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27 Total Process Reliability
TOTAL PROCESS RELIABILITY
2019 - A YEAR IN REVIEW
Written by, TPR Coordinator, Mike Woody
INNovember 2019, we passed the two-year mark on our TPR journey at Ajax Paving. We have come a long way in 2019 identifying and taking action on areas needing improvement. We have been successful in our TPR endeavors because of you - the members of the Ajax Team and the TPR Focus Teams. Below is a summary of what each team accomplished and where we plan on going in 2020 with each team.
OPERATOR CARE
Chad Schmidtke led the operator care team with team members Tommy Kidd, Dale Purcell, Lee Strauss, Andrew Cary, and Dejan Vujaklija. The team developed operator care standards for skid steers, asphalt rollers, live-bottom “flowboy” tractors/ trailers, and our triaxle dump trucks. The team also developed quarterly operator care training and facilitated those training events at the area shops throughout the year. The events trained operators and supervisors in the proper care of equipment. One of the final achievements of the team was to stock file boxes with operator care standards at each area crew supply room, enabling foremen and operators to have access to new standards when the existing ones are damaged or missing. In 2020, the operator care team will begin developing operator care standards for all of our grade crew equipment and facilitate quarterly operator care training events for those equipment operators and foremen.
AUDIT TEAM
Mike Morgan and Jayson Brown led the Audit Team with team members Ginger Johnson, Sam Loumani, Jared Hardy, Matt Horan, Jason Prokopetz, and Steve Ayers. The purpose of the audit team is to ensure that operators and crewmembers are performing operator care by scheduling supervisors in each area to conduct an audit of equipment every 6 months. The team this year developed a method to schedule, record, and track equipment and shop audits. The team also coordinated training auditors and creating audit forms for the equipment with completed operator care standards. In 2020, the team will expand the audit program to include grade crew equipment, flowboy tractors/trailers, and other class B equipment.
PREVENTATIVE MAINTENANCE
CLAIRE/EIT TEAM
Alex Claessens led the Preventative Maintenance (PM) Team with team members Clay Collins, Tim Smith, Wilmer Moldanado, Chip Gaines, and Dennis Wilson. The PM Team utilized manufacturer service manuals along with team member experience to create detailed preventative maintenance manuals (checklists) for our mechanics to use during services. The team created PM manuals for asphalt pavers, asphalt transfer machines, tack trucks, broom tractors, and a select few asphalt rollers and dozers. The team also analyzed the current rate of PM services conducted by the equipment division and tracked compliance of our scheduled services. The efforts of the team, in coordination with the equipment division, led to an increase in scheduled service compliance and an overall increase in PM services of our equipment fleet. In 2020, the team plans to create additional PM Service manuals for the remainder of our paving train equipment and grade crew equipment. In 2020, the team will also incorporate conditional inspections of our fleet equipment into the PM program to help early identification of potential machine failures and repairs.
COMMUNICATIONS TEAM
Elliott Kresse led the Communications Team with team members Kara Coggins, Cassie Rubio, Sam Loumani, Danielle Bentivegna, and Trish Moore. The team developed an awards program for TPR that includes a $50 reward for operators passing their first audit and a quarterly audit award winner. As always, the team kept us abreast of current TPR happenings with newsletter, emails, event video, and most recently, video messaging. A staple of the communications team is posting via our social media platforms. The team also coordinated the installation of televisions at each shop and area office that will be used to display company and TPR information for visitors and employees alike. In 2020, the communications teams will continue to keep employees informed of TPR news and explore new methods of communicating our successes.
Clay Cross and Sonny Webb led the CLAIRE/EIT Team with team members Erica Washington, Garrett Fons, Justin Scharping, David Kidd, Henry Suggs, and Roger Owens. The team planned 5 successful events, listed below. The intent of the events is to improve the state of the equipment, provide a team building opportunity, and train crewmembers in TPR. In 2020, in coordination with Construction Managers, the team will continue to plan CLAIRE equipment improvement teams and events.
