Piedmont Fiberglass Blog

On May 27-29, 2009, thanks to a grant from the State of North Carolina, Piedmont Fiberglass was the recipient of a workplace organization training event facilitated by David Beard of Catawba Valley Community College. During this training, we learned the 5S’s of workplace organization and flow, which are:

• S1: Sort - Keep only what is needed in your area
• S2: Set in Order - A place for everything and everything in its place
• S3: Shine - Clean up the workplace
• S4: Standardize - Develop a system (rules) to maintain what has been done
• S5: Sustain - Self discipline to maintain established procedures

For this event, we concentrated on the Finishing Department which assembles, does body work, sprays gel coat and polishes to produce the final product of steeples, baptistries, slides and other large components. During this 3 day event, 9,000 square feet of our plant was reorganized. The objective of this training was to understand how 5S works by creating a model work area (Finishing, in our case) and improve productivity and efficiency by improving the organization of the workplace and the flow of the product.

Observations and Opportunities

The following observations were made in our existing system, creating opportunities for improvement!

1. Flow was counter-productive
2. Too much staging
3. Aisles were obstructed
4. There were unnecessary items in the work area
5. Aisles are too narrow
6. Many opportunities for visual controls to be added
7. SAFETY: Extension cord on wall
8. SAFETY: Fire extinguisher locations should be more visible

S1: Sort

The first order of business was to sort. Unnecessary items were removed from the workplace.

S2: Set in Order

We created boundary and flow lines throughout the work area, and improved those that were faded and worn. More than 800′ of lines were painted. We also created labels or visual controls on as many items as possible, creating clarity about what things are, and where they belong.

Workplace Organization: Overstock

Before the 5S Event, excessive inventory was prevalent. In the case of the most used sanding disk, 30 sheets were needed; but more than 300 sheets were routinely found in the target area.

In terms of cost, $13 of inventory was needed; $120 was on the floor. Excess inventory was removed and returned to stores.

Workplace Organization: Tools

Tools were sorted into Job-Specific tool carts. These were color-coded by Department (Blue) and Work Station (Yellow, Red). Then shadow boards were created, and labeled. This resulted in reducing the tool inventory in the department by 2/3.

Safety

Before the event, electrical extension cords were strung the length of the work area. This created a potential safety hazard. By changing the product and work flow, the risk was eliminated. The work area requiring access to electrical power was greatly reduced.

Workplace Organization: Flow

Before the 5S Event, the Finishing Department work area was congested, and the layout worked against the product flow. The new layout corrected flow and removed the congestion. Tools and materials were also moved closer to the Point of Use (POU).

The product flow was counterproductive. Start-to-Finish work stations were set up, and staged product blocked any flow. During the event, the team brainstormed ideas to improve the flow. The layout was changed to create flow lanes for different product families. The work was rotated 90 degrees to make the flow linear. 3 different process work stations were set up.

S3: Shine

As part of S3 - Shine, the work area was cleared and swept. Old outdated lines were scraped and sanded off the floor.

S4: Standardize

For S4, Standardize, the challenge was to create a system whereby we can maintain the improvements made. A Job Cycle Chart was created to make clear what to do, when to do it, and how to do it. From this, job assignments were made. A Data Board displays who does what, creating visibility and accountability for each task.

Audits - As we learned and made improvements, audits were done in teams each day, then averaged together to create overall scores:

• Day 1: 1.59
• Day 2: 2.33
• Day 3: 3.62

Results

The following improvements were made in the Finishing Department as a result of this event:

• Improved 5S Rating: From 1.59 to 3.62
• Workplace cleaned and organized.
• 9,000 square feet cleaned and organized.
• More than 800’ of lines painted on the floor
• Standards and procedures put in place to maintain results.
• Safety; Aisles clear; Flow lanes created, extension cords eliminated; Fire Extinguishers more visible.
• Productivity/Flow improved
• Flow lanes identified and marked
• More than 267 Material/Tool locations identified and labeled

“We thought that we were organized and efficient before this event. Now we are better organized, safer, and have a much higher level of efficiency.” - Terry Davis, Plant Manager

“It is exciting to see the improvements that we have made in our entire process. We are grateful to Catawba Valley Community College for providing this training for us.” - Douglas Caudle, President

S5: Sustain

Our challenge going forward is to sustain what we have achieved and apply what we have learned to our other departments as well.

Workplace Organization Team

Back L-R: Terry Davis, Lee Davis, Jason Morgan, Douglas Caudle, David Beard
Front L-R: Randall Mayberry, John Eakes, and Steven Bowman.

Most churches have 501(c)(3) status, so you don’t expect to pay sales tax, however, we are required by law to charge sales tax for products sold or picked up inside North Carolina. What we can do is provide you with form E-585 which can be used to obtain a refund from the Internal Revenue Service after the sale is complete.

What Is Taxable. What Is Not.

