Austin Overview - 2015 PDF

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PEOPLE. PERFORMANCE. SOLUTIONS.

Austin’s Culture

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• Founded in 1918

• 100% Employee-Owned

• 7,500 Austin Industries Employee-Owners

• 5,500 Austin Industrial Employee-Owners

• $2 billion in annual sales

• #41 ENR

• Texas’ largest contractor by revenue-Texas Construction

• Diversified

₋ Commercial

₋ Bridge & Road

₋ Industrial

• No Debt

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Austin Industries – Our Parent Company

Company Overview

• Employee Stock Ownership Plan Established in 1986

• By 2000, Austin Industries was 100% employee-owned (at no cost to the employees)

• Austin Industries has paid out over $300 million in retirement benefits through the ESOP.

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How It Benefits You

Because our company is 100% employee-owned, our customers know that each individual they contact throughout our company has a vested interest in the success of their projects.

Employee-Ownership

• Leader in Safety

• Every Employee is an Owner

• One of the largest maintenance contractors in the U.S.

• More than 120 active maintenance and capital construction sites

• Self perform practically all of our work

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Austin Industrial

Maintenance

• Millwright/Mechanic

• Welder/Pipefitter

• Boilermaker

• Equipment Operator/Rigging

• Electrical/Instrumentation

• Fire Sprinkler Systems

• Vibration Monitoring

• Fiberglass

Construction/Small Cap

• Piping

• Structural Steel erection

• Equipment Setting, Assembly, & Alignment

• Electrical/Instrumentation

• Civil

• Project Controls

• Subcontract Management

Specialty

• Scaffold

• Insulation

• Paint/Coatings

• Asbestos Abatement

• Lead Abatement

• CUI

• Fiberglass

• Steam Tracing

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Plant Services

•Facilities

•Warehouse

•Logistics Support

•Janitorial

•Grounds

•HVAC

•Tool Room

•Operations Support

Heat Exchanger

•Bundle Insertion/ Extraction

•Rigging

•Tube Replacement

•Torqueing

•Tube Plugging

•Bundle Repair

•Insulation Blanket

Turnarounds

•Boilermaker

•Exchanger Services

•Scaffold/Insulation

•Paint

•Welder/Pipefitter

•Specialty Welder

•Planning/Scheduling

•Equipment Operator/Rigging

Material Handling

•Rail Loading

•Tank/Bulk Truck Loading

•Barge Loading

•Switching

•Packaging

•Drumming

Austin Capabilities

Current and

recent

site locations

Austin Offices

Where We Work

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Austin Offices

• La Porte, TX

• Augusta, GA

• Spartanburg, SC

• Calgary, AB

• Baton Rouge, LA

• Nederland, TX

• Borger, TX

• Ponca City, OK

• Mobile, AL

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• Albemarle

• Advance Aromatics

• BASF

• Baker Petrolite

• Bayer

• Bridgestone

• Clariant

• DSM

• Dixie Chemical

• Duke Energy

• ExxonMobil

• International Paper

• Lanxess

• Linde/BOC

• LCY Elastomers

• Lubrizol

• LyondellBasell

• Marathon

• Miliken

• Motiva

• Navajo Refining

• Noltex

• PCS

• Phillips 66

• Prayon

• Shintech

• Syngenta/GB Bio

• Targa

• Timken

• TOTAL

Customer Base

Core Safety Values “All Accidents are Preventable”

Austin Driving to Zero

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Zero is achieved through the following

philosophies and best practices:

• Safety, Health and Environmental Protection Takes Precedence Over All Else

• Management Engagement and Visibility – Boots on the Ground

• Zero in the Hearts and Minds of the Individual

• Safety Culture Survey

• Austin Risk Behavior Assessments

• Safe Work Policies, Procedures and Practice Conformance at All Times

• Employee-owner Empowerment, Engagement And Participation

• Targeted English Training For Spanish Speaking Employee Owners

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2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 YTD

TRIR

Wo

rk H

ou

rs (

MM

's)

