
After shift change

20. 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

21. Meeting Agenda (cont.) Maintenance Issues Quality Control Issues Parts
Service
Quality Control Issues
Strength
Testing Required
Spec Issues

22. Meeting Agenda (cont.) Ask about any tools or equipment they need
Address any Corrective Actions from their department

23. Communicating with Sales

24. 1. Find the Common Ground Provide for their family Turn a profit
Future Success
Less conflict

25. 2. Define Your Problems Shipping Schedules Stock Outs
Machine Breakdowns
Raw Materials Restraints

26. 3. Discuss Solutions Explain your capabilities and limitations
Do not assume they know what you are going through

27. 4. Acknowledge Alternate Solutions
Create “ Buy in” by having them be part of the solution

28. 5. Recognize Objections Hear them out
Be willing to attempt an unproven method

29. 6. Summarize
Go back over the problems

30. 7. Ask for the action you want
Provide a timeline
Get it done

32. Production Schedule
Here is a very basic production schedule, make one on how

33. Discussion
Questions for the group

34. Thanks