Production Flashcards
1
Q
Who should operate a high pressure, steam boiler?
A
Qualified technician. (per the MSC)
2
Q
At how many pounds of steam pressure does a Cintas laundry generally operate a high pressure, steam boiler?
A
100PSI
3
Q
What pieces of equipment in a typical Cintas laundry require steam?
A
Presses, Steam Tunnel, Washers, Dryers, Ironers
4
Q
How often is a high pressure steam boiler inspected and why?
A
Tunings every 6 months Insurance every 6 months. State Inspection Annually.
5
Q
At what frequency should the controls and safety devices be inspected and tested?
A
Tunings every 6 months. Daily inspections for low water, chemical is daily. High pressure switch is daily.
6
Q
Why is chemical treatment important for a boiler?
A
Keeps corrosion out of the boiler, prevents scaling from the water
7
Q
What purpose does a water softener provide for a boiler system?
A
Removes hardness out of the water
8
Q
What purpose does a boiler feedwater system provide?
A
Chemical injected and heated to reduce gas burn while filling a boiler
9
Q
If your boiler is scaling, what does this mean?
A
Chemical reactivity is poor
10
Q
Why should boilers be blown down, and at what areas should blowdown occur?
A
Top and bottom rail to help reduce scaling and impurities
11
Q
What does night firing a boiler mean, and why would you do it?
A
Keeps the water hot while all other boiler system is shutdown. Keeps boiler water at temp.
12
Q
You walk into your boiler room and it is operating at only 50 psi. What pieces of equipment, if any, would not function at this pressure?
A
Washers will error out.
13
Q
If the situation in the previous question, (boiler at 50PSI), were to occur, then how would you try to continue to operate, or would you shut down?
A
Minimize the usage by shutting down a couple fo washers and uni presses so we can maintain use of the steam tunnel.
14
Q
What pressure devices are present on a high pressure, steam boiler?
A
Pop off valves, High and low limit safety devices,
15
Q
What water level safety devices are present on a high pressure, steam boiler?
A
High and low
16
Q
What type of information should be kept within a boiler log?
A
Chemical , high and low steam. High low water, then the blow down, hardness.
17
Q
What is tempered water and why do we use it?
A
Lower degree water used for rinse.
18
Q
At what temperature should your hot water tank be set?
A
140 Degree
19
Q
Why do we have holding tanks for hot and tempered water?
A
For when washers are not operating under normal conditions and these tanls would act in keeping a constant pressure.
20
Q
What is a boiler stack economizer? What water temperature increase should you typically see when using this piece of equipment?
A
Uses exhaust gas to heat our water. 20 degrees
21
Q
What is a wastewater heat reclaimer and how does it function?
A
uses heat from the waste water water and heats our tempered watrer.
22
Q
With respect to the flow of city water, what direction does the wastewater flow and why? Is there any reason this direction would ever change?
A
the heat reclaimer has a 4 way valve on the end of it. Its sole purpose is to change the direction of the water inside of the system. Its main purpose is to back flush the system to help Prevent clogs. The valve typically runs in forward for 27 minutes and then changes direction for 3 minutes. Therefore, this happens twice an hour. Note: The waste water flows on the inside
23
Q
What does the word “approach” mean, and what should it be on a wastewater heat reclaimer?
A
approach=is calculation of water in and out of the heat reclaimer.
24
Q
If your wastewater heat reclaimer goes down, what impact would this have on your operation?
A
Costs wouold increase, might not be within City Limits of hot waste water. 100 degree discharge per the permit. Potentially could shut production down.
25
How else do we heat hot water? Is this an open or closed system?
Steam Closed system
26
If a hot water pump goes down, what would you do?
Switch it to the other pump. Then rebuild the pump that failed.
27
At what pressure should the air compressor operate?
100PSI
28
What is the purpose of an “air dryer” and why is it important?
Takes the moisture out of the air to prevent clinoid malfunctions. Helps prevents rust also.
29
Why do we pump our pits? How often should this be done?
