Sunday, February 29, 2004

Kissimmee, FL

Relieved Troy at 6 AM and began to add up the Delivery Tickets from Friday. After that I checked my e-mail and printed out Martin's Kronos timesheets for this week and lastweek as he asked me to do. Then I swept the office and took a damp mop to the tile floor.

I ordered pizza for Martin and Ricky from Hungry Howie's for lunch. They cannot complain that we never get food or anything for them now.

Around 9 I began to sweep out the plant floor. We were running T-007's and they looked good and the equipment was running very well. Then it began. . . around 10 the loader and unloader began to stop. We reset them multiple times. The Fault Screen on the controller was incorrectly assigning blame to various proximity switches on each machine. I think if a breaker trips or the machine is delayed, the next switch or sensor the program expects to get a signal from "times out" after an interval and causes the controller to stop the machinery and give a fault message. We reset the machine again and again. Then the circuit breaker, MSS 4, began to trip and had to be reset again and again.

I called Bob and told him what was happening. He thought that the loader motor was going bad, had a bad bearing, or a dirty track it was trying to run on - anything that could make it draw enough current to trip the breaker. I found a replacement breaker for the Allen-Bradley XXX-406 breaker and tried to replace the breaker, but alas, it did not have screws for the red wires ! Another call to Bob revealed that an attachment snaps into the breaker with the screws in it. He said he had a whole bag of them. Looked around in the cabinet and found them and fixing the breaker was literally "a snap".

As I was attempting to replace the contactor, it dawned on me that some of the screws for the wires were in the wrong place. The numbers were identical on the used contactor and the new one, but they were not configured the same. So, I called Bob again. He said you have to disassemble the contactor, turn the part in question over, and put the contactor together again. I did that and then began to plug all of the wires back into the contactor and breaker again.

Rick got up on the ladder and using the air hose, cleaned the rails off thoroughly and blew off the drive motors on the spade loader and unloader. Meanwhile we had a clean-up going on.

When we started back up all of the equipment ran perfectly again. So, I called Bob to let him know that the machinery seemed to be operating properly again. But as we started back up, someone accidentally reset the Daily Runtime to zero. Runtime was 41 minutes when we discovered it. So I did some quick figuring and told Troy to add 10 hours 48 minutes to whatever the runtime was at 10 PM tonite.

Equipment ran fine for the rest of the afternoon. I predict that we will make 24000 T-007's today... not stellar, but hey, if this is a "bad" day, we will take it.

The rest of the afternoon was spent managing my second shift people. Sorting and re-stacking T-47's, cleaning the yard, etc etc. It looked like the rest of the day was going to be a cinch.

Ten minutes before Troy was supposed to relieve me, Martin noticed the pressure washer leaking an abnormally large amount of water. So, we went up to the mixer to investigate. Seems that all the water was coming from a brass pressure regulating valve on the discharge side of the pump. Troy came up to see what the problem was and not knowing what the valve did, we were reluctant to just pull it and put a plug into the hole.

Troy called Bob this time. Our new Skako mixer was delivered on Saturday and with it comes an entire new pressure washer. Bob directed us to open up the pine crates in the yard, find the new washer, and swap out the parts. Jens from Skako will have to get us a replacement. Too bad the damned thing only has a 12 month warranty. That problem kept me there until 7 PM.

Tomorrow it will be me and Bob most of the day. David will be off and Doug is going down to West Fort Pierce to help them with their start up. It will be okay - only two more days in the plant, then I have three days of school this week.

Today was warm - around 75F and partly cloudly. Really a nice day. Too bad I was preoccupied with machinery troubles and did not notice or appreciate it.

It takes two things to blow down a tree: a heavy wind outside and rot and decay inside. So it is with man. The winds of adversity may cause him to bend, but if he's strong and vigorous within, he will arise and grow to new heights after the storm passes.

Friday, February 27, 2004

Kissimmee, FL

Today was a rather cold damp day.

More work with Purchase Orders. Then I applied for an Employee Vendor Number so that I can submit expense reports.

Escorted the infrared thermography guy, Warren, around to all of our controller cabinets while he took images of all of the wires, fuses, breakers and switches. He found a potential problem on the cuber control panel that I should be able to fix on maintenance day easily.

Skako mixer for 2 Plant is going to be delivered tomorrow. Bob had to find a crane so that we can get it off the truck. Of course the trucker would bring it on a Saturday.

Wanted to get out of there at 2 PM, but ended up staying until 4. Was kinda tired by the time I got home. Ate hot wings for dinner. Ran the vacuum cleaner.

Got my Navy Federal Credit Union online access set up. Now I can transfer money and check balances from right here. Next I have to set up my 401(k) with Merril Lynch.

Too beat to make it out. I have tomorrow off. But I have to be back in there Sunday morning. I am going to wash my truck tomorrow and get some more groceries. One day off is better than two weeks with NO day off.

Thursday, February 26, 2004

Kissimmee, FL

Turned out to be a beautiful day. Warm, blue skies with a few scattered white clouds. Really nice.

The machinery was running pretty well today... I believe we will turn out 32000 T-081's today.

