nuts & bolts
a quarterly newsletter for the employees of Tennsco Corp.
volume 10 issue 1 Winter 2006
Tennsco adopts
drug free Photo below shows
overhanging light. See tilted
workplace rules lower shelves in photo at left.
T he statistics are...well, sobering.
• 60% of the world’s production of illegal
drugs is consumed in the U.S.
• Nearly 70% of current users of illegal
drugs are employed.
• Nearly 1 in 4 employed Americans
between the ages of 18-35 have illegally used
drugs in the past year.
• One-third of employees know of the
illegal sale of drugs in their workplace.
• 20% of young workers admit using
marijuana on the job.
According to the Tennessee Department of
Labor, substance abuse in the workplace has a
real impact on the bottom line. Substance
abuse drains more than $100 billion from
Flexible, quality work
American businesses every year in worker’s
compensation claims, medical costs, absentee-
ism, lost productivity and employee turnover.
earns library kudos
To head off these problems, Tennsco
became a Drug-Free Workplace in May 2005,
an official certification bestowed upon entities
T ennsco recently closed the books on another “game maker” job - the
massive renovation and new construction within the library system
of Jacksonville, Florida.
by the state’s Department of Labor’s Drug- Tennsco supplied shelving for 13 different library buildings scattered
Free Workplace Program. The organization around the city.
must adopt drug-free and other employment The crowning piece, the main library located in downtown Jackson-
policies and train supervisors and employees ville, opened in November 2005. It has 300,000 square feet of made-to-
on the signs of substance abuse and how to order Tennsco’s Estey products - steel, cantilevered library shelving.
access help. The renovation of six branch libraries, the construction of six addi-
There are benefits to the employees and the tional branches (10,000 to 50,000 square feet of floor space in each) and
company. the construction of a massive main library were part of a $2 billion
Employees are more productive and have infrastructure improvement called the Better Jacksonville Plan.
better morale when their health and safety is “One of those (projects) a year is the object of the game,” for Tennsco,
Continued on Page 8 Continued on Page 3
1 Winter 2006
nuts & bolts
almost no excess paint in the booth because it
has been reclaimed through use of a powerful
Latest and best vacuum that sucks the excess into a reservoir.
Air guns and hoses automatically blow out
the excess powder, cleaning themselves in the
Plant 2 replaces paint booths
process. Employees can change colors in the
Wagner in 15-20 minutes. McClurkan said this
is where the switch is generating the greatest
with new generation systems savings.
Better paint transfer efficiency. The paint
booths operate on basic physics. The powder
F aster. Better. Less expensive.
You could argue that this is the motto of
every American manufacturer—make your
paint is given a positive charge as air blows it
out of the paint nozzle. Parts being conveyed
into the booth are negatively charged. The
products more efficiently, continuously paint is electro-statically drawn to the parts.
improve and save resources. This isn’t new technology; Tennsco’s current
Tennsco certainly works toward those goals paint booths operate this way. But there is a
as it tweaks everything from procedures to drastic difference.
packing to keep a competitive edge. The Wagner booths are made of plastic, not
After 10 years of experience painting metal metal, thereby reducing the amount of paint
parts with powder paint, Plant 2 is moving to electro-statically drawn to the walls. They are
the next generation of powder paint booths. wiped down once a week with special cloths
In mid-October, crews switched from to reduce their static electricity. McClurkan
The clouded look in Iontech paint booths and installed a new said tests showed that 65% of a pound of
this booth is powder Wagner paint system. In mid-January, paint is transferred to the part as it moves
employees began dismantling more of the old through the booth. He’s uncertain of the
paint being electro-
booths and planned to install another Wagner specific improvement but speculates it could
statically drawn to by the end of the month.
the charged parts. be a 20-25% improvement.
The new system features vacuum technol- The remaining 35% of the paint is automati-
Powder that doesn’t ogy and quick color change capabilities. cally cleaned from the bottom of the booth
adhere to the part is Plans are to replace the four older paint through use of a vacuum that draws the
pulled back through booths with two Wagners. excess into what is called the cyclone. The
the system by a Shift manager Steve McClurkan said the cyclone moves the particles around at a speed
vacuum. new system has several advantages: of 18,000 cubic feet per minute, separating
Less energy use. It’s and reclaiming 95% of the paint at this step.
expensive to supply This reusable paint is pumped back into the
power to the booths color cans for use in the paint booth. The
and maintain the unusable paint is discarded.