Keeps sludge out of our pumps. Helps with out permit levels. Between 5 an d 6 months depending on soil level.
30
What is the purpose of the equalization tank?
blend together different different wash alley dischsarges with wide variations of pollutants and contaminatnets. Is critical in the effective operation of the DAF.
31
What is the optimum pH for wastewater treatment to remove metals and proper DAF operation?
9-9.5ph
32
How often should pH probes be cleaned and calibrated?
Weekly
33
What are the staffing requirements for a location who has pretreatment (DAF)?
Waste water tech per shift being run.
34
What are the requirements of a pretreatment operator?
testing of waste water for chemical dosage, pump screens, trench screens, DAF cake removal, cleaning of the J Press
35
What is the minimum clarity required to operate the treatment system in order to obtain compliance?
10
36
What do we test our sludge for and how often should this be done?
Contaminates, metals, toxins Annually usinga T clip
37
How do we know what the legal discharge limits are for non-hazardous sludge disposal?
Through our city limit permit
38
What categories are on a sludge manifest?
Generator, Transporter, what and how much is being transported.
39
What is the importance of knowing the quantity and location of sludge disposal?
As a part of EPA compliance we own the entire process until it is disposed of. We keep copies of the for auditing purposes.
40
What is necessary in order to comply with wastewater discharge?
To prevent plant shutdown due to poor sludge program. Can cost you fines with the City and the EPA.
41
What steps should you take to ensure your waste hauler is obeying all pertinent dumping laws?
Debrief with the vendor during pick ups. Follow the driver to ensure proper routing is being followed.
42
Does Cintas process any hazardous materials within the wash alley? If yes, what customers?
Not at this location.
43
What are the different soil classifications you will use in the soil room?
Micro fiber, Terry, Shop, Mats, poly, cotton, FR, heavy metal, heavy soil
44
How do we determine the correct poundage for sling weights?
Determined by the chemistry and washing machine type. Corporate and WSI sets the standards.
45
What is soil separation and how do you feel it should be handled in a plant?
The separation of product by type. i.e. MF towel vs mops.
46
In what sequence will you process your garments?
This will be done by batch day and location. Also keeping a good wash alley mix using the wash eye legend.
47
There are five components of successful washing. What are they?
Time, Temperature, Chemical, mechanical action, water.
48
Who will determine whether garments will be special washed or not?
Plant and Service leadership.
49
You are finding out that white shirts are mixed in with the color shirts. What steps would you use to eliminate this problem?
Discuss soil separation with the load team and the capacity operator. Ensure that proper coding is taking place. Ask the wash alley operator what they are seeing. Work with the Service department to ensure proper soil separation.
50
What are re-deposition, thermal shock, and overload?
Overload=too much product, Thermal shock=not the correct cool down sequence at the end of a hot wash. Re-deposition--when a substance from one linen moves into the wash water and gets “redeposited” onto other textiles.
51
Your water usage in your plant is running three gallons/pound of garments processed. Do you agree that three gallons/pound is excessive? If so, what steps would you take to find the problem?
Yes. You would like to see 1gal per 1 per lb. Check the chemical calibrations, water calibrations. Also contact WSI.
52
Your total chemical cost in your plant is running .5% of rental sales. Do you feel this normally is low or high to target average? What would your strategy be to fix this problem?
Determine that the soil sling logs are accurate. Determine our run efficiency is 95% or greater. Ensure that the calibrations of the washers are correct per spec.
53
How many wash loads will it take to wash 3,600 pounds of shirts in a 450 lb. open pocket washer?
8
54
How many wash loads will it take to wash 5,400 pounds of pants in a 450 lb. open pocket washer?
10
55
At what temperature do we wash 65/35 garments?
145-150 degree
56
What are the 4 components of CWC phase 1?
soil weight accuracy, washer turn time, washer run efficiency, dryer efficiency.
57
What happens when we load a washer with 600 lbs. of bar towel soiled weight on a 450 lb. washer while the program is set for 900 lbs. of soiled weight and this is consistent through the entire week?
