Aggregates Manager Digital Magazine
Issue link: http://read.dmtmag.com/i/883641
16 AGGREGATES MANAGER / October 2017 S howing customer appreciation is important, but it needs to be strategic so it doesn't slow down cycle time. "It may seem totally harmless to have snacks and coffee at the scale house, but get rid of it if you really want to move trucks along," says Ron Becker, a business consultant at Command Alkon. "You want trucks coming in and getting rid of material. If they stop for 10 minutes here and there, that time could add up to a load." The ability to print a loadout ticket at the scale also helps keep cycle time and the loading process moving along because it keeps trucks in the line of traffic. "It adds huge efficiencies so things don't break down at the scale house," Becker says. There is also a safety aspect of print- ing a ticket directly at the scale instead of drivers going inside the scale house and potentially falling, especially in ar- eas that experience inclement weather, such as snow and ice. "If you are watching your gate-to- gate times and accurately tracking them, it skews the numbers when someone comes in to get a ticket and then talks for 10 minutes." Becker adds. Although it's good to keep the drivers happy, ultimately, the truck- ing company is the paying customer. "When a trucking company calls and asks why a load took so long but you have no explanation, because the tick- et time doesn't reflect how long it took to complete the load cycle, it could be problematic," Becker says. Instead, he suggests planning a separate event in spring or summer during good weather. "There is nothing wrong with having a grill near the scale house and handing out a hot dog on the way through to get a ticket," he says. "This allows you to take care of the customer — the trucking company — and show appreciation for the driver, too." T o have the most efficient load- ing and ticketing process, all elements of the system need to be integrated and simplified. This in- cludes pulling together equipment load cells, scales, PLCs, and incorporating information to do a batching load-out and inventory. "From this information, you can develop a graphical, user-friendly sys- tem for operators to be able to easily load-in and load-out," says Jay Wise, a partner with Kruse Integration. Graphically depicting a physical sys- tem makes it easier to be understood and allows for quick learning, opera- tions, and troubleshooting. Within the system's PLC and database, a variety of batching recipes can be created so they can quickly be selected via a drop-down menu. "You might want a different mix of materials for load out into the trucks or rails," Wise explains. "There may be different silos and cement bins — and even belts — that drive the system when a truck goes under them to load the material. The drop-down menu of formulas allows a different batch to be loaded to each truck." A system that tracks and records information such as downtime and inventory allows producers to identify problems, as well as what is keeping the loading and ticketing process mov- ing along. "You can't fix something or improve it if you aren't recording data," Wise says. Report details highlight specific areas that require improvement. Wise gives an example of the old school way of reporting downtime to a supervisor — a napkin with notes on it about the reasons for downtime. "This isn't detailed enough," Wise says. "If not as efficient as possible, you won't be able to keep costs down. Selling a ton of sand or rock for $6 or $7 is a low margin. If you're not automated to get reports, you aren't being as profitable as possible." A t Cemex's Victorville, Calif. facility, the largest portion of its trucks are dispatched, making it paramount to keep the loading and ticketing system as efficient as possible. To expedite the process, white cards are handed out to all drivers at the guard gate and each driver is asked to fill out his/her information. "This speeds up the process when the information is being put in for ticketing," explains Glenn Carr, Cemex regional manager of logistics operations for the West Region. "The card is used to confirm any discrepancies with the customer." It also allows the loading system in place to operate efficiently, enabling a truck to be loaded in less than seven minutes. "Keeping the drivers in their equip- ment as we load their trucks minimizes the potential for slips and other acci- dents," Carr adds. Moving the signature pad and ticket delivery closer to the drivers' hatch-clos- ing station also further reduces custom- er exposure and time at the terminal, which reduces the average trip time between loads, he says. "The utilization of a traffic light system is another effective way to communicate with the drivers on the scale," Carr adds. "In our environment, communication is key. Starting with spotting the truck on the scale, a good PA system is important. This eliminates wasting time trying to get the truck under the spouts." Producers should ensure they have a good recovery system in place and keep the operation's baghouses maintained for top efficiency. Keeping the baghous- es and air pad silos in good condition enables trucks to be loaded both cleanly and quickly. "If you have a good supply of cement, but it overruns your recovery system, your load time will be substantially be reduced," Carr points out. "Investing in a good baghouse and recovery system can help the process." Voices of Experience Ron Becker Jay Wise Glenn Carr