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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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