You will see a lesser quality product. In addition the dryness will be off and need to be run through the dryer again. Go to the bulk cool down log and detemine that it is being used properly. Then review this with the Maintenance Supv. and determine potentiol casues reasons. Then educate on the importance of runniung the play as called. Washer should be set at
58
How can you improve on washer turn times? (The time between a washer completing a load and the starting of the next load)
Ensure run efficiencies are meting goals. Ensure that we are using the correct soil sling weights and are coded properly. Ensure that wash alley operators have a management style that fits the needs of the business. Ensure they know how to read the wash eye legend.
59
How can you improve on washer run efficiency? (The standard formula run time divided by the actual run time/goal > 95%)
Ensure that all PMS are done according to schedule., Determine that bags are relesing properly. Determine if there is a steam valve issue. We use the steam to heat ther water.
60
A Pant Formula is programmed at 450 F inlet 180 F outlet, the temp. differential of 150 F. Max dry time is 30 min. what will happen if the temp. differential of 150 F is not met?
It will utilizer the max time and state that it is done. Therefore could come out wet and then need to have to dry it again. Should be seen in the bulk cool down log.
61
If you see a dryer with many max. dry time alarms, what can this tell you
that the differential is not being met. Screens could be dirty, maintenance is not being kept up to schedule. Dryer lint screens not being regularly cleaned.
62
A Shirt Formula is set up on temp., the inlet setting is 450 F and outlet 180 F. The temp. differential is 140 F. You notice the shirts are coming out too dry. What do you do?
Increase the temp differential. This could be affected by time of year.
63
Dryers will have a hard time drying on temperature if they are missing what parts?
Thermal coupler, temp probes top and bottom, cleaning schedule.
64
To identify the top 5 soiled product types in your plant to ensure proper weighing, where would you look?
WSI Report wash eye cloud
65
What documents would you consult to ensure that “See Something, Say Something” is in practice?
Soil sling log, Bulk cool down log, Wash eye cloud reporting,
66
What can having efficient dryers help you with?
Turn time, plant processing, Energy consumption.
67
You are out of compliance with your wastewater discharge. What is your first step in responding to the violation?
Report to field Engineer, Chemical environmental engineer, GM, PM, RPD,WSI and the City. Determine if a new test is needed.
68
Your sludge is tested and is labeled as hazardous. What would be your next couple of steps to handle this problem?
Contact Chemical Engineer, PM, GM, RPD, WSI, then follow the hazardous waste program.
69
What is the difference between a compliance limit and a surcharge limit?
Your within the limit of the compliance for the City. Surcharge exceeded city limits and therefore they will charge you per the over the limit. i.e if your at a 22 they would charge you for the 2 on a limit of 20.
70
After analyzing your wastewater for the parameters identified within your permit, what are you required to submit to the City.
Submit the parameters to the City up to and including the following: flow rates, chemical usage in the building, T Clips that we get annualy, Garbage disposal in yds per year.
71
If you cannot send water to your Dissolved Air Flotation system because of equipment downtime/failure, what are your options for discharging the wastewater?
call the City to see if they will allow, Discharge from the building. Call a company to clean us out, or shut down.
72
If you have a chemical spill that enters your wastewater treatment system, what steps must you follow?
Get the water tested, notify the City is going through our DAF unit, Notify, GM, PM, chemical engineer, RPD. Contain the spill prior to entering the water system.
73
What is a universal waste and how are they regulated?
Universal waste is waste that is common in most households. i.e. TV'S, batteries, computers, These are regulated through the state.
74
What is SARA Title III Tier II Requirements? What and when are you required to report?
Annual report for Chemical use at our facility. In Michigan this is due March 3.
75
How long must you maintain a copy of your compliance records (wastewater analytical data, notifications from the city, etc.)
10 years
76
If shop towels with ink are sold at your location; who is permitted to process them?
