Lean Manufacturer of Biomedical Lab Equipment Improves Facility LooksCustomer: Facility Manager chooses flooring system to replace vinyl tile floor that was failing due to moisture: A leading manufacturer of biomedical testing instrument systems that simplify and automate laboratory processes needed a new flooring system. The polished concrete and tile floor in their Brea, California facility was failing due to moisture. The client needed to maintain conductivity in their facility and due to the problem with high vapor emissions they needed a better solution to eliminate continuous repair and maintenance. The maintenance manager at another facility wanted to help so he recommended that the officials take a look at the Poly-Crete MD floor that they had installed at their facility. They immediately liked the look of the floor and since the maintenance manager had nothing but good things to say about it, they decided to contact Steve Little and Aram Dicochea of Pro-Tec Coatings who did the installation in their facility. Steve Little and Aram Dicochea of Pro-Tec Coatings came in to evaluate the floor in the Brea, California facility. The floor was blistering in spots and when asked, the facility owners said they were unsure if a vapor barrier was installed. Steve performed a moisture test that showed the floor had between 8 and 10 pounds of moisture (even the Petri dishes had collected water inside) and the core samples showed that there were excessive amounts of sodium silicate present. These two factors would raise the PH levels to about 12 or 13 which is too high, so Steve and Aram recommended a Koster system. The technicians at Koster would guarantee their moisture mitigation system to facility owners for ten years if Pro-Tec would shave three eighths to one half inches off the floor and install a synthetic cementitious floor. A synthetic cementitious floor was required because an organic floor's high ph levels would attack the organic properties in the cement. Facility owners declined by saying they had no extra money to install a separate system, so Steve and Aram consulted Steve Lipman at Dur-A-Flex, Inc. for advice. Instead of shaving the floor and installing the Koster system, Pro-Tec laid a Poly-Crete MD test patch. After the system cured they invited the owners to try to break the bond by smashing the area with hammers to test the durability of the system. The Poly-Crete MD system held up and facility owners were convinced that this was the system to use. They found there would be no added costs for installing a separate system, the Poly-Crete MD handled the high ph levels and solved the moisture problem and the ESD topcoat met their industry standards. Pro-Tec installed 15,000 square feet for the first part of the renovation, and according to Steve and Aram, this is now the standard floor for the Brea, California facility. Summary: As a result of the installation, facility directors are proud to showcase their production area to prospective customers. The client has reported increased "partner" morale and a sense of ownership among employees that has led to an increase in production and efficiency. Pro-Tec Coatings, Inc. provided them with an aesthetically pleasing system that tolerated high vapor emissions while maintaining its functional properties. They were also able to decrease the overall labor costs associated with maintenance. The company practices lean manufacturing, and as an integral part of their lean production plan, the flooring system assists in increasing their quality and productivity by providing a safe, functional seamless floor that helps to increase the flow of equipment assembly. By solving the moisture problem and providing larger ESD areas, the system also enabled them to reconfigure assembly lines to maximize efficiency. The increased production efficiency enables them to meet equipment delivery schedules, and enables them to meet the compliance requirements for their specific industry. This leads to a better quality product and enhances the overall image of their brand. Dur-A-Flex Inc. |