An Aluminum Rolling and Recycling plant, a good Horner customer in Terre Haute brought Todd Cochran (Sales) a problem/ or opportunity to Indianapolis Field Service. The customer has two, 2,000 HP DC motors coupled together, to deliver 4,000 HP to their mill. These motors are about 5-6 foot square, and 10 feet long each.
The inside motor, the one coupled between the mill and the second motor, failed and had to be replaced with a spare. This is not something they can shut down for a couple of days.
Of course this happens when the Indianapolis Field Service group is working at other large Indiana companies. None of these customers are customers we could just walk away from and leave work partially completed! So I feel like every single guy in Indianapolis Field Service was affected by this job when we had to start juggling people on all of those other jobs, and playing musical chairs with the crews to come up with enough people, with the right skill sets, to be able to start on the swap out of the DC Motor job. I don’t think I left a single job untouched with the juggling.
But we ended up with Mark Rosebrock as the lead, then we had Corban Hartley, Gary Anderson, Theo Rodgers, Bill Carhuff, Rusty Syrus and Landon Herbert all starting on the job at 8:00 AM the next morning. They did a great job on this, they set a new personal best for Horner in the amount of time that it took to change the motor. The crew turned it over to the customer at about 10:00 PM. By 11:00 PM, they were running the unit at their normal 115% of current load on the motors.
These guys did a great job for the customer, with the plant manager actually taking time the next day to send a thank you note to Horner for their performance.
This was hot, dirty, tough work, there is virtually no air flow in this area of the plant, and they knocked it out of the park. Thank you to each of theses guys, but again, the entire Indianapolis Field Service group deserves credit, if they were at the plant or not. The lead guys on all of those other jobs adjusted to the crews they had, to the manpower they had available and they were all successful in keeping all the other jobs on track and completing on time. This truly was a team effort, and everyone should feel the pride of jobs well done.