Shop towels we will process in house. A 3rd party vendor will procerss the inkl towels.
77
What is the maximum flash point for which towels cannot be processed at a Cintas facility?
Flash point is 140 degrees if we out source ink or shop towel.
78
Where in your facility should ink shop towels be stored for shipment to approved vendor to process?
Conex container with 20' radius.
79
What is the first action when you have a wastewater violation?
Contact City, Environmental partner, Engineer, GM, PM, and send for a retest.
80
What type of air emissions are regulated?
shop towel, Other Textile throughout,
81
What recordkeeping requirements are typically required in an air permit?
Poundage for shop and other textiles throughout, poundage and therms.
82
What is the definition of hygienically clean?
Cintas industrial laundry facilities follow a unique healthcare wash process developed in conjunction with our chemical provider WSI.
83
What policy is Cintas’ plan for food and healthcare processing?
r-4010 HAACP Plan
84
What are the thresholds for food service and healthcare hygienically clean?
Less than 20 CFU for healthcare less than 50 CFU for food service (Colony forming Unit)
85
Describe the TruCount Process.
Garments are picked up and scanned, returned to Cintas to be hygienecally cleanedand then scanned at the final station. Any missing garments are reconciled and acocunted for. Hytgienically garments are retuned to the customer. Service Summary is reviewed with the customer.
86
Explain the benefit of TruCount to our customers.
Every Garment is scanned so you know and we know where your teams unifroms are from the time they are turned in to be professionally laundered to when they come back hygienically clean and crisp the following week. It is an uparalleled inventory managment system exclusively offered by Cintsas.
87
What are the Quality Audit expectations for the rental division?
All partners are responsible for the quality of our products. Quality inspections are to be completed throughout each processing step and every partner has the responsibility to identify quality opportunities: A secondary quality audit partner will be designated from service and from production.
88
What are the most common defects noted in the Product Quality Audit?
holes, buttons, etc.
89
What can you, as a Plant Manager, do to improve quality in your location?
Regularry check garments as they come out of the dryer, steam tunnel and shakeout. Detemine if any issues are a people, process or product issue and handle accordingly.
90
How are garment repairs handled?
From The Field the SSR will scan and tag the garment for repair. If dirty it will be washed then reviewed for quality by production partner. If failed qaulity issue then it will be sent to a mender for repair. It will be determined if this is a customer issue and charges applied if necessary. Then tagged and sent back the SSR to review with the customer and a new garment presented where necessary.
91
How are “pressed” accounts handled?
Garments are identified with a sticker on the barcode. They are sent ot the pressing partner for processing. They are then scanned for credit and sent to the route for delivery.
92
How are late pieces injected?
These are either married in prior to delivery or placed on the late line for SSR to marry in prior to delivery.
93
What defect percentage standards should you be achieving at your location, and what is your defect rate?
<2.5%
94
What are your locations standards for Shakeout, Sorts, Wrapout, Press, Bulk, and Mats?
90% R/E=shirts-220/hr, pants-221/hr, Wrapout-1800 per hour, Press-pt/96, sh/60, Bulk-varioous depending on product type, Mats-156/hr
95
What are you doing to improve your locations standards without sacrificing quality?
Daily discussion with quality auditor, product review with production leadership, attending Service meetings.
96
Discuss the set up and purpose of the Production Labor Audit (PLA). What is needed to do so and what is the importance of the labor audit?
This is based on the production of your team. Take credit through scans for everything that we do. This information is inputed on the incentive file. Weather on the clock or off the clock product processed goods are entered. This will then determine the amount of partners needed.
97
Explain in depth what each criteria for Production Manager PEAK is and what they can do to get better.
Days wrapped out: is the length of time it takes a scanned garment to get through the system and returned to customer. Garment Return Rate: OWT: The promise to the customer they will receive their garments on their scheduled day. Every box every day. Pull%: Our stockroom effectiveness to maintain a compliant stockroom. 5% inventoried weekly, Short picks inventoried daily, excess inventory shared. Turnover: all about partner retention. Get to know your partners and they you. maintain a firm fair and consistent environment. CIFE.
