Kansas City Star, The (MO)

April 1, 2003
Section: TUESDAY BUSINESS
Edition: METROPOLITAN
Page: D23
Column: BEST PRACTICES


Going underground is a cool move for company New environment boosts productivity and adds space
RUTH BAUM BIGUS
Special to The Star

The company : Collins Machinery and Engineering designs and manufactures large outdoor equipment including portable backhoes and sawmills. The 5-year-old company generally sells its products to farmers, contractors and individuals.

Telephone: (816) 455-5035

Address: 8600 N.E. Underground Drive, Kansas City

Web site:

www.collinsmachinery.com

Ownership, top management: Bill Johnson is owner and president.

Employees: 10

Challenge: Improving the work environment to increase

productivity

Background: Collins Machinery started out in a small warehouse. All its operations were together, including welding materials and other objects used to manufacture its products. Later, the company moved into an un-air-conditioned warehouse in North Kansas City. While the new location gave Collins more room, there were some problems.

"With our business, there is a lot of metal welding and it generates a ton of heat," Johnson said. "The space was impossible to cool in the summertime. ... It's just hell on these guys to do the work. They have to wear a lot of protective gear. They're dressed to be in 30-degree temperatures when it's 100. Even folks who weren't welding were uncomfortable."

"People were working at half speed because of the heat, especially in July and August, which is our busiest season," he said.

The business receives regular deliveries of metal precuts to produce its equipment, but the warehouse lacked high-dock unloading facilities to accommodate such deliveries. And there was no covered area to unload the steel, so when it rained or snowed, the steel would rust.

"Then you have to sand blast the materials before you paint, increasing the costs, and it takes more time," Johnson said.

Action: Johnson set out to find a new location for Collins' operations.

"It had to meet our criteria, which were that it was economical, have a drive-in door with dock-high loading and with certain lighting," Johnson said. "We need to have control over the environment, where we could cool it in the summertime and heat in the wintertime."

Johnson looked at various above-ground locations, but none met all of the company 's needs. Johnson was aware of various caves in the area that provided a controlled environment.

"Hunt Midwest was able to put together a package that was most accommodating," Johnson said. "They covered our big things and our little things."

Collins Machinery moved into a 35,000-square-foot space, more than doubling its old facilities. Johnson said the temperature in the cave runs about 60 degrees, and increases to around 75 degrees when the equipment runs in the summertime.

Results: When Collins moved into the caves, Johnson saw an effect almost immediately.

"Our production dramatically improved," Johnson said. "We don't have any dip in our production now because it's in a controlled environment."

Johnson said he's seen a difference in his employees' attitudes as well.

"They were thrilled to death," Johnson said. "Most had worked in jobs where there was no air conditioning and now they are inside in a cool place. Not only are they more productive at work, but when they go home they're happier, too."

The addition of high loading, covered dock space in the caves has saved Johnson money and time.

"Instead of having two people outside unloading, I have one person unloading inside in a dry environment. It's an amazing change," he said. Got a solution?

Has your business found an innovative solution for a management issue? Call a Star editor at (816) 234-4870 or fax (816) 234-4346. Or e-mail Ruth Baum Bigus at ruthwrite@everestkc.net.


When Collins Machinery and Engineering relocated to caves at 8600 N.E. Underground Drive, things cooled down for the welders and productivity improved. Oscar Holguin is a welder for the company .

Photo (color)

BEVERLY JOHNSON/The Kansas City Star


Copyright 2003 The Kansas City Star Co.