(Part II – The Paving Site) 36th Annual Rocky Mountain Asphalt Conference & Equipment Show February 18-20, 2009 Use Common Sense Train for and Implement Best Practices Focus on Quality and Customer Service Include Employees Be Willing to do Things Differently! Account for predictable traffic patterns in scheduling – Know traffic patterns to job. Rush hours, special events, school and factory hours. Adjust routes and timing. On mill and fill projects, use delivery trucks to back haul RAP – Save on trucking. May need release agent at paving site. Mill different layers separately to allow more flexibility in RAP use – Different layers may have different materials. E.g., milling surface layer with high friction aggregates will provide RAP for surface mixes. Evaluate costs of extra pass and separate stockpiles. Sort milling teeth by the amount of wear to reuse less worn teeth – When replacing worn milling teeth, sort them by the wear. They can be used together to obtain smooth milling. Saves on number of teeth used each year. Install weigh bridge on milling machine conveyor to maximize truck load – Minimize the number of trucks during the day. Position trucks side-by-side in front of milling machine to keep continuous operation. – Save time in truck exchange. Minimize water spray during milling to keep RAP dryer – Minimizing cooling water reduces delays in re-filling tank and reduces moisture in the RAP, reducing plant fuel consumption. Calibrate electronics on distributor truck every day – Important to obtain proper coverage and quantity. Install plate at the end of distributor spray bar to avoid overspray of curb and gutter – Avoids cleanup and keeps customers happy. Make sure each paving crew has a wooden level to check the screed (daily), transverse joints, and mat behind the screed – Identify warped screeds, smooth transverse joints and proper drainage. Install a bumper in back of the spray bar on distributor truck - Protects the spray bars, avoids down time. Investigate use of trackless tack –Reduces the time for an emulsion tack to break. This can increase productivity and reduce tracking. Attach a magnetic grade gauge on the back of the paver ($55 each) – Provides a check of crossslope control on paver. Provide paving crew and roller operators with daily feedback on smoothness and density – Allows the team to know the score. Share bonus with employees on bonus jobs, when successful – Get buy-in from employees on the importance of quality. Keep biodegradable release agent on board paver for tool and paver clean up - Keep tools and paver parts clean, saves time and avoids using diesel. Assign one member of crew to look after the electronics and store them in a dry, safe place One person responsible for the care and storage of the electronics to avoid costly malfunctions.. Install hooks, buckets, and bins on pavers for tools (e.g. putty knives, wood level, 30’ tape, 100’ tape, gloves, 12’ straight edge, whisk broom for tacking pavement edges) - Having all of the tools needed saves time. Tools should be inventoried, cleaned and placed back on the paver at the end of every shift. Use MTV in places requiring hand work or when trucks can’t get to paver - This helps to deliver mix to the paver in places where trucks cannot reach or stay in contact with the paver. It can also be helpful in depositing mix in areas requiring hand work. Cut off feeders and run augers to avoid piling at end of paver pulls –Cutoff the feeders and run the augers properly to avoid piling mix at the end of the pull. Use a paint marker system on pickup truck instead of string line –Improves productivity by speeding job layout and improves safety by keeping employees away from traffic. Have auger and tunnel extensions available on site– Auger and tunnel extensions reduce segregation and improve longitudinal joints. Waiting for them or proceeding without them hurts productivity or quality. Check tire pressures on pneumatic rollers often – Important to the ability of pneumatic rollers to obtain density. Purchase a “vibe tachometer” for each vibratory roller to ensure proper frequency ($500 each) – Assures proper roller operation for compaction and smoothness. Always stop roller only on cool pavement at an angle – Avoids bumps in the pavement for maximum smoothness and to avoid re-work. Inspect scrapers, wipers, and cocoa mats on rollers and have spares available – Keep drums and tires clean to avoid pick-up. Avoids mat blemishes and improves smoothness. Install small rubber bumpers on all perimeter frame rollers – Protects the sheet metal from damage. Fill roller water tanks and check the water spray system at the beginning of each shift –All equipment should be fully functional prior to beginning paving to avoid time delays and quality issues. Stopping to fill or repair rollers may affect density and require stopping paving operations. Have welder wire available to clean roller water spray nozzles and have extra water spray nozzles available - Welder wire is an easy and cheap way to clean clogged nozzles. Nozzles should be checked periodically to avoid down time. Install infrared sensors on rollers or equip operator with infrared gun and set temperature targets for each type of roller - Assures rolling temperatures are correct. It keeps the operators aware that they are working in the right temperature zone. Equip all rollers with high-intensity discharge xenon lights for night