environmentally The Wagner features “eyes” (called a light
controlled work space curtain) that scan a part as it enters the booth
the paint booths need. and determine its size and the spacing
Eventually, Plant 2 will between parts. This information is immedi-
run two paint booths ately transferred to the paint nozzles to
rather than four, maximize coverage. There’s even something
McClurkan said, and called a Z-axis gun (think three-dimensional
the room could be geometry) that follows the contour of a part,
reduced in size. like the bottom of a shelving unit, and paints
Quicker color those hard-to-reach places.
changes. The older More consistent paint thickness/less hand
booths require two to painting. The Wagner allows for finer control
three employees of the paint’s thickness through more sophis-
working up to five ticated electronics. McClurkan said the
hours each cleaning the control is programmable, allowing the
inside of the booth of employee to save the settings to a computer
excess paint that didn’t file and reload the settings the next time that
adhere to parts. With same part is painted. Better automatic paint-
the Wagner, there is ing reduces the need for manual touchups.
Winter 2006 2
nuts & bolts
Main Library, City
of Jacksonville,
Florida.
Blankenship said.
“That’s how you sell these. You do
what they ask.”
Once Tennsco landed the job, the
company impressed the planners
with its flexibility.
“You all really came through,” said
Alice Jones, library project manager
for the City of Jacksonville/Better
Jacksonville Plan. “It was terrific.”
She cited Tennsco’s special produc-
tion runs, coordination of extra needs
that were communicated to the
Library Nashville project.
company late in the project, and
product quality.
“I was never bothered with a list of
missing or defective parts,” Jones
Continued from Page 1
Jacksonville planners had specific said. “You all must have your act
said Chris Blankenship of the requests for the shelving: Bottom together. This was one of the easiest
company’s sales staff. “We’re con- shelves that tilted the books up for things we did.”
stantly looking for that next big one.” easier viewing of the spine and lights Jones was especially proud that a
The Jacksonville job is a textbook atop some shelves that would illumi- Tennessee company performed so
example of how networking, flexibil- nate the books and back light a sign. well. She’s a native of Erin, in nearby
ity and exceptional production “We had seven Houston
‘(Tennsco) really came
response won the contract and to eight meetings County.
garnered raves for Tennsco’s work. down there going Blankenship
The story really began with the through product through...You all must have said Tennsco
opening of Nashville’s Main and development,”
branch libraries in 2001. Tennsco Blankenship said. your act together.’ adapted to
Jacksonville’s
supplied 12 tractor trailer loads of Tennsco’s --Alice Jones, situation,
shelving - 90% of the total - to the engineering, tool Library Project Manager particularly
main library alone. design and after three
Fast forward to 2004. Jacksonville production hurricanes
city leaders decided to model their departments created a sloping, slowed construction. Then, when the
main facility after Nashville’s and adjustable shelf with end bracket and project needed to be hurried,
tapped the same architects (Robert a light with an acrylic cover. Tennsco’s Plant 5 trimmed produc-
A.M. Stern Architects) and same “They didn’t want it outsourced.” tion time from six to three weeks.
project manager (Heery Interna- They wanted one company to supply Jones held out a carrot that Tennsco
tional). the shelving and the lights, he said. might expect more business in the
“The facility is almost a mirror job” “We did everything they wanted us area. “We’re also going to do a
to the Nashville project, Blankenship to do. If it wasn’t a standard product courthouse later,” she said, adding
said. Tennsco got invited to bid on for us, we created it. Those were the that Tennsco’s local dealer representa-
the project due to the success of the nails in the coffin for everyone else,” tive was expected to bid on the job.
3 Winter 2006
nuts & bolts
R icky Vaughn has a time capsule. Yeah, it’s
a piece of art crafted from wood, thin
strands of steel and embellished with some
award-winning dobro player David McMillen,
a Dickson resident.
Vaughn has made quite an investment in his
inlaid mother-of-pearl...it’s a banjo. But, hobby. He’s on his sixth banjo, a Gibson
when Vaughn puts on his picks and Granada Mastertone. The cost? “You don’t
strums a bit, he is instantly transported want to know.” The banjo is a new model
back to the $50 based on the one Earl
guitar he started Scruggs once played.
out with 20 years
ago.
When
Supervisor When he strums the
strings, the rich, twangy
sound fills the room as
Vaughn, a
fabrication
supervisor at
helping though it’s plugged in.
The group has done
some recording. “When
Plant 2, it started, we were just
starts to talk
about why he likes
and plays bluegrass
preserve going to make a CD for
everyone” in the group.
So many folks have
Ricky
Vaughn strums
music, he’s transported
even further into the past.