Work Hours (MM's) TRIR

Safety Performance

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Managing Values and Culture

• Management Visibility and Engagement -

Leading by example

• Risk Behavior Safety Assessment and key

follow ups

• Austin Safety Culture Survey and key follow

ups

• On-Boarding process

• Employee-Owner empowerment expectations

• English language comprehension assessment

• 360 Supervisor Review and Dialogs

• Safety Meetings

• Expectation Meetings

• Employee-Owner Dialog Meetings

• Bilingual JHA/JSC’s

• Audits/Listening Tours

• Mentoring Process

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Austin Quality Control

• ISO-Based QC Program – All Disciplines

• Project Specific Quality Execution Plan

− Tailored to fit service offering

• Alignment with Project Specifications

• Inspection & Test Plan Process

• Supervisor and Craft Quality Training

− Proprietary Weld Quality Program

− Includes Welders, Supervisors, Pipefitters &

Inspectors

• Non-conformance process

• Corporate Weld Acceptance rate – 97.8% (2013

average)

• Corporate X-Ray acceptance rate – 97.9% (2013

average)

• A Boiler Assembly

• PP Pressure Piping

• U Pressure Vessel

• R Repair & Alteration- National Bd.

Certification

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Welding Quality

2013 2014 YTD

Butt Welds Made 29,594 21,822

Welds Radiographed 4,582 4,703

Welds Rejected 96 89

Weld Acceptance Rate 97.9% 98.11%

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NCCER Training

• One of the highest participation rates in

NCCER training in the country

• Craft subject matter experts

• Austin Industrial developed and

implemented craft assessments in

1993

Workforce Development

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NCCER Training (contd.)

• Training based on assessment prescription

• Austin is affiliated with 22 local High Schools and vocational schools to

acquire NCCER curriculum (we are mirroring this program in the

Southeast)

• Helper Progression Program

Supervisor Development

• Supervisor Training

• MAP (Accountability Plan)

• Austin University

• Site Manager Training

• Leadership Development Programs:

• Leadership Development Group (LDG)

• Supervisor Cornerstone

Workforce Development

• Establish site steering team & establish benchmarks

• Evaluate effectiveness of current work flow process

• Develop KPIs & targets – mutually agreed

• Develop site-specific strategic plans

• Implement Opportunity for Improvement process

• Review training requirements

• Review indirect staff requirements

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Maintenance Workflow Process

Work

Selection

Receive

Work Planning Scheduling Execution

Scaffolding

• Piping

• Equipment

• Tanks

• Towers

• Boiler Internals & Externals

• Ductwork Internals & Externals

Insulation

• Piping, Towers & Equipment

• Hot and Cold service

• Reusable Blankets

• Fiberglass Panel Systems

• Fireproofing

• Refractory

• Asbestos Abatement

• Steam Tracing

Painting/Coatings

• Piping

• Equipment

• Tank coating and lining

• Sandblasting

• Lead Abatement

• Environmental Compliance

• Epoxy Fireproofing (Chartek)

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Scaffold Efficiency

• Labor Analysis

• Material Utilization Analysis

• Scaffold Location Analysis

• Scaffold Movement KPI’s

• Historical Data

• Reduced Material and Labor Costs

• Scaffold Elimination

Heat Loss/CUI

• Thermographic Survey Process

• Identify areas of CUI & Heat Loss

• Establish Asset Protection Program

• Quantify potential Energy Savings

• Certified Thermographers

Paint Program

• Paint Survey to identify areas and levels of corrosion

• Prioritize and schedule specific areas to be painted based on:

• Corrosion Levels

• Environment

• Schedule Value

• Equipment Criticality

• Provides cost effective asset protection

Specialty Services

Services

Systematic

Programs

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Austin Scaffold Asset Program (ASAP)

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Paint Program

Best Time to Paint

Worst Time to Paint

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Heat Loss/CUI

Plant layouts using

Electronic Maps

Heat Loss Reports CUI Reports

Plant Layout

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Equipment

The most advanced extractor

technology

• Aerial Extractors

− 99,000# capacity

− Diameters to 8’2”

• Truck Mounted Extractors − 44,000# capacity

• Self Propelled Extractor − 55,000# capacity

• Bundle Trailers − Crane-free design

Exchanger Services

Austin has the only

manufacturer’s certified training

program in the world!

