produced by: cement plant shutdowns during lean times seth a. tyler txi
TRANSCRIPT
Produced by:
Cement Plant ShutdownsDuring Lean Times
Seth A. TylerTXI
Cement Plant Outages in Lean Economic Times
Outage Preparation
Outage Execution
Key Learning's
Questions
Key Topics of Presentation
Introduction & Overview
TXI-Midlothian Cement Plant
• Processo Limestoneo Silica o Aluminao Iron o Fire o Clinker o Gypsum
Introduction & Overview
TXI-Midlothian Cement Plant
Introduction & Overview
TXI-Midlothian Cement Plant
• Major Equipmento Crushers, Vertical Roller Mill, Rotary Kiln, Finish Mills (6), Scrubber, RTO
• Typical Outageso Kiln (1 major and 1 minor per year)o Finish Mills
Slide 6
Cement Plant Outages in Lean Economic Times
No Contractors, No Overtime, No Money
• Changing Goalso Production to Cash Preservation o Proactive (fix it) to Reactive (defer the cost)o Minimizing Risk to Taking on More Risk o Around the clock to four tens and everything in betweeno Two Weeks to Two Months, Three Mondayso Resource Abundance to Resource Constraint (contractors)o Lack of Sense of Urgency, Challenge of Motivation
Slide 7
Outage Preparation
The Most Critical Step, Regardless of the Economy
• Pre-Planningo At least one meeting per montho We try for one per week (We have 6 mills, 1 kiln)
• Safetyo Pre-Outage Contractor Safety Meeting
Set Expectations and Consequences Send out Packets at least 2 weeks prior to meeting Insurance Requirements
Slide 8
Outage Preparation
The Most Critical Step, Regardless of the Economy
• Schedulingo Gantt Chart
Slide 9
Outage Preparation
The Most Critical Step, Regardless of the Economyo Use Gantt Chart
Details-more time up front, but will help with the “little things” that always get you in the end
Assign Resources for each task Use Critical Path Function Cold Oil-Put the Task on the Chart
o Excel vs. Project
Slide 10
Outage Preparation
The Most Critical Step, Regardless of the Economy
• Parts Stagingo Specific areas for parts, preferably near equipment locationo Use a shipping container-Inconvenient, but you can lock up
partso Difficult in lean times due to lack of resourceso Have suppliers tag parts and hardware so you know where
they go—Work Order and Asset Number
Slide 11
Outage Execution
It’s The Best of Times and The Worst of Times…
• Parts Stagingo Chasing parts
Even though parts are staged, you still have to get them Contractors stay on job, employees get parts No contractors
Slide 12
Outage Execution
It’s The Best of Times and The Worst of Times…
• Daily Planning Meetingo One formal meeting daily-All Stakeholders are Representedo Contractors presento Agenda-Follow ito Discuss progress in each area on Gantt Chart-This should be
updated prior to meeting.o Rental Equipment, Scaffolding, Cranes, Electrical needs…o Give all an opportunity to speak-go around the room
Slide 13
Outage Execution
It’s The Best of Times and The Worst of Times…
• Daily Planning Meeting-Financial Discussiono Contractors are not Presento All contractor time should be turned in and received daily
We have a specific Time Sheet we require them to use We have their labor rates for each craft We are watching each contractor total to see if we are getting in
trouble in any specific areao All direct charges should be updated dailyo All Inventory issues should be updated daily
Slide 14
Outage Execution
It’s The Best of Times and The Worst of Times…
• Shift Handover meetingo We have these at each job locationo Supervisors are thereo No night shift!
Slide 15
Outage Execution
It’s The Best of Times and The Worst of Times…
• Contractor Controlo Start out with none, bring in as needs increaseo Minimize weekend work if possible (start on Monday)o Bring in slowly and get out fast—don’t keep too many for too
longo Kiln cool downo Watch the in and outs
Slide 16
Outage Execution
It’s The Best of Times and The Worst of Times…
• Scope Creepo Management team discusses risk and rewards of performing
unplanned work.
• Budget Shrinkageo We don’t have the money…
We re-prioritize the work Willing to accept future downtime---but keep good notes
Slide 17
Outage Execution
It’s The Best of Times and The Worst of Times…
• Expecting the Unexpectedo Know there will be things o Depend on your Technicians to come up with solutions
• Rental Equipment Managemento Assign one person to be responsible coordinating rental equipment
Understand the rental terms—28 dayso Assign equipment to each job and share when possible
There are those who didn’t plan and they will “borrow”…
Slide 18
Outage Execution
It’s The Best of Times and The Worst of Times…
• Consumableso Clearly dictate to contractors what you will pay for and what
you will provide. This should be in the pre-outage contractor package
o Have hardware supplier restocking every day, twice a day when going back together.
• Utilize Production Inspections and minor repairs
Slide 19
Outage Execution
It’s The Best of Times and The Worst of Times…
• After Action Review Meetingo What went righto What went wrongo List for next yearo Contractor evaluation
It’s the Little Things….
• Hardware, Parts Staging are Critical to Successo Vendor managed at least daily, tag parts
• Plan, Plan and Plan Some Moreo Use detailed Gantt Charto Stick to your meeting agenda
• Keep Track of Your Expenseso Receive contractor time dailyo Keep up with inventory and direct charges daily
Key Learning’s
• Questions?
Cement Plant Shutdowns During Lean Times