“It’s just holding on to
bluegrass asked for copies, the
group has pressed sets
of CDs two additional
the past and not letting it times.
his banjo at right;
group’s CD
pictured above
fade away. Flatt and
Scruggs, the Stanley
past The group, called
Bluegrass Overdrive,
Brothers and others has a local following.
blazed a trail and I want to keep it For three years, the group has played at the
going,” Vaughn said, referring to American Cancer Society’s Relay for Life
legends in country music. event. For the last two years, the guys
“I love (bluegrass). It has a have entertained at the folk festival at
great message about love or Montgomery Bell State Park. They
despair...the harmonies, the non- have also played the Charlotte
electric instruments...it’s just a part Festival.
of the past.” Vaughn said bluegrass
Vaughn and the Dickson group music has enjoyed
he plays with regularly, have renewed popularity
“no aspirations of making the through the movie, O
big time. We like being Brother, Where Art
home every night,” he said Thou? Through
with a laugh. But, “I am recordings and
serious about it. I am videos from
very serious. If I didn’t artists such as
thoroughly enjoy it I Patty Loveless
Wellness fair wouldn’t do it.” and Allison
March 9-11 Most weeks, the Krauss, “people
quintet jams at Bill’s are really interested
Mark your calendars
Tire Service on College in it. There’s just a
for Tennsco’s Spring
Street in Dickson. Bill harmony to it that draws
Wellness Fair. The
Littleton, owner of Bill’s, people.”
fair hours will be:
sings and plays mandolin. If you’re driving through
Ken Johnson sings and plays Vanleer, and you hear haunt-
Thursday, March 9
guitar as does Kevin Crabtree. Fred ing strains about good ole
1 to 5 pm
Mayberry sings and plays bass. boys, moonshine or old horses
Vaughn plays banjo and stomps his wafting through the trees,
Friday, March 10
foot. you’re probably near Vaughn’s
1 to 5 pm
“I just play. If I do sing, it’s where home. “I get it on satellite. When
nobody can hear me,” Vaughn said. everybody’s gone, I pump it
Saturday, March 11
Sometimes the group is joined by up.”
8 to 10 am
Winter 2006 4
nuts & bolts
Die designer keeps They got
bonuses
soccer kicking in Hickman The following
employees received a
Y ou could say Tennsco’s Gordon family has
established a soccer dynasty.
Plant 1 Tool Room Supervisor Billy Gordon
parents in line. When I get a complaint, I’m
ready to hand (the complainer) the whistle,”
Gordon said.
$50 cash bonus as of
Sept. 30, 2005, for
perfect attendance.
first brought soccer to Hickman County in There’s plenty of fundraising - 25% of the Plant 1
Ricky L. Parchment
1986. league budget has to be solicited from con-
Jimmy L. Winters
Son Wendell Gordon, die tributors. The remaining Plant 2
design engineer at Plant 5, three-fourths comes from Raymond O. Boone
carries on the tradition, Wendell fees. “We try to keep fees Sandra D. Cotton
Gordon down so families can afford Gerald L. Curtis
currently serving as
Garry A. Donegan
president of the East to play,” Gordon said. Kenny H. Forsee
Hickman Buford McCord Gordon’s been involved Walter Dean Proctor
Soccer League. The league in soccer since he was a Plant 3
Harold L. Givens
serves more than 100 child. Hickman County
Roger D. Hollis
children from three to 16 didn’t have a high school Larry D. Stafford
years old and it’s growing. team, so Gordon played in Juan Valdez
The recreational league is the recreational league his Billy W. Vetter
Plant 4
based in Wrigley just off dad established. He earned
Thomas A. Buttrey
Highway 100. a spot on the UT Martin Plant 5
In addition, Gordon soccer team for two seasons Gary D. Bailey
coaches a team and takes and also coached and Charlotte A. Roberts
his turn officiating at officiated there, too. He said James R. Tate, Jr.
games. His involvement he enjoyed games against
comes from sheer love of the more well-known The following
the sport, and kids. Southeastern Conference teams. employees received a
“I love soccer and the kids needed some- While the league plays a fall season and a $50 cash bonus as of
where to play (his own son and daughter spring season, Gordon’s volunteer job is year Dec. 31, 2005, for
play). The league needed a president. It was round. He’s in his second year as league perfect attendance.
Plant 1
going to go away if someone didn’t volun- president.