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Heat Exchanger Services

Real-Time Continuous Improvement Process

Approved/ Prioritize

WorkPlan

Establish Best

PracticesSchedule

Release to

Austin

Review Equipment

File

Execution Prep

Execute Events Log

Analysis for Performance

GapsProcure

After Action Review Questions:· What did we set out to do?· What actually happened?· Why did it happen?· What should we do next time?

Analyze for Performance Gaps:· What is the performance Gap?· When did it happen?· What effect did it have?· Who should improve it?

Work Flow Process

Feedback to Improve Info Used in Work Flow Process

Feedback to Improve Work Execution

Job did not go as expected

After Action Review

Update Equipment

File

Identify Execution

Improvements

Equipment File Content:· Work Procedures or Requirements· Exchanger Dwgs· Fastener and Gasket Info· Torque requirements· Crane and / or Rigging Plans· Tools Requirements· JHAs· Lessons Learned

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Turnarounds

Austin has extensive experience in all phases of the turnaround cycle from the

front-end efforts of planning and scheduling through execution, system turnover and start-up. Performing both embedded and stand-alone turnarounds, Austin has particular in-house expertise in performing Alkylation Unit projects.

Austin routinely performs:

Alloy welding

Bolt torqueing

Offsite pipe fabrication

Pipe installation

Bundle extraction

Valve replacement

Tower and column work

I/E work

Vessel modification

Code work

Millwright work

Scaffolding

Insulation

Planning/scheduling

Purchasing/subcontract

management

PHASE 1

Business Strategy

PHASE 2

Preliminary Development

PHASE 3

Develop/Refine Scope

PHASE 4

Finalize Planning

PHASE 5

Pre-turnaround Activities

PHASE 6

Turnaround Execution

PHASE 7

Close-out/ Review

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Keys to Success

• Early Involvement

• Goal Alignment

• Detail Execution Planning (Work/Resources)

Turnaround Execution -

A Phased Approach

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Construction Capabilities

Civil/Structural

- Site prep & survey

- Underground utilities

- Foundations &

area paving

- Structural steel

erection

Mechanical

- Equipment

installation

- Rotating equipment

assembly &

alignment

- Piping

- Rigging

E&I

- Electrical

- Instrument

installation

- Conduit

- Tubing/piping

- Terminations

Specialty

- Scaffolding

- Painting/coatings

- Insulation & abatement

- Fireproofing

Additional

- Commissioning/

start-up support

- QA/QC program

w/complete ITPs

- Earned value-

based project

controls

- Procurement

- Lean construction

work processes

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Construction Overview

Project controls in support of Austin’s work include:

• Estimating in support of project development

• Detailed project estimates

• Project control execution plans and control of work processes

• Detailed, logic-driven & resource loaded schedules

• Quantity-driven progress tracking and earned value reporting and forecasting

• Change Management

• Integrated turnover system tracking

• Integrated quality process from award through close-out

• Structured to fit size & complexity of project

• Development of integrated capital projects team philosophy

• Early construction input during FEL 2 & 3

• Project-specific estimates with uniform work breakdown structure

• Project-specific, resource loaded, logic driven schedules

• Timely & accurate physical field progress reporting for earned value progress

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IPA Best-in-Class Program Award

Small-Cap Capabilities

• Executive Sponsors

• Alliance Steering Teams

• Site Steering Teams

• Site Strategic Plans

• Quarterly Key KPI Reviews

• Individual Accountability Plans (MAPs)

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Strategic Customer Alignment

• Best in Class Safety Performance

• Employee-Ownership

• Proven Performance and Cost Savings

• Best in Industry Supervision and Crafts

• Resource Capacity/Flexibility

• Geographic Footprint

• Broad Range of Capabilities

• Committed to Customer Key Business Drivers

• Access to Multiple Sites and Industry Best Practices

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Summary