We are required to collect sales and use tax for all products sold inside North Carolina. We are also required to collect taxes for products sold outside of North Carolina, but picked up by the customer at our plant. Taxable items include all material products and freight sold to the customer.
We are not required to collect sales and use tax for products sold and delivered outside of North Carolina. Non-taxable items include steeple installation and baptistery pre-plumbing.

Obtaining Your Tax Refund

We can provide you with the form E-585 or you may go online to http://www.dornc.com/downloads/sales.html and complete it there. The IRS will then handle any tax refund that is due.

There are, of course, many items you need to juggle as you consider the construction or upgrade of your church building. We regret to add to that list, but wanted you to be aware of some changes in building code requirements, updated in February, 2009. Please read this carefully as this may apply to your project with us and, if so, will require some legwork on your part.

The new international building codes (1509.5 & 1509.5.1) require the use of non-combustible resin in towers, spires, domes, and cupolas. Piedmont Fiberglass has the option to use either combustible or non-combustible resin in your construction. The catch is that using non-combustible resin is about 30 percent higher in cost than using combustible.

This is where you come in. As with most building codes, there are exclusions and variations, so it is possible that you wont need to use the non-combustible resin. Please consult your local building code official for a determination on your specific project, then let us know which material you require.

How do I know what size steeple is right for my building? How can I help minimize wind and weather damage over time? What is a receiving ring and do I need one? What is Krinklglas? These may be some of the questions bouncing around in your head and you try to select the right steeple for your building. Piedmont Fiberglass offers a wide variety of sizes, styles and options. Here are some tips for selecting the right steeple for your church, and an explanation of some of the options available.

What is the Right Size Steeple For My Building?

As a rule of thumb, your steeple height should match the height of your building. The width should be 10% of your building width.

What Will the Wind and Weather Do to My Steeple?

Wind loading, Overturning Moment, and Roof Calculations are all terms given to determine how much force a steeple places on a roof. Under calm conditions, a steeple only places weight directly down on a roof surface. However, under windy conditions the steeple is a flat surface that is against the wind causing resistance. This results in uplift and down force. Uplift is on the windward side and is the amount of pressure that is applied to the anchoring system in an upward motion. Down force is on the opposite side and is the amount of pressure that is pressing down on the roof surface. These calculations must be completed by a licensed engineer for your state and varies by location and size of the steeple.

How Can I Protect My Steeple from Lightning?

This is a detail you don’t want to neglect. A burned steeple is not a pretty sight, and difficult if not impossible to repair. We offer a simple solution in our Lightning Protection option. This is simply a solid aluminum or copper rod that extends above the highest point of the steeple. It is connected via a flexible copper or aluminum cable to a solid copper rod that is driven into the ground. Specific details about how the cable is to be routed and the distance that the ground rod is to be in the ground varies by region. You will want to consult your local building inspections department for specific requirements in your area.

What Type of Anchoring is Required?

Steeples are anchored directly to the roof support system. In the case of a truss system, anchor beams are attached across several trusses. A metal or masonry building also has the steeple attached directly to the roof support system. Your building style and material will determine the correct anchoring system. Consult your building contractor and inspection department for the proper anchoring system.

Many churches have chosen to use pre-engineered metal buildings. This creates a challenge in attaching a steeple. For this purpose, Piedmont Fiberglass has pioneered the Receiving Ring, which is an exact match to the anchor ring inside of the steeple. The receiving ring is pre-shipped to the jobs site and is attached to the building by the building contractor or other qualified personnel. Please note that the receiving ring is only necessary for pre-engineered metal buildings with medium and large steeples. It is not necessary for the smaller Ambassador series steeples, or other types of buildings.

What is a Ball and Cross?

An optional cross may be added to any of our steeples. The ball is used to create a smooth transition from the spire to the cross. The cross may be made from fiberglass, aluminum, copper, or any other material. It is recommended that the cross be made from fiberglass to ensure proper bonding and to reduce electrical conductivity. Crosses permanently bonded to the spire is best as this reduces the chance of twisting, bending, or warping.

How Can I Make My Steeple Look Unique?

To customize or enhance the beauty of a standard steeple you may include decorative panels. These can range from louvers to windows to religious symbols.

Louvers may be false to give the appearance of functioning louvers or they may be operational. Operational louvers may be vented and screened. Venting allows sound or air out of the steeple and screening keeps birds and other things out of the steeple. Speakers, bells, and carillon systems may be added to the inside of steeples with the proper amount of interior clearance.

Windows are available on most models. The window has a fiberglass frame and panes. The glass may be made from plate glass, stained glass, acrylic, or krinklglas. Krinklglas is a faux stained glass available in many colors and styles. It is made from fiberglass and is durable and weather resistant.

Color: The standard color for most steeples is white. However, all units may be custom painted to accent the roof or building color.

Still have questions? Post a comment and we will answer it, or visit our website at www.piedmontfiberglass.com .