implementing twi at gopher resource
TRANSCRIPT
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Implementing TWI at Gopher Resource, LLC
An Overview for Enterprise Minnesota
11/12/2014
THE CONTEXT OF IMPLEMENTING TWI – JI
GOPHER RESOURCE, LLC
The Basics 2014 Eagan Site
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• Founded 1946
• 62 Acres
• 166 Hourly production EE
• 1 Administrative/Leadership
• Secondary* lead smelting: 2 of only 12
facilities in the U.S. • Primary smelting refines mined lead ore
• Secondary smelting recycles used lead
• Recycle spent lead acid batteries and
other lead bearing materials
• Fully permitted TSDF (Treatment, Storage & Disposal Facility)
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Warehouse &
Scale house
Resource Plastics &
The Recycling Zone
Refining
Furnace Area
Office/ Hygiene
RMPC
Maintenance
Compost Site
City Soccer Fields
Storm Pond
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Refining
Furnace Area Office/ Hygiene
RMPC
Maintenance
Storm Ponds
Resource Plastics
• Wholly owned subsidiary of Gopher Resource, LLC
• Founded 1992
• 1 of only 3 U.S. companies recycling battery cases
• Processed 23 million pounds of polypropylene in 2013
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The Dakota County (MN) Recycling Zone Co-located with Resource Plastics
Gopher Resource has operated Dakota County’s Household Hazardous
Waste Collection program since 1993, providing a place for residents to
bring recyclables (including electronics) and a safe way to dispose of
their household hazardous waste.
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2013 volume
• 52K individual drop-offs
• 4K - 5K paint cans / week
• 3 semi-trailers of
electronics / week
• And much more
Lead Acid Battery Cycle
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99%
of batteries sold
are returned for
Recycling!
Plastic
New Batteries
New
Battery
Old
Battery
Old Batteries
Battery
Manufacturer
Lead
Refining Lead from both furnaces is refined in 100 ton kettles
into customer specified alloys
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Finished Goods
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1 ton Blocks
25 lbs. and 90 lbs. Billets
Alloys are cast into 3 basic shapes
70 lbs. Pigs (bars)
– 25 Pigs per Bundle
Training Within Industry Implementation
Team and Project Leader Competencies
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Training Within Industry Implementation Journey
Proven System of Training
Making the Decision with Business
Partners
Need for a Plan
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A 3 on TWI JBS SYSTEM
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Action Name TWI- Eagan and Tampa Report 5/23/2014
Action Owner Maureen Conway Date
Brief Action Description -
Problem Statement: The need for a standardized approach to teaching operators the one best way to successfully do their job. This program will reduce expenses related to operator errors on equipment, waste, and quality output of products. The project also targets increased efficiency in production and
developing a standardized approach to teaching operations-related-skills across the company.
Project Risks - Time and resources. Trainers are VERY busy with their own projects/goals. New ISD person needs integration/immersion time.
CI Metric Baseline Expected Actual
Sign-off by Priority Leads Sponsor: Nick De Nicola Champion: Rob Oberle and Justin Barnhill Financial/ Capital:
Project Expense Proj Capex/Mtce Expense Financial Target
Action Plan (Implementation Requirements) Responsible Party
Completion Date
Status w Roadblocks/Mitigation Target Revised Completed
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Implement TWI phase III, IV, V of plant trainers and audit results on integration of JBS/OJT in Refining, Pollution
Control, and Shipping
Training Team 06/30/14
Different dates for Tampa and Eagan due to levels of maturity in the project
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Create and coordinate BLITZ plans: (pilots)
TAMPA RMPC/Lab/Furnaces (Jansen)
Refining/Pollution Control/Shipping (Jeff)
EAGAN Refining/Shipping/Baghouse (Dan)
Furnaces/RMPC/Lab (Rock) Training Team 06/02/14 08/15/14
08/2014
Eagan
Training Blitz scheduled in Refining
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Create Marketing Plan for each site for TWI
Maureen 06/05/14 05/23/14
Completed plan - ready for implementation starting in June, 2014
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Organize TTT for TWI JI Certification for Trainers and schedule for training additional TWI Trainers at both sites
Maureen 07/01/14 06/23/14
TWI Institute Training on week of July 14 in Eagan for all 4 instructors
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Oversee the Tablet project including but not limited to:
Securing lock boxes; color-coding tablets; Installing tablets
in the control room of the plant; Designing a formal training
plan for the TWI Trainers in the plant Training Team 07/30/14 08/2014
Eagan and
Tampa
Work with each site team on this where needed.
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Communicate with Operations Leadership about status, needs and schedules
Maureen Ongoing Completed
Will use monthly Ops Leadership/Training meetings at both sites.
