Better Roads

October 2013

Better Roads Digital Magazine

Issue link:

Contents of this Issue


Page 17 of 82

3PG It's Dangerous Out There ALWAYS BE SAFE Whether you work off the road or over the road, Bridgestone wants you to make safety your first concern. Maintaining a safe workplace and reinforcing safety rules contributes to a more productive operation and reduces costs. If you need a better reason, it saves lives. LESSONS IN SAFETY There is simply nothing more important than starting your shift safely and getting your people home without harm. That's why we've produced a series of short videos that you can use in safety meetings or at shift start. Access them at bridgestoneminingsolutions .com/safety and select from a range of topics. Bridgestone Commercial Solutions For your nearest Bridgestone Authorized Dealer, visit our website ©2013 Bridgestone Americas Tire Operations, LLC. All Rights Reserved. Text INFO to 205-289-3789 or visit BAN120164_Equip World Fractional Roads1 16 October 2013 Better Ad 1 Bridgestone_BR0413pg12.indd 1 JOB # BAN120164 Gorman_BR1013.indd 16 CLIENT Bandag year to this focus on preventive maintenance and to getting all of the shop employees and equipment operators involved in the service and welfare of the equipment. The company also started a second shift in the shop because many repairs happen at the end of the day, which reduced overtime spending. Gorman's procedures for handling tires demonstrate how data and training improve outcomes. In 2012, mechanics responded to 60 emergency calls for tire failures, so Corbett started a training program for equipment operators and gave them all tire gauges. Now, the operators are responsible for checking and recording tire pressure every day. Shop mechanics received training in recognizing tire wear and reading tire codes. The work has paid off. So far this year, there have been only nine emergency calls for tire failures. "Training does play a large role in everything we do," Corbett says. "I think that's imperative because then the guys know you're investing in them, too." Every new hire at Gorman goes through TPR training, even if he or she will work in a supporting position. The company does refresher training every spring as employees gear up for the roadwork season. The focus on organization and orderliness through a process called 5S — sort, set in order, shine, standardize and sustain — also results in cleaner equipment and a more appealing and orderly maintenance shop. Everything in the shop, and on each truck, is labeled, and there is a process for cleaning the equipment and shop each day. Every tool and every item have a home location. Chip seal foreman Jim Brush has been working in the maintenance shop during the winter season for about 10 years and remembers it being different in the early days. "The garage was always dirty, dingy looking, dimly lit, and now it's great going to work," Brush says, adding that the commitment to orderliness and upkeep appealed to him because he was raised to take care of his equipment. Implementing Total Process Reliability (TPR) lowered Gorman's emergency repair rate to 1.6 percent halfway through this year, saving about $500,000. Gorman officials credit TPR for the maintenance improvements and believe the strategy has improved employee morale, customer perceptions and the bottom line. "What we have seen this year has been the extreme positive feedback from our customers," says Brian Jones, Gorman's technical services/continuous improvement manager. "They are commenting on the appearance of our equipment and saying, 'Your crew showed up, and they were ready to go.'" Savings can be measured by calculating maintenance costs as a percentage of the equipment's estimated replacement value. Currently, Gorman's figure is 2.8 percent in an industry where the average is 15 percent and the best-in-class mark is 4 percent. The figure was 12.1 percent when the company started TPR. Change is never easy, but having a structured approach allowed The Gorman Group to get on the road to becoming the best-in-class operation.
"My advice to other owners? You've just got to go for it," Mark Gorman says. He admits the company had its problems "for years but just didn't have the guts to follow through. TPR is the best decision we ever made." v About the author: Virginia Demaree Johnson is a freelance writer and editor based in Raleigh, North Carolina. 12/19/12 2:19 PM 3/28/13 12:26 PM DATE 12.19.12 INITIALS CD Rob P. DATE 9/30/13 1:57 PM

Articles in this issue

Links on this page

Archives of this issue

view archives of Better Roads - October 2013