austin industrial intro
Post on 22-Jan-2018
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PEOPLE. PERFORMANCE. SOLUTIONS.
Austin’s Culture
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• Founded in 1918
• 100% Employee-Owned
• 7,500 Austin Industries Employee-Owners
• 5,500 Austin Industrial Employee-Owners
• $2 billion in annual sales
• #41 ENR
• Diversified
₋ Commercial
₋ Bridge & Road
₋ Industrial
• No Debt
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Austin Industries – Our Parent Company
Company Overview
• Leader in Safety
• Every Employee is an Owner
• One of the largest maintenance contractors in the U.S.
• More than 120 active maintenance and capital construction sites
• Self perform practically all of our work
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Austin Industrial
Maintenance
• Millwright/Mechanic
• Welder/Pipefitter
• Boilermaker
• Equipment Operator/Rigging
• Electrical/Instrumentation
• Fire Sprinkler Systems
• Vibration Monitoring
• Fiberglass
Construction/Small Cap
• Piping
• Structural Steel erection
• Equipment Setting, Assembly, & Alignment
• Electrical/Instrumentation
• Civil
• Project Controls
• Subcontract Management
Specialty
• Scaffold
• Insulation
• Paint/Coatings
• Asbestos Abatement
• Lead Abatement
• CUI
• Fiberglass
• Steam Tracing
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Plant Services
•Facilities
•Warehouse
•Logistics Support
•Janitorial
•Grounds
•HVAC
•Tool Room
•Operations Support
Heat Exchanger
•Bundle Insertion/ Extraction
•Rigging
•Tube Replacement
•Torqueing
•Tube Plugging
•Bundle Repair
•Insulation Blanket
Turnarounds
•Boilermaker
•Exchanger Services
•Scaffold/Insulation
•Paint
•Welder/Pipefitter
•Specialty Welder
•Planning/Scheduling
•Equipment Operator/Rigging
Material Handling
•Rail Loading
•Tank/Bulk Truck Loading
•Barge Loading
•Switching
•Packaging
•Drumming
Austin Capabilities
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• Albemarle
• Advance Aromatics
• BASF
• Baker Petrolite
• Bayer
• Bridgestone
• Clariant
• DSM
• Dixie Chemical
• Duke Energy
• ExxonMobil
• International Paper
• Lanxess
• Linde/BOC
• LCY Elastomers
• Lubrizol
• LyondellBasell
• Marathon
• Miliken
• Motiva
• Navajo Refining
• Noltex
• PCS
• Phillips 66
• Prayon
• Shintech
• Syngenta/GB Bio
• Targa
• Timkin
• TOTAL
Customer Base
Core Safety Values “All Accidents are Preventable”
Austin Driving to Zero
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Zero is achieved through the following
philosophies and best practices:
• Safety, Health and Environmental Protection Takes Precedence Over All Else
• Management Engagement and Visibility – Boots on the Ground
• Zero in the Hearts and Minds of the Individual
• Safety Culture Survey
• Austin Risk Behavior Assessments
• Safe Work Policies, Procedures and Practice Conformance at All Times
• Employee-owner Empowerment, Engagement And Participation
• Targeted English Training For Spanish Speaking Employee Owners
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2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 YTD
TRIR
Wo
rk H
ou
rs (
MM
's)
Work Hours (MM's) TRIR
Safety Performance
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Managing Values and Culture
• Management Visibility and Engagement -
Leading by example
• Risk Behavior Safety Assessment and key
follow ups
• Austin Safety Culture Survey and key follow
ups
• On-Boarding process
• Employee-Owner empowerment expectations
• English language comprehension assessment
• 360 Supervisor Review and Dialogs
• Safety Meetings
• Expectation Meetings
• Employee-Owner Dialog Meetings
• Bilingual JHA/JSC’s
• Audits/Listening Tours
• Mentoring Process
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Austin Quality Control
• ISO-Based QC Program – All Disciplines
• Project Specific Quality Execution Plan
− Tailored to fit service offering
• Alignment with Project Specifications
• Inspection & Test Plan Process
• Supervisor and Craft Quality Training
− Proprietary Weld Quality Program
− Includes Welders, Supervisors, Pipefitters &
Inspectors
• Non-conformance process
• Corporate Weld Acceptance rate – 97.8% (2013
average)
• Corporate X-Ray acceptance rate – 97.9% (2013
average)
• A Boiler Assembly
• PP Pressure Piping
• U Pressure Vessel
• R Repair & Alteration- National Bd.
