Editor's Note: The following is a
first-person account of Goodrich, Texas-based Pro Star
Waste's experiences with a fully automated collection
system, told by one of the firm's executives.
HESITANTLY, CARL (not his real name) reached for the
button control as he eased up to the next cart in the row
laid out for his training. Was he exactly lined up for the
arm to grasp the container? He pushed the button, and the
arm picked up the cart.
With more assurance now, he pushed the button commanding
the container to tip into the side hopper. Unfortunately,
the cart fell into the hopper. Slightly panicked, Carl
quickly stopped the packer mechanism and jumped out of the
cab. Vaulting onto the ledge next to the hopper, Carl fished
the cart out in the nick of time, undamaged.
Six years ago, Carl's first day of training with a
fully automated system had its ups and downs. Today,
however, Carl is thriving under automated collection. So is
his employer, Goodrich, Texas-based Pro Star Waste.
In fact, we recently received an unsolicited letter
nominating Carl, who is known to patiently answers
customers' questions about the system, position the carts of
new customers for pick-up and even hand out dog biscuits to
neighborhood canines, for “Ambassador of the Year” for his
care and personal touch with customers. The impromptu
designation stuck, and Carl now is known as “the
Ambassador.”
So why did Pro Star Waste choose to go fully automated
when it was formed in 1999, given the rural Texas
nature of its service area, the many poor roads its drivers
encounter, the challenges of managing individual billing,
the expense related to staging carts and getting service
agreements signed, and all the internal tracking of carts,
routes and driver maps? One word: Profitability.
The costs of automated trucks and carts, a trained
in-house mechanic staff, parts stocking and inventory
management, and specialists to coordinate and track
individually billed residential cart service are outweighed
by having to employ only one person per truck. In addition,
we can hire brains instead of the brawn needed to lift
unwieldy items into rear loader trucks. When seeking new
drivers, we put a strong emphasis on men and women with the
smarts, alertness and the personality to talk with
customers, and our drivers are told to think of themselves
as the owners of their routes.
So
how do we sell our largely rural customer base on the
benefits of once-a-week, automated service as opposed to
twice-a-week, manual service? The biggest selling point is
the elimination of rural animal problems. The smartest
raccoon cannot stand on the attached lid of an automated
cart and open it at the same time. In addition, the benefits
of not having to place trash in garbage bags by the curb and
exposing the bags to the weather are another plus.
Warehousing trash in the Texas summer heat is enough to
cause marital discord, and the odor control provided by
placing waste in the automated cart with the lid closed over
the built-in raised lip just might save marriages.
A while back, one of our managers
was driving around observing one of the automated routes and
was flagged down by a customer who admitted, “I want you to
know I never thought these $%#@ carts would work, but I like
‘em!” Comments like these often are made to our drivers or
are written on billing statements.
What You Need
What do we at Pro Star Waste look for in an automated
vehicle? These are garbage trucks, not rocket ships.
Overall, we look for simplicity of design.
While it is wonderful having only one button for the
driver to push to perform the automated functions, we prefer
the driver to have one button for each stage — grabbing,
lifting, emptying and releasing — of the arm's handling of
the cart. In this way, the control shifts away from
complicated computer systems that can be difficult to
maintain.
Grippers must be designed to service the particular style
of cart you are using, or you will damage a lot of them.
As for the truck itself, no matter your preference, make
sure the frame is heavy enough for your operations and has
plenty of cross members because the constant arm motion
tends to twist the truck frame. A heavier suspension and
good springs will help to stabilize the platform. We often
compensate for the extra workload of the springs on the
loading side of the truck by adding an extra spring or
increasing the arc of the spring to offset the continuous
motion. We call this “tricking the truck out.”
Right-hand drive (steering on the right) is an expense
and extra maintenance problem we choose to bypass. Drivers
quickly adapt to the mirrors and cameras that they use when
steering from the left.
Spend your time and money on hiring
good drivers and training them, as opposed to spending on
gadgetry. And, make sure your truck is not under-spec'd for
the body.
Gotta Maintain
What, exactly, is involved with the inventory and
mechanical aspects of automation? Being a rural company, Pro
Star Waste maintains an extensive inventory of parts onsite
since dealers may be far away, temporarily out of stock, or
not able to return phone calls quickly when a truck is down.
We carefully examine which replacement parts our vehicles
consistently need to determine the supply of extra
components to keep on hand. If you are always replacing
gripper belts and micro switches, then always keep more than
a few in stock.
Preventive maintenance is the law, with all of our
vehicles being regularly reviewed for performance. Daily
greasing of the trucks is performed, as are checks for
leaks, broken welds, cylinder tightness and the vehicle's
overall mechanical condition. Basically, we shake the truck
a little to see what, if anything, is loose! Our route
breakdowns are greatly reduced by preventive maintenance.
Perhaps the most important advice to haulers considering
automation would be to tell them to be ready to perform
proper maintenance. You cannot do “fall off” maintenance,
meaning that you fix components as they break down. Haulers
must stay ahead of the maintenance on an automated truck.
What about mechanic training? Basically, any mechanic who
can read an electrical schematic and hydraulic flow
schematic can diagnose and repair automated trucks.
At Pro Star Waste, we track our customers and carts
through editable mapping software that we began programming
ourselves more than 30 years ago. We use the Linux operating
system on our computers.
Each day, the drivers have updated maps that are
color-coded to indicate new customers, customers whose
service has been suspended for non-payment and customers who
no longer use Pro Star Waste. Drivers are trained to review
their maps before starting their day's routes. The maps
allow any driver to drive any route. We may automate our
route monitoring operations as technology becomes
increasingly simple and affordable, with global positioning
system (GPS) tracking and daily DVD recording of stops
serviced. We always view with interest what other companies
are doing and try to adapt new technologies to improve
efficiencies.
In summary, purchasing, “tricking” out, and maintaining
automated trucks is expensive, but this is more than offset
by needing only one driver per truck. If you don't purchase
quality vehicles, modify them as appropriate and maintain
them properly, they will not last very long. Short- and
long-term repair expenses will eat up the profits quickly.
Cindy Jones is an assistant
manager for Goodrich, Texas-based Pro Waste Services.
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