sign manufacturing and maintenance
DESCRIPTION
Sign Manufacturing and Maintenance. David Cook, P.E. State Maintenance Engineer, SCDOT. Sign Shop Consolidation. 3 Manufacturing facilities 3 Sign Shop Supervisors 2 Delivery Trucks 25 Total Employees Long wait time (up to 100 days). 1 Manufacturing facility 1 Sign Shop Supervisor - PowerPoint PPT PresentationTRANSCRIPT
Sign Manufacturing and Maintenance
David Cook, P.E.State Maintenance Engineer, SCDOT
Sign Shop Consolidation
Before After
3 Manufacturing facilities
3 Sign Shop Supervisors 2 Delivery Trucks 25 Total Employees Long wait time (up to
100 days)
1 Manufacturing facility
1 Sign Shop Supervisor
Free Shipping! 9 Total Employees Orders filled in 30
days or less Reduced production
cost by over $500,000 per year
Production Analysis Production Goals Staffing Estimates SMART Goals Monitor
Performance
How We Got There
Time Studies - Employees were observed performing tasks.
Prep time and volume was considered
A reliable maximum production value was identified
Production Analysis
Screen Printing Rolling and
Trimming Large investment
in set-up time is for setting up screen printer, making screens, & clean-up
Standard Signs
1 8 15 22 29 36 43 50 57 64 71 78 85 92 99 106 113 120 127 134 141 148 155 162 169 176 183 190 1970
5
10
15
20
25
30
35
40
45
Time per sign
One screened sign about 40 minutes
50 screened signs about 52 minutes
Screen Printing Production
100 screened signs 65 minutes
1 15 29 43 57 71 85 99 113 127 141 155 169183 197 211 225 239 253 267 281 295 309 323 337 351 365 379 393 407 421 435 4490.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
18.00
Time Per Sign
Roll & Trim
1 sign about 15 minutes
50 signs about 2 hours
Roll & Trim Production Times
Hand laid sign production was more difficult to quantify
Assumptions and estimates were used
We used a 24”x 72” sign for an average size
Made allowances for the unique nature of these types of signs
Hand Laid Signs
From our production study we determined maximum production values
Observed maximum production was modified to expected daily production ◦ Safety meetings, training, ancillary duties,
facility maintenance, etc. This value was further adjusted with
yearly realistic reductions◦ Annual leave, sick leave, holidays, special
projects, equipment down time
Production Goals
750,000 signs in South Carolina
10 year replacement schedule 12.5% additional for new and damaged signs.
About 84,000 signs per year
Estimating Sign Demand
52 weeks X 4 days = 208 days/year Holidays = 13 days/year Sick days = 8 days/year Annual leave = 12 days/year Special projects = 3 days/year Inventory = 5 days/year Annual average work days = 167 Required production 84,000/167 = ~ 500/day
Required Production
1-Supervisor1-Screen Printer 2-Roll and Trim2-Hand laid signs1-Admin1-Shipping/receiving
Staffing by Production Estimates
SMART production goals are part of the position description
Production is monitored daily Coaching and counseling is used for
underperforming employees All current employees are meeting or
surpassing required production goals
Performance Monitoring
Costs were compared to measure efficiency of new sign production process
Private vendors were queried but would only give verbal estimates
SCDC Prison Industries produces signs and has a current contract for various types of signs
SCDOT production costs encourage in-house sign production
Cost Comparison
SCDOT Cost Prison Industries Price Private Vendor Price$6.00
$6.20
$6.40
$6.60
$6.80
$7.00
$7.20
$7.40
$7.60
$7.80
$6.67
$7.68
$6.83
Hand Laid Sign Production Costs per SF
10 20 30 40 50 100 200$2.00
$3.00
$4.00
$5.00
$6.00
$4.20
$3.90 $3.81 $3.76 $3.74 $3.68 $3.64
Standard Sign Manufacturing Cost per SF
Cost per Manufactured Sign Prison Industry's Price
$4.52 - PI cost
Private industry price is 3.70 per Sq.Ft. for 100 or more.
Sign Maintenance
In 2003, SCDOT implemented HMMS
Need to inventory assets to know what needed to be managed
Sign Inventory◦ Barcode signs and
assemblies
History
Sign◦ Manufacturing Process
Manufacture Date Sign Type Sheeting Type Sign Legend
◦ Installation Process Install date Directional Information Linked assembly
Barcode Information
Assembly◦ Installation Process◦ Location
County, Route, Milepoint
GPS◦ Associated signs
Barcode Information
All barcode information was manually recorded and entered into HMMS◦ Paperwork Lost◦ Entry Delay◦ Entry Errors◦ Inefficient◦ ….Inaccurate database
IT Presentation – Barcode Readers and Tablet PCs
Data Collection Method
Retroreflectivity – Minimum standards◦ 23 CFR Part 655◦ 2009 MUTCD◦ Regulatory, Warning, and Ground Mounted Guide
by January 22, 2015◦ Overhead Guide by January 22, 2018
Management Method◦ “Blanket Replacement Method”◦ “Expected Life Method”
Sign Management
Scanners for Sign Manufacturing Shop
iPads and Bluetooth Scanners for Sign Crews
Technology Enhancements
200056
90 sign trucks statewide 15 signs per day per truck – (avg. daily prod) Reduction of data collection and entry by 2
minutes per sign Results in a savings of 45 hours per day Average loaded rate of $21.75 /hour and 217
actual days worked per year. Total Annual Savings: $213,000 Additional benefits:
◦ Real time data◦ Accurate data
Cost Savings
Need to have sense of ownership from IT Need to cache data so it isn’t dependent on
cellular service
Lessons Learned
Research Project – Life Expectancy◦ Develop more specific replacement schedules
Sheeting color Direction Sheeting type …?
Remove unnecessary signs
Future Improvements
Questions?