Power and Production

January 4, 2009

   It was about six years ago when we converted our main floor machines to the 220V Italian models. Going back to working with the mono-rotary 110V machines would be akin to a fabricator, now using a CNC to produce 10 kitchens a week, wanting to go back to a rail saw and hand polishing.
   Although you may not like the monthly payment on the CNC, it’s not the extra labor and risks of breakage from the old methods. Not to mention, of course, the effort in trying to install a countertop when all the measurements fail to match up.)
   A few weeks ago, we had a big job in Canada where I had the opportunity to train a new manager in not only time-management, but also on machine use. Seeing that we had an extra hand on the job, I decided to roll out the old, faithful 110V Mono-Rotary Warrior that got me started in the business. (A single tear rolled down my cheek).
I hadn’t done time comparisons in a long time, but what we found out compared to the 220V machine was very interesting.
   First, let me say that (in the spirit of staying positive), when we finished the job and compared the two machines’ floors side-by-each (that’s a Canadian term), you wouldn’t notice a difference in the overall finish of the job. And after all, results are what the customer is paying for … right?
   However, I’ll clarify that the final polish with compound was done with the heavier and more powerful 220V machine. Could that have affected the outcome? Could the weight and power of the final polish actually make a difference? (More on that a little later.)
   When it came down to actual production times, the 220V, planetary-head machine covered more ground (actually, solid stone) – hands down. How much more? A rough estimate showed that the 220V Monster put out at least 6:1 more square footage in a day than the little 110V Warrior.
   For example, the smaller, older machine spent the first day on the main floor in a small bathroom, grinding, honing and polishing up to 1500 grit. Single toilet, single-bowl vanity with about 80-100 ft² of floor area.
In comparison, the new Italian model, in the same time, did an office (3X the size of the bathroom), two walk-in closets and the 6 1/2’-wide hallway that joined the four rooms together lengthwise (as in all on one wall – not opposite of each other). Impressive? I thought so.
   The next day, the little engine that could still did about 100 ft², but it was overshadowed by the mighty 220V 4 HP giant that produced about 600 ft² on its own.
   So why did I even bother bringing out the little guy after he was humiliated on the first day? Because:
   • Hey, it was still 100 extra square feet that day, and it beat having a man stand around watching;
   • I didn’t happen to have another 220V machine just lying around that day (I wonder if the union has anything to do with that); and
   • It’s good for the “kids” (the new ones in the industry) to know how to operate the older tools if anything happens to the new ones. Because if for any reason, Mario Marblegrinder decides to break down one day, we can still put out about 100 ft² and be only 500 ft² behind schedule instead of 600.
   Consider, too, how my new guy got to see the difference between the two styles of operation. Would he be willing now to go work for a competitor using only 110V equipment after noticing the difference? And, when he’s training workers in new offices (we’re expanding, by the way) down the road, he’ll be able to explain why we’re using uniform machines and not cheaping-out with the lowest-price option.
   Let’s also look at what 500 extra square feet per day means to a service-based company. Time is money and labor (quality labor) is not getting any cheaper.
   If it costs you $150/day for a technician, and he’s only putting out 100 ft² a day, that equals $900 for your technician’s production that only costs me $150 for the same area. I can make an extra $750 per 600 ft².
   On this particular 3,500 ft² job, that would translate to $5,250 for your 110V-machine wrestler vs. less than $900 for my 220V jockey, or a difference of approximately $ 4,350 … on one job, no less. Let me hear again why you can’t afford the 220V machine.
   Let’s go back and consider the final polishing with the 220V vs. the 110V. On another job, a few years back, we did the lobbies of two identical condo units side-by-each (it’ll grow on you). To save time, I had one crew polish the one lobby with the high-voltage implement, while another technician and yours truly tackled the other floor with the 110V wonder horse.
    When the dust settled (or, should I say, the rinse water evaporated) the floor polished with the newer, larger, more-powerful machine actually had a better gloss. And it was me, after all, working the little machine!
   Henceforth, we banished said noble 110V warrior to the confines of the dusty place in the trailer, never to be spoken of again until, well, we needed it.
   And so the tale of the battle will be told. While the Little Volt tried and tried with all its might, it just could not keep up with Big Volt. The newer machine had it on power, performance and production.
   What can I say about the once-proud iron warrior of stone? He lived a good life, bought me a great truck and every once in a while … if the mood is right, I’ll let him come out and dance with his old master, but you know what they say about reminiscing: It ain’t what it used to be.
   Until next time, keep your stick on the ice. (For a before and after video of the job described here, you can find it at greatnorthernstone.com/gallery.html).
   Tom McNall is founder and owner of Great Northern Stone Care, a Huron Park, Ontario-based stone-cleaning and -restoration company servicing all of southern Ontario. Tom offers corporate and private consultations, serves as a trainer for the Marble Institute of America, and is also on the organization’s board of directors. He can be reached at stone_rx@earthlink.net.