2019 TPR TEAMS
Roadtec Paver – “A-Team” – Bob Popielarz, Broderick Belvin, Desmin Belvin, Ernest Williams, Fenel Meade, John Chaney, Keith Atwater, Pete Walker, Bob Rondeau, Aaron Chaffin, David Kidd John Deere 310 Combo – “Team Demolition” – Fredy Garay, Richard Gifford, Richard Garay-Colon, Michael Peery, Darren LaBolt, Michael Green, Dennis Wilson Service Truck – “Dream Team” – Tony Tovar, Jordan Brown, Dominique Figueroa, Skylair Mrazik, Todd Reynolds, David Kidd Terex Mixer – “Team Gear Heads” – Tim Smith, Matt Bell, Cody Dahlberg, Ed Bittner, Tyler Bowser 3x5 Roller – “Team Misfits” – Harry Hoxsie, Sam Manahov, Bobby Wolfe, Austin Whitehead
Continued from pages 24/25
5-S TEAM
Tim Gearheart led the 5S Team with team members Sam Loumani, Andrew Kirkpatrick, Mike Eaton, and Eric Delaney. The team had three main tasks this year, all of which revolved around asphalt plant operations/maintenance. The first was to build a plant maintenance trailer (PMT) at Palmetto Plant 3. The team built the PMT to be a self-sufficient, total maintenance trailer for plants, complete with generator, lighting, tools, welder, air compressor, and other small items needed to repair asphalt plants. The second task was to clean up and repair the old shops at plant 3 and plant 7. The last task was to convert the old plant 3 shop to an asphalt plant parts warehouse and catalog parts into a database for use by asphalt plants 3, 5, 6, and 7. In 2020, the 5S team will be on standby and utilized as a special event crew when a facility or area is determined to need a 5S event.
ROOT CAUSE ANALYSIS
This year we established a new team for Root Cause Analysis (RCA) consisting of Clay Cross, Nate Hassler, and Jim Price. The intent of this new team is to provide dedicated investigative work into issues that Ajax deems impactful to the entire company or, in the case of equipment, that may surpass a certain repair cost. In lieu of an initial “mission” to set this team on, Ajax decided to utilize the team to create crew supply stock rooms. The team established the overall plan and employed John Eagens to carry out the plan and streamline it. With a big effort from John Eagens, Ajax currently has and maintains a crew supply stock room at the Fort Myers yard, Palmetto Plant 3, Tampa 301 shop, and the Venice Plant 1 yard. John also spearheaded the renovation of the main shop equipment wash bay and coordinated the final stages of completion for the Fort Myers equipment wash bay.
Service Truck – “Dream Team” – Tony Tovar, Jordan Brown, Dominique Figueroa, Skylair Mrazik, Todd Reynolds, David Kidd
Roadtec Paver – “A-Team” – Bob Popielarz, Broderick Belvin, Desmin Belvin, Ernest Williams, Fenel Meade, John Chaney, Keith Atwater, Pete Walker, Bob Rondeau, Aaron Chaffin, David Kidd
Terex Mixer – “Team Gear Heads” – Tim Smith, Matt Bell, Cody Dahlberg, Ed Bittner, Tyler Bowser
3x5 Roller – “Team Misfits” – Harry Hoxsie, Sam Manahov, Bobby Wolfe, Austin Whitehead John Deere 310 Combo – “Team Demolition” – Fredy Garay, Richard Gifford, Richard Garay-Colon, Michael Peery, Darren LaBolt, Michael Green, Dennis Wilson
WHAT’S TO COME?
In the last few months of 2019, Ajax decided to restart the CAM Tech team, Inventory Control Team, and the Planning/ Scheduling Team. Updates for these teams will be coming in the next few months as these teams formally establish their missions and processes. This year we have come a long way with TPR, and we plan to continue our improvement into 2020.