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Oversee plan for bringing Area TWI trainers together to create JBS and share "lessons learned" from the Phase IV
teaching
Training Team 06/01/14 Completed Need common talking points and exercises (Eagan can use as well). Ongoing
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Work JBS's and LMS Course Catalog into seamless execution
Maureen and new Curriculum Manager/LMS
Coordinator 7/10/2014 and
ongoing
Completed (will need
some work with new
LMS) Need to review at Bi-weekly meeting with Ops Leadership and include HR
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Oversee phased-in Go'Lives for TWI Phases with
each site Training Team 07/15/14
Complete Eagan
Go-Live Oct Tampa In coordination with Department Managers
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Oversee plan for bringing Area TWI trainers together to create JBS and share "lessons learned" from the Phase IV
teaching and Training Team 06/15/14 In Progress
Eagan Need Lessons Learned form or format for recording electronically (can use in Eagan, as well).
11 Develop and track metrics for effectiveness
Training Team ongoing In Progress
Eagan Can use same metrics at both sites
Training Within Industry Implementation Journey
Many Moving Parts
Certification Levels
Cav Coms and Tablets
Role Training Plans
Course Catalog Design and Codes
Training Matrix
Kiosks
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Phases of TWI – Job Instruction
TWI Trainer Certification
JBS Creation & Validation
TWI Training Prep/Planning
Training, Training Blitzes & Results Recording
Training Audits & Needed Retraining
Measuring Effectiveness Aligned with Productivity, Costs, and
Quality Standards
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Training Within Industry Implementation
The Culture Shift
Need for Change Management
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Training Within Industry Implementation
Utilizing Systems Thinking
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Training Within Industry Implementation
Content Management
JBS writing and validating
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FURNACE COMPETENCIES (Groups of Jobs)
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Training Within Industry Implementation Journey
The Big Pay Off
Measuring Effectiveness
Staying the Course
C I
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Role Training Plans
• Furnace Laborer
• Furnace Operator
• Furnace Advanced Operator
• Refining Laborer
• Refining Operator
• Refining Advanced Operator
• RMPC Laborer
• RMPC Operator
• RMPC Advanced Operator
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• Baghouse Operator
• Shipping & Receiving Operator
• WWT Operator
• Lab Operator
• Process Engineer
• Lead Person
• Supervisor
• Department Manager
Furnace Laborer Training Plan
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New Hire
Orientation
Furnace
Laborer
Certification
Annual
Mandatory
Courses
Annual Safety &
Environmental
Training
General Department
Qualification
Reverb Laborer
Qualification
Forklift
Certification
New Hire
Training
Blast Laborer 1
Qualification
West Reverb Laborer
Qualification (Eagan
only)
IT Training
Torch
Usage
Furnace – Laborer Level Certification
Department General Qualification
Ventilation Cleaning
Cleaning Spray bars
Wash and Toss/Cleaning Scrap Metal Decontamination
Running Lead Samples (Furnaces)
Cutting Scrap Rebar and Pipes
Barrel Crusher
Furnace – Laborer Level Certification
Reverb Operator Qualification
Reverb Lead Side House Keeping
Reverb Lead Side
Jib Crane Operation
Graphite Mold Release
RAT Horizontal and Incline Screw LOTO
Pan Pusher LOTO
Drag Bar Plow
Reverb Slag Side House Keeping
Reverb Slag Side (Tapping Slag)
Reverb Slag Sampling
Air Lancing (Bubbling) Reverb Slag Side
Dust Bin Dumping
Checking Pile Height
Barrel Crusher
Cutting Scrap Rebar and Pipes
Furnace Operator Training Plan
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Furnace
Operator
Certification
Blast Operator 2
Qualification
Furnace Operator
Qualification
Annual Safety &
Environmental
Training
Annual
Mandatory
Courses
Furnace – Advanced Operator Level Certification
Reverb Charger Qualification
Volvo for Furnace Volvo for Reverb Chargers
Daily Volvo Wash I-Pad Controller
Weekly Volvo Wash Pulling Grid from M-75 and M-7
Volvo Seat Adjustment Blending Dross
Bringing in Sleeves Filling the Slow Feed Table
Bringing in Fluxes Making a Press Bed
Reverb Charger 1 Scraping Press Hallway to RMPC
Dryer System LOTO Emptying the Dross Bin
Dryer Burner LOTO Moving a Row of Feed
Cross Over Screw LOTO Inspecting and Cleaning Incline Belt Rollers
Incline Feed Conveyor LOTO Inspecting and Cleaning the Incline Belt Feed Scale
Coke Breeze Feeder LOTO Calibrating Incline Feed Belt Scale
Slow Feed Table LOTO Dust Feeder LOTO
Spreader LOTO Filling the Dust Feeder
Reverb Start Up Inspecting and Cleaning Dryer Chute Teflon
Reverb Shut Down Inspecting and Cleaning the Dryer Combustion
Chamber
Reverb Charger House Keeping Inspecting and Cleaning the Dryer Exit Screen
Back
Training Within Industry Implementation Journey
QUESTIONS
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