Decision Making in Building a New Plant The Moss Point Experience

Transcription

1 Decision Making in Building a New Plant The Moss Point Experience Danny Faucette Tindall Corporation PCI Convention Rosen Shingle Creek Resort, Orlando, FL October 5, 2008

2 AGENDA Tindall s history on the Gulf Coast Hurricane Katrina and the aftermath The Planning of the Moss Point Plant Moss Point Today

3 History Tindall Biloxi Plant Biloxi Prestress Concrete Started in 1960 s by Michael Construction Bridge beams for I-10 and Biloxi-Ocean Springs bridge construction Located on the water at Point Cadet on the Back Bay in Biloxi

4 History Tindall Biloxi Plant Biloxi Prestress Concrete Evolved into a leading Gulf Coast precaster during the 60 s and 70 s Selling to other contractors AASHTO beams Able to ship by barge from Florida to Louisiana

5 History Tindall Biloxi Plant Biloxi Prestress Concrete Parent company experienced financial difficulty Out of business by late 1980 s

6 History Tindall Biloxi Plant Tindall Mississippi Division Developed on same property as old Biloxi Prestess Filling need for parking structures for Mississippi casinos Started in late 1993

7 History Tindall Biloxi Plant

8 History Tindall Biloxi Plant Began with one double tee bed for one job Grand Casino - Gulfport Added Columns, then beams, then litewalls Eventually added flatwork Gradual Growth through late 1990 s to the mid 2000 s Serving Florida panhandle through Louisiana

9 History Tindall Biloxi Plant

10 History Tindall Biloxi Plant

11 History Tindall Biloxi Plant

12 History Tindall Biloxi Plant ISSUES Leased Property No Roof Rainouts Thunderstorms (15 minutes = 2 Hour setback) Finishing Problems Summer Heat

13 History Tindall Biloxi Plant ISSUES No Batch Plant Minimal control over concrete Cost Delivery Uncertainty - Downtime Minimal Steel Fabrication Cost per Unit Leadtimes Larger Inventory Required

14 History Tindall Biloxi Plant ISSUES Limited Storage Space Downtime Looking for Product Storage wide spread Required 24 hour shipping during peak periods Waterfront location in High Hurricane Risk Area

15 History Tindall Biloxi Plant August 29, 2005

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22 Tindall Reaction to Katrina Company Employees

23 Stay in this market Decisions Stay to help rebuild the Gulf Coast Relocate plant from leased property on the waterfront to owned property on higher ground

24 Location Away from the water Acre site obtained Near Moss Point. MS 45 minutes from Biloxi Plant

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26 Planning of the Moss Point Plant Decision on or around PCI Convention in 2005 Organization of Planning Group William Lowndes, III Owner Full time Project Coordinator Newly hired Industrial Engineer Peter Helvey Project Team

27 Decisions Scope Building design, size, production capacity Guidelines for Planning Process Best within Tindall Best within US Prestress Industry Best in the World Our own innovation/ingenuity

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29 Planning and Research Poll Tindall Managers/Engineers regarding best practices you have seen in other plants Meetings with Vendors World of Concrete Plant Visits US, Finland

30 Building Decisions Scope Building Specifications Spans Bay Sizes Construction

31 Equipment Selection Best of Tindall Cab Cranes Carpentry Shops Warehousing/Material Control

32 Equipment Selection Best of US Prestress Industry Steel Shop Equipment Automatic Stirrup Bending Automated Band Saws Batch Plant/Mixer

33 Equipment Selection Best of Prestress Industry World Elematic Concrete Delivery System Comcaster Pouring Machine Translucent wall panels natural light

34 Building Design Tindall Innovation Open Spans Easy Access Support Shops to Production Beds

35 Planning Phase Began December 2005 Substantially completed by April 2006 Turned over to Lockwood Green May 2006 Project Coordinator returned to Mississippi on August 29, 2006

36 Dates of Significance Ground Broken November 14, 2006 First Production Moved from Moss Point June Production Move Complete November 1, 2007 Dedication Ceremony March 12, 2008

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38 Tindall Corporation Moss Point, MS

39 Dates of Significance Ground Broken November 14, 2006 First Production Moved from Moss Point June 7, 2007 Production Move Complete November 1, 2007 Dedication Ceremony March 12, 2008

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41 Dates of Significance Ground Broken First Production Moved from Moss Point Production Move Complete Dedication Ceremony March 12, 2008

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44 Moss Point Today Double Tees, Flat Panels, Spandrels, Litewalls, Columns, Beams, Stairs Carpentry, Steel Fabrication and Warehouse in bay adjacent to Production Standley Batch Plant KF Batch controls Elematic Concrete Delivery System two shuttles and pouring gantry Adequate Storage

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47 Moss Point Today Double Tees, Flat Panels, Spandrels, Litewalls, Columns, Beams, Stairs Carpentry, Steel Fabrication and Warehouse in bay adjacent to Production Standley Batch Plant KF Batch controls Elematic Concrete Delivery System two shuttles and pouring gantry Adequate Storage

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53 Moss Point Today Double Tees, Flat Panels, Spandrels, Litewalls, Columns, Beams, Stairs Carpentry, Steel Fabrication and Warehouse in bay adjacent to Production Standley Batch Plant KF Batch controls Elematic Concrete Delivery System two shuttles and pouring gantry Adequate Storage

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55 Moss Point Today Double Tees, Flat Panels, Spandrels, Litewalls, Columns, Beams, Stairs Carpentry, Steel Fabrication and Warehouse in bay adjacent to Production Standley Batch Plant KF Batch controls Elematic Concrete Delivery System two shuttles and pouring gantry Adequate Storage

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60 Moss Point Today Double Tees, Flat Panels, Spandrels, Litewalls, Columns, Beams, Stairs Carpentry, Steel Fabrication and Warehouse in bay adjacent to Production Standley Batch Plant KF Batch controls Elematic Concrete Delivery System two shuttles and pouring gantry Adequate Storage

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62 Issues Resolved All production except beams/columns under roof Producing own concrete better quality, lower cost, less downtime Plenty of storage space Steel Fabrication coming up to speed

63 Questions?