James M. Carpenter
teer.” Gordon sees his program helping the His hardest task, he said, is finding enough Raleigh E. Davidson
public school teams, too, serving as a training time to get everything done. “Sometimes, I’ll Harry Harry, Jr.
ground for the county’s varsity sports. be on the phone all night scheduling teams William P. Mays
Rickey L. Story
The younger Gordon started work at and refs,” Gordon said. There are always new
Plant 2
Tennsco in 1989 as a part-time AutoCad teams to start up and new referees to train. Gene C. Alderidge
employee in engineering. He went full time in His most time consuming chore? Cutting Eric M. Brake
May 1992 after graduating from the Univer- grass on the three soccer fields and trimming Thomas E. Fambrough
Howard C. Forsee
sity of Tennessee at Martin. the fence rows. Even with some other volun-
Leonard A. Jackson
Gordon is using his management degree teer help, Gordon estimates he puts in eight Leonard Modena
from Martin to help oversee projects at to 10 hours a week for the league. He’s Lonnie G. Parker
Tennsco and run the soccer league. “Yeah, I dreaming for bigger mowers to make the Billy D. Sensing
William H. Smith
use it in juggling Tennsco projects. I have grass cutting go faster.
Plant 3
to...there’s a lot going on.” Gordon is hoping to fulfill the dreams of Onetta Fern Arnold
With the soccer league, “I have to have the some future soccer players. He’s going to Brenda L. Capps
money right. I have to make sure there’s start a program to provide equipment for Darrell Davis
Lannon A. Gladden
enough money to pay the referees, buy those who can’t afford soccer balls, shin
Ben G. Harper
trophies and pay fees,” Gordon said. guards and shoes. Robert N. Rodgers
He hasn’t experienced any of the horror There’s an upside to all the grass cutting Plant 4
stories of fans getting unruly with referees. and refereeing he does for the league. He Douglas Edward Parker
Plant 5
“I’m the only adult ref. The rest are teens. usually loses a few pounds during soccer
Jason W. Corbin
These kids are exceptional. The league season - which gets him in shape for the adult Plant 6
couldn’t function without them. softball league he plays in at Tennsco’s Shannon L. Fambrough
“I tell every coach to keep their (team’s) softball park!
5 Winter 2006
nuts & bolts
Winter 2006 6
nuts & bolts
See anything unsafe?
Report to plant committee
S ee anything unsafe happening around
you? Bugged by a nagging feeling
that your work can be done a little
ment. That’s where you get ideas
from.”
The committees look for trends
safer? and make suggestions on how to
You have a place to turn make their facility a safer work-
to - your plant’s safety place.
committee. Thank you
For instance, a couple of
The committees’ structure years ago, Plant 5 had three for calling
is simple, but the work is eye injuries within a year. Tennsco
serious. After some study, it became Stephanie Tidwell has
Committees serving each mandatory for all Plant 5 paint joined the Tennsco
plant meet quarterly. The panels line employees to wear goggles. staff as the Main
review all OSHA injury/illness “Since that started, there have been no Office receptionist.
records for their particular plant, more eye injuries,” Adams said.
discuss each accident or injury and In March 2005, a new coolant begain
find ways to avoid future accidents. causing eye irritation. The safety committee
“These individuals have very good insight looked into the situation and recommended
into what happens,” said Tennsco Safety changes. Tennsco changed vendors, got a
Director Woody Adams. “Most of the people
Vending
different product and there have been no
have worked years in that particular depart- more eye irritations. machine
costs up
Tennsco Safety Director Woody Adams, is the chair of each plant’s safety committee. Following are the Into every life
current members of the committees: eventually must
Plants 1&4: Management Member - Dennis Wilson; Hourly Representatives - Robert Donegan and Ricky come...a price
Parchment. increase. Employees
Plant 2: Management Members - Mark Holland and Wayne Hargrove; Hourly Representatives - Kevin have probably already
Ellis and Dowell Jones. noticed vending
Plant 3: Management Members - Jewell Loggins and Gary Carlton; Hourly Representatives - Corey machine prices have
Madden and David Finch. gone up by a few
Plants 5&6: Management Members - Robbie Alberd and Kenny Stone; Hourly Representatives - Gary cents.
Sugg and Shannon Fambrough.
Old price New price
35¢ Coffee 40¢
EMPLOYEE ANNIVERSARIES ■ This listing of employee anniversaries includes those celebrating a 70¢
70¢
Candy
Pastry
75¢
75¢
five-year interval. $1 20 oz drink $1.10
$1 20 oz water $1.10
NO. OF 25¢ Soup crackers 30¢
October - December 2005
PLANT NAME DATE YRS
Small bags of chips at
NO. OF 2 LOWE, HALLIS R. 10/26 5 50¢ each were
PLANT NAME DATE YRS 2 PORTERFIELD, FRANCES I. 11/28 5 removed and
Off BARKLEY, BRANDY 12/4 5 2 SMITH, WILLIAM H. 11/8 5 replaced with “Big
Grab” bags at 75¢
Off FREY-MCCALLA, SANDRA 11/1 15 2 THOMAS, MICHAEL S. 12/18 5
each.