Spent most of the day in the office performing Goods Receipt and generating Purchase Orders to cover Invoices for supplies and parts we have ordered. Bob was nearby for most of it to help me. Wayne showed up today for about two hours, then he had to get up the road to Ocala.

We shutdown at one for a quick clean up, then brought the plant right back up.

I left at two thirty, about 30 minutes later than planned, but Mine and Mill Supply salesman, Glenn, showed up and I had to order some 1/8" and 1/4" keystock. Left Martin Trejo in charge and left him to do the turnover with Walt this evening.

Went up 17-92 to Kissimmee and stopped at the H&R Block (Henry and Roy Block ?) office to file my federal and New York State income taxes. A nice lady, se llama Esperanza "Hope", took care of my taxes "impuestos". I expect to get checks from the US Treasury and NY State Department of Revenue soon for $2550 and $277. My return was a little more complicated than most they see and it took Esperanza about three hours to finish.

After that I went to Sonny's Barbeque for dinner. A nice, obviously gay waiter named Kevin waited on me. He was all smiles the entire time. The can of snuff in his back pocket was a little incongruous. Toward the end of my meal, another waitress, who obviously did not have enough customers and looked like a trailer park resident, sat down to chat with me. She was bemoaning her terrible job and her life in Polk County. Man, was I glad to get out of there !! LOL !

Nice quiet evening here at home now. Fascinating news articles in the paper. Mike Eisner's support at Disney is crumbling, lots of hypocrisy about gay marriage, US foreign policy; Greenspan calling for Social Security cuts, etc etc... truly turbulent times we are living in. Also, an article about a 2.3L inline 3-cylinder Triumph motorcycle called "Rocket III" that can do 0 to 60 MPH in 2.9 seconds !! If it were less than the $15900 SRP, I would be very interested in getting one !

Working another short day tomorrow... Bob said he will work Saturday. So, I will get one day off.

"When down in the mouth, remember Jonah - he came out alright."

Wednesday, February 25, 2004

Kissimmee, FL

It rained all night. I drove to work in some hard rain this morning. Wore my 'new' white shirt in to work.

Troy had the T-081's running when I got there and he was not planning to shutdown for maintenance. At 0630 the block began to come out very very wet. So wet that the sides were falling off of them. When we tried to dump them they were sticking to the pallets. First we turned off the chemical admixtures - DBM-S and Daraccel. Next we added more cement to the batch. Nothing helped and all we were doing was wasting material. So I had them shutdown and begin our maintenance day.

I called Bob and told him what happened. He agreed with me.

We fixed the leaking hydraulic fixtures on the pattern maker by swapping them out with identical fixtures on the semi-automatic pattern maker. We greased the block machine and the cuber, cleaned grease off of the block machine, cleaned under the rackveyor and swept the plant.

Bob arrived while I had Martin performing the Aggregate Moisture Content By Drying test. Concrete sand was 10%, 3/8" pea rock was 12%, and limestone screenings were 16%.... way too wet !

While the yard guys loaded preloads and picked up the yard, Bob and I busied ourselves with paperwork. I filled out a Material Downtime report for Jan Marie, performed Goods Receipt for our materials, and reminded Bob that we had to fill out my 90-Day Probation Evaluation Form and send a PCN along with it to get my signing bonus.

I guess other plants went down because of the weather too... and the Ready-Mix organization decided to stop the trucks from running because they felt it was not safe. Now we really WILL be slammed the rest of the week as they struggle to catch up. I bet they run on Saturday too.

Around 1230, Bob decided to try to start back up. He figured the material up in the bins had had enough time to drain, so we started the mixer up, brought a batch in and started up the metering belt. That first batch was still so wet the metering belt had a hard time running it up to the machine. We got the block machine running again and in a short time we were turning out acceptable T-081's again.

The block ran wet all afternoon, but the machinery ran flawlessly for the rest of the day. I guess we will run 81's for another day, then put the T-007 mold back into the machine to catch our regulars back up. Can't let ourselves run out of 007's !

Tomorrow I am only working 8 hours. Going to go to H&R Block to get my income taxes done after work. I still need to get a chair for the computer.

It is supposed to rain until tomorrow afternoon. I just wonder how the monsoon weather is going to be this summer, and whether it will force us down often.

Tuesday, February 24, 2004

Kissimmee, FL

Clouded up today. It remained warm, but got more and more cloudy.

Bob and I worked on Purchase Orders and Goods Receipts in SAP.

While we were outside watching a man demonstrate a fork lift-mounted lot sweeper, Wayne arrived. He spent the rest of the afternoon with us.

Right after Wayne got there it began to rain, and it rained HARD, and it was COLD ! Severe weather warnings across the region today. Supposed to rain all night, tomorrow, and clear up on Thursday. It has been over two weeks since we had a good rain.

My new shirts arrived today. I have 4 short-sleeve and 4 long-sleeve shirts with my name embroidered on them. I will look more professional tomorrow.

Teddy was off today. It is his 31st birthday.