Certification
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Welding Quality
2013 2014 YTD
Butt Welds Made 29,594 21,822
Welds Radiographed 4,582 4,703
Welds Rejected 96 89
Weld Acceptance Rate 97.9% 98.11%
• Establish site steering team & establish benchmarks
• Evaluate effectiveness of current work flow process
• Develop KPIs & targets – mutually agreed
• Develop site-specific strategic plans
• Implement Opportunity for Improvement process
• Review training requirements
• Review indirect staff requirements
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Maintenance Workflow Process
Work
Selection
Receive
WorkPlanning Scheduling Execution
Scaffolding
• Piping
• Equipment
• Tanks
• Towers
• Boiler Internals & Externals
• Ductwork Internals & Externals
Insulation
• Piping, Towers & Equipment
• Hot and Cold service
• Reusable Blankets
• Fiberglass Panel Systems
• Fireproofing
• Refractory
• Asbestos Abatement
• Steam Tracing
Painting/Coatings
• Piping
• Equipment
• Tank coating and lining
• Sandblasting
• Lead Abatement
• Environmental Compliance
• Epoxy Fireproofing (Chartek)
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Scaffold Efficiency
• Labor Analysis
• Material Utilization Analysis
• Scaffold Location Analysis
• Scaffold Movement KPI’s
• Historical Data
• Reduced Material and Labor Costs
• Scaffold Elimination
Heat Loss/CUI
• Thermographic Survey Process
• Identify areas of CUI & Heat Loss
• Establish Asset Protection Program
• Quantify potential Energy Savings
• Certified Thermographers
Paint Program
• Paint Survey to identify areas and levels of corrosion
• Prioritize and schedule specific areas to be painted based on:
• Corrosion Levels
• Environment
• Schedule Value
• Equipment Criticality
• Provides cost effective asset protection
Specialty Services
Services
Systematic
Programs
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Outages
Austin has extensive experience in all phases of the turnaround cycle from the
front-end efforts of planning and scheduling through execution, system turnover and start-up. Performing both embedded and stand-alone turnarounds, Austin has particular in-house expertise in performing Alkylation Unit projects.
Austin routinely performs:
Alloy welding
Bolt torqueing
Offsite pipe fabrication
Pipe installation
Bundle extraction
Valve replacement
Tower and column work
I/E work
Vessel modification
Code work
Millwright work
Scaffolding
Insulation
Planning/scheduling
Purchasing/subcontract
management
PHASE 1
Business Strategy
PHASE 2
Preliminary Development
PHASE 3
Develop/Refine Scope
PHASE 4
Finalize Planning
PHASE 5
Pre-turnaround Activities
PHASE 6
Turnaround Execution
PHASE 7
Close-out/ Review
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Keys to Success
• Early Involvement
• Goal Alignment
• Detail Execution Planning (Work/Resources)
Outage Execution -
A Phased Approach
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Construction Capabilities
Civil/Structural
- Site prep & survey
- Underground utilities
- Foundations &
area paving
- Structural steel
erection
Mechanical
- Equipment
installation
- Rotating equipment
assembly &
alignment
- Piping
- Rigging
E&I
- Electrical
- Instrument
installation
- Conduit
- Tubing/piping
- Terminations
Specialty
- Scaffolding
- Painting/coatings
- Insulation & abatement
- Fireproofing
Additional
- Commissioning/
start-up support
- QA/QC program
w/complete ITPs
- Earned value-
based project
controls
- Procurement
- Lean construction
work processes
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Construction Overview
Project controls in support of Austin’s work include:
• Estimating in support of project development
• Detailed project estimates
• Project control execution plans and control of work processes
• Detailed, logic-driven & resource loaded schedules
• Quantity-driven progress tracking and earned value reporting and forecasting
• Change Management
• Integrated turnover system tracking
• Integrated quality process from award through close-out
• Structured to fit size & complexity of project
• Development of integrated capital projects team philosophy
• Early construction input during FEL 2 & 3
• Project-specific estimates with uniform work breakdown structure
• Project-specific, resource loaded, logic driven schedules
• Timely & accurate physical field progress reporting for earned value progress
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IPA Best-in-Class Program Award
Small-Cap Capabilities
• Executive Sponsors
• Alliance Steering Teams
• Site Steering Teams
• Site Strategic Plans
• Quarterly Key KPI Reviews
• Individual Accountability Plans (MAPs)
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Strategic Customer Alignment
• Best in Class Safety Performance
• Employee-Ownership
• Proven Performance and Cost Savings
• Best in Industry Supervision and Crafts
• Resource Capacity/Flexibility
• Geographic Footprint
• Broad Range of Capabilities
• Committed to Customer Key Business Drivers
• Access to Multiple Sites and Industry Best Practices
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Summary
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