work - Important safety and quality issue. Explore intelligent compaction for rollers – This technology could help quality and productivity on paving jobs. Select rollers to match paver and planned production rates - Roller selection is part of the daily planning. The wrong type and number rollers can mean the difference between high production and quality, and wasted time. Have a printed daily maintenance check list for equipment operators and truck drivers – Avoids downtime and holds them accountable for the equipment they operate. Have parts “uptime” kits for pavers and rollers –Have high wear and repair parts in stock or on site so they can be available at a moments’ notice. Install pre-cleaners in front of air filters on rollers and pavers – Improves fuel economy, and improves engine and filter life. Set start time for operations and meet it - Start time for paving crews should mean when the first truck dumps into the paver. There is a 20 to 30 minute lag (while the paver warms up and the crew gets ready) between the “start time” and when the pave starts moving. Stagger start times for crews on long days to avoid loss of momentum – Not all employees need to start at same time. Different members of plant and paving crew can start and quit at different times. Outline tools on tool racks in utility trucks so they are kept in the same place all the time – Saves time when people know where to get the tool they need and when a tool is missing and needs to be replaced. Tape a list of tools contained in toolboxes and periodically inventory – Saves time by knowing that key tools are available. Install ice machines for employees at each yard to avoid stopping to buy ice – Crews stopping at convenience stores wastes time. Install common key locks on all equipment to avoid waiting for lost keys –Time can be lost looking for the correct key or waiting for someone to show up with it. Plan each day’s production and paving in detail – Every days’ production needs to be planned in every detail for maximum productivity. Equip dump man, paver operator, and MTV operator with radio headsets, especially at night, for better communication. (one ear phone, not voice activated) - These are an inexpensive way to coordinate between the dump man, MTV operator and paver operator and can result in higher production and greater safety. Avoid unusually long shifts for employees – Tired employees are more likely to make mistakes affecting quality and safety. Longer hours do not mean more productivity. Keep cooler of water and electrolyte drinks with drinking cups on paver at all times – This is a safety issue. Dehydration can reduce good judgment and result in heat exhaustion or heat stroke. Enhance safety at every opportunity – Improved safety reduces insurance costs and improves productivity. Examples: “X” on back of safety vests means “I’m not facing you,” distinctive red headgear for new employees to indicate they are new, backup cameras on all trucks, reversible flashing arrows on front of tack truck to indicate direction for oncoming traffic, orange flags on the ends of distributor spray bars, flashing strobe lights on pavers, rollers and other equipment. Provide an incentive plan for employees for safety, quality and cleanliness – Safety and quality affect your bottom line. Cleanliness can affect safety and presents a better image to your customers. Establish a training program for paving company customers – Value the customers and it will improve the quality of their work, reducing the number of bad jobs and conflicts. Provide attendance incentives such as food and giveaways. Keep them informed on future changes in company and industry, and emphasize the importance of best practices. Cross train people in critical positions – If a critical employee does not show up, another should be trained to take their place. Motivate employees to do the right things. Explain how it benefits them – Use bonuses and commendations to motivate employees. Point out how quality affects the bottom line. Have a regular training program for employees – Training affects quality and reduces employee turnover. Examples of training include: toolbox talks, regular training sessions, on-line training, equipment manufacturers’ schools, and using professional trainers. Provide “train the trainer” classes for superintendents and foremen – This will make them more effective in teaching others how to do their jobs. Have an employee appreciation day at least once a year – Shows your employees that you value the work they do, improving morale and productivity. Call on customers - Increases customer satisfaction and helps maintain repeat customers. Make sure job is done right the first time to avoid expensive call backs – Never take shortcuts or accept marginal material to get the job down. It is much more expensive to remove and replace materials than it is to do it right the first time. Put paving crews in uniforms so they look and act professional – This provides and better image to your customers and the general public. It can also instill pride in your workers. Have a person responsible for site clean-up throughout the day – This assures that the site is kept clean since one person is responsible. Provide accessible trash bags on pavers and other equipment to keep job site neat – This portrays a better image to your customers and the general public. It may also prevent trash from ending up in the mat.