We ran over 32000 block yesterday. If we could run 33000 a day for a week, we would make 231000 block. I think the record for a 3V-12 machine is 218000 block. This week could possibly be a record-setter.

Troy is changing the mold to T-081 tonight. Hopefully we can get those to run as well as our regulars have been running.

Tomorrow we are going to have a maintenance day. It is going to be very short. Just long enough to stop a leak on the pattern maker, grease all of the fittings and bearings, and get her back to production.

Ate some shoulder steak, baked sweet potato, and asparagus for dinner. Packed some left over for lunch tomorrow.

Sunday, February 22, 2004

Kissimmee, FL

Today was another beautiful sunny warm Florida day. I wore a flannel shirt to work in the morning, but by 10 AM I took it off because I had gotten too warm.

Started off getting all of the delivery tickets added up so that the sales would be brought up to date. Then I performed goods receipt of all of the materials (concrete sand, limestone screenings, 3/8" pea rock, cement) via SAP and the computer network. Finally, I made sure that we had inventory worksheets, clipboards, pencils and calculators available for the monthly inventory.

We only had to count the Top 5 Sellers for the month which were T-007, T-012, T-018, T-081, and T-150. Problem is, many of the "special" block are stacked on "pallet block" which are regulars - T-007. So, all of the pallet block in the yard has to be counted along with 100% of the Top 5 Sellers. Bob and I were in the yard counting for about 3 hours. Then we came in, added up our numbers seperately, and to our astoundment, got the very same totals ! We had to go back out and count block that had already been loaded onto trucks because the Ready Mix guys did not post those tickets yet, but that only took a few minutes. Then we compared our hand count with the numbers that SAP had and all of the differences were acceptable.

Next we had to inventory our raw materials. To begin I had to take a stainless steel box that is one foot on each side our to the stockpiles and fill it with the material, bring it in and weigh it. The sand weighed the most at 88 pounds per cubic foot. Next came the screenings at 85 pounds per cubic foot and lightest was the pea gravel at 82 pounds per cubic foot. Taking a measuring tape we went out to the stockpile bins and roughly measured how much material was in the bins and converted to cubic feet. By multiplying the volume by the weight per cubic foot we determined how many pounds of each material we had. Don't ask me now... the numbers were millions of pounds.

Mercifully, the equipment ran flawlessly while we were doing all of this. I was pleased with how well the plant ran. I think we will make over 30000 block today. Yesterday we ran 33000 and the day before 28000. Bob was looking at the numbers for the month of January and it turns out that Davenport beat all of the other plants... even West Fort Pierce! We produced almost 3 days of production more than them!

Looks like I will be working all of this week because Doug and David are in Michigan now. I bet they go ice fishing or snow mobiling ! LOL ! Bob forgot about covering their hours. He said we will probably ask one of the leadmen to come in early so that I only end up with 8 hour days later in the week. I will have a long week next week too - Wed., Thur., and Fri., I have SAP Purchasing Basics class in Orlando. So, I guess I don't get a weekend for the next couple of weeks.

I need some time off so that I can get a Florida Drivers License, register my truck in Florida, get my income taxes done, and other things like groceries and laundry.

The day went pretty quickly because I was busy all day, and it really was a beautiful day.

Saturday, February 21, 2004

Kissimmee, FL

Got e-mail from my old friend, Geoff Guth today. He is still working on his degree out in Arizona. After he finishes that he is going to depart for places unknown now. I still think about him sometimes, not often like I used to, but sometimes.

Beautiful day today. Sunny, 82 degrees, just nice. Went out to Target today. Was looking for a new computer desk chair, but ended up buying diet soda, three shirts, a sunshield for the truck windshield, and a hat. Went to Office Depot to look at chairs, but they had too many and I could not make a decision.

I was dismayed to learn that Casey Jones of Block Manufacturing West Region decided to let my friend, Mike Foreman, go on January 26. He said that he did not believe that Mike enjoyed making block. If anything Mike had a better attitude than I do, and Mike is even more mechanically able than me. Dumb mistake Casey. I will be asking Wayne Bruner about this.

Went out this evening for a couple of hours. Only drank bottled water as I have to be up in the morning to work from 6 AM to 6 PM. Bob will be in - we have to do the monthly inventory.

Thursday, February 19, 2004

Kissimmee, FL

I have finally gotten Internet access restored! The Bright House guy came today and installed my new Road Runner cable modem and set up my computer. Now I am able to blog on a daily basis again.

Geez, so much has changed since I last wrote. I am living in sunny Central Florida now - Kissimmee, FL, and I am working for the second largest employer in the state of Florida - a construction materials company. I work at the block manufacturing plant in Davenport, FL. The plant is about 18 miles from my apartment. My supervisors are named Bob and Doug. They are very laid back and easy to get along with. I have been working at Davenport for 2 months now and pretty much like it.

Stuck with my diet all this time. I have lost a total of 43 pounds since I left New York in July. Weight loss has kinda stalled lately, but I will redouble my efforts, eliminate the carbs that have crept back in, and go on to lose another 10 pounds or so.

Go forward and live the life you have imagined for yourself." -- Henry David Thoreau