Off MCCALLA, HAROLD R. 10/1 15 3 GRIFFIN, SHANNON R. 10/20 10
Off YOUNG, JANET M. 11/20 5 3 LOGGINS, JEWELL 10/1 25
1 ELLER, CHRISTOPHER M. 10/5 10 3 OVERTON, LORRAINE G. 11/14 5
1 RYE, DARRELL T. 10/9 15 5 GEARY, DEBBIE 10/9 10
1 WEAVER, DERRICK R. 11/2 10 5 REYNOLDS, BRANDON S. 11/29 10
7 Winter 2006
nuts & bolts
Drug free their former job with all associated
Continued from Page 1
pay and benefits.
protected from the increased As an employer, Tennsco will:
dangers and risks that substance • receive a five percent credit
abusers present in the workplace, on its insurance policy;
Families according to information from the • have the authority to
discipline or discharge an
state. The program allows substance
growing abusers to voluntarily enter treatment. employee for cause, or refuse to hire
a job applicant, found to be in violation of
If they successfully complete a treat-
ment program, they are reinstated to the Drug-Free Workplace Program;
Three Tennsco
• be released from the responsibility of
families have paying a worker’s compensation claim if an
celebrated the arrival injured employee tests positive for illegal
of babies over the Benefits explanation drugs or alcohol in a post-accident drug test,
or refuses to take the test.
last few months.
Newborn babies of coming 1x a month Safety Director Woody Adams said the one
hour of training for each employee and the
Tennsco employees Changes have been made to statements two hours for each supervisor were educa-
receive a $50 savings detailing employee medical benefits. tional and informative. He said the amount of
bond from Tennsco. Health Cost Solutions, the administrator of paid work time devoted to the 30-plus train-
Tennsco’s health care plan, has consolidated ing sessions demonstrated the company’s
Haiden Brent Bates its reporting to employees into a Monthly commitment to having a drug-free workplace.
Family EOB (explanation of benefits). The The union representing Tennsco’s employ-
was born to Brent
data had been reported to employees and ees, Local S-234 of the Allied Stove, Furnace
Bates and Stephanie dependents on a per claim basis. and Appliance Workers, Divison of Boiler-
Browning on 10/3/05. Karen Sanders, Tennsco’s account manager makers, also signed off on the program.
He weighed 6 lbs., 12 with Health Cost Solutions, said the monthly Adams said the company got the union’s
oz. statement will summarize in one location and cooperation before taking the proposal to the
at one time all family claim information and entire workforce.
out-of-pocket responsibility to service While Tennsco hasn’t detected a tremen-
Rebecca Ann Shear
providers. dous substance abuse problem among em-
was born to Peter Those with questions can contact Tennsco’s ployees, there are isolated incidents through-
and Kelly Shear on 9/ Benefits Coordinator Martha Vaughn at out the year, Adams said.
20/05. She weighed 7 326.0633 or Karen Sanders directly at Since the training began in May, Adams said
lbs., 6 oz. 1.800.526.3919, ext 1141. two or three employees have admitted they
have a drug or alcohol problem. Each year, an
Courtney Jade Happy birthday, average of eight to 12 individuals show
positive for drugs either through pre-employ-
Williams was born to
Timothy Williams and
nuts & bolts ment testing, post-accident testing or testing
done due to suspicious activity.
Amanda Alderidge on With this issue, nuts & bolts begins its 10th
12/14/05. She year of telling the Tennsco story. It’s been a
weighed 7 lbs., 1 oz. decade filled with stories about new prod-
ucts and processes, the challenges of the
economy and profiles of the interesting
people who make up the Tennsco family.
Thanks to all who give of their time to tell
about their work, hobby or fundraiser that Tennsco Corp.
Tennsco’s involved in. 201 Tennsco Drive, Dickson, TN 37056-1888
My appreciation goes to those who pa- 615/446-8000
tiently explain things, sometimes several
times. And to those who smile when the Stuart Speyer ................................................ President
camera flashes...bless you. Phil Corbin .......... Vice President, Human Resources
--The Editor Gary Fouts .......................................... Editor, gf grafix
Winter 2006 8