98
When looking at your electric bill, what does “demand charge” mean? How is it determined and calculated?
A measurement of the highest usage of electricity in any single 15-minute (or 5-minute) period during a monthly billing cycle. Demand is measured in kilowatts (kW). o a single spike in one day will determine maximum power demand for any given customer for that entire month.
99
If your electric costs are running high, what areas should you look at to reduce this number?
Overtime, equipment running that should not be, utility tracker.
100
What are the top four or five areas in your plant that you would consider pulse points in your operations?
Autosort, Wash Alley, FLM, mat production
101
Who will have the final say regarding the holiday schedule at your operation?
This is created by service and reviewed by the PM.
102
In any area of your plant, what type of learning curve do you expect until a new partner will be at standard?
If we are discussing an incentive based partner they are given a 4 week ramp up period.
103
Who will be responsible for cost control when you are out?
This is coordinated down to the Production and Maintenance supervisors.
104
What system are you going to use to control hanger costs?
We have a recycle program. A partner is assinged to review hangers for qualtiy and added back into the system. SSR'S are incentivised to return hanger sto Cintas.
105
What are the hanging guidelines for shirts? Pants?
Hangers for both have a rate of efficiency they are expected to meet. Pants=198 @90% and shirts 190 @90%. Both have time for waulity inspectations as a part of the eqaution for determining R/E.
106
Who is responsible to develop a Preventive Maintenance Work order for new equipment?
Maintenance Supv, and PM.
107
What is the Production Department’s role in upgrading?
As a part of oiur qualtiy review and repairs process partners are to determine if the garment integrity is compromised at which time they will process a L/R charge if ncessary. Then order a new garment. It will recive a sticker and sent back to the SSR to review with the customer.
108
Who is responsible to upgrade “R” garments less than 18 months old?
IV. Garments marked "R" (Rough Wear account) on the I.D. tape will not be upgraded by the Production Department unless it is determined that the garment is completely unwearable. The garment should be replaced with a grade "D" garment. R-4002
109
What are the five components of an effective reliability program?
Business managmement, Manufacturing process, Equipment reliability Organization and leadership, Work Management.
110
What are some consequences to delaying a repair on a piece of equipment?
Creates a gigger problem down the road. By keeping up with repairs and PM's the longevity of the equipment can be extended.
111
What are some conditions that cause our equipment to break down prematurely or unexpectedly?
Poor PM plan/follow through, hosuekeeping,
112
How can an effective PM program prevent these conditions?
It is a proactive approach towards preventing breakdown.
113
What are the 4 "buckets" of material cost on the WOR? Explain each and how MC is allocated.
Garments, FRC cleanroom, Garments Less FRC Clnrm, Garments Less FRC CLNRM & Javkets
114
How is material cost calculated?
MC%=MC$ Divided by Route Volume+Garment lost replace+peripherals+Service Charge
115
What factors impact a location's stockroom OWT?
Emblem processing, On time ordering, shipping, proper ordering utilizing the grading system., inventory management.
116
Explain the benefits in inventory sharing (stock transfer) between locations.
Garments are already paid for. This prevents from ordering outside your facility increasing your material cost. Reduces spend.
117
What are the major functions of the stockroom?
Receiving, Grading, Assembly, Inventory
118
Explain A, C, S, and D grade garments.
A-new, C=minimal staining some wear, S=staining and worn, D=Very used lots of wear.
119
What is the purpose of the standard product line?
This is to reduce the amount that we hold in our stockroom. This will reduce material cost and increase efficinecies in the stockroom. It doesn' tmake sense to have an over abundance of garmetns for a few customers.
120
Name 10 of the Material Cost 20 Keys:
MC training, Rail organization, OWT, Inventory management, Pull percentage, SSR ordering behavior, Garment LR, Bsack order tracking, Emblem Trim defects, New Account and Poer add approval process.
