Bandag Tire Procedure Manual

Tire Policy and Procedures Manual 2016

Bandag Locations Only 01-06-35-37 Rev. 8-25-16 Return to Main Page

Tire Inventory Controls Administration of Tires “In” and “Out” and “While in Inventory” Section: I.

Hogan Tire Policy • • • •

Tire Pull Points Inflations and Load Ranges Retread and Steer Application Guidelines General Repair Guidelines

II. Getting Tires “In and Out” of Your Inventory • • • • •

Purchase Orders Work Orders Transfers From Another Location Special Tire Activity Situations Damaged Tires

III. Handling Tires While in Your Inventory IV. Monthly Physical Inventory V. Over The Road Purchases Reference I, II, III, IV I. Purchase Orders II. Clerical Management III. Grading Casings and Specs.

IV. Monthly Inventory and Part Number Reference.

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Section I. Hogan Tire Policy Under No Circumstances should a tire that has been repaired, ever be used as a steer tire (except on a Spotter). Prior to installing any used tire to the “Steering” application, it must be inspected for repairs, without exception.

TIRE PULL POINTS: • Drive tires: 4/32 • Trailer tires: 4/32 • Steer tires: 6/32 Note : Tires must have enough tread to make it to the next PM

MISMATCH / INFLATION : • •

• • • • • •

4/32 difference between duals must be pulled for proper mating or 6/32 from one side of vehicle to the other, on the same axle.

Air inflation pressure for all 22.5 and 24.5 sized tires: Load Range H Steer 110 p.s.i. / Load Range G Steer 110 p.s.i. / Drive 110 p.s.i. / Trailers 110 p.s.i. / All Wide Base 100 p.s.i. or manufacturers maximum inflation pressure found on sidewall of tire if lower than above.

Any tire with a psi drop of 30 p.s.i. of standard inflation pressure must be broken down for inspection to find cause.

Alligator flow through caps to be installed on all Hogan equipment.

Alligator caps are to be tightened to snug using pliers or valve wrench.

New valve grommets required on all tire replacements.

All field applied tire repairs must be done in accordance with Bandag procedures, by an Authorized Bandag Service employee.

Tandem Drive tires with 6/32 or more between the forward drives and rear drives need to have tires rotated between forward and rear positions. This will be found on units with O.E. tires or units that have had all eight drives replaced at the same time. The rear drives wear faster. This practice will extend the life of the drive tires and help keep tires wearing evenly and more economically.

Policy, Section I, Page 1 Return to Main Page

Notice : All Sleeper Units Must Have Load Range H Steer Tires Installed At Steer Tire Replacement

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Tire Weight Ratings (Load Range) Per Tire

Example shown for 275/80/R22.5: Single Tire Application: Load Range G 14ply = 6175 at 110 psi max = 12,350 per axle Load Range H 16 ply = 7160 at 110 psi max = 13,360 per axle Dual Tire Application Load Range G = 5675 at 110 psi max = 22,700 per axle Load Range H = 6165 at 110 psi max = 24,660 per axle

Notice : All Sleeper Units Must Have Load Range H Steer Tires Installed At Steer Tire Replacement

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Section I. Hogan Tire Policy Retread application guidelines.

Only Casings judged acceptable by the Bandag Inspection process are to be used on our fleet.

In the following text, there is mention of the DOT date. This is the last 4 digits for 2000 and newer. Example: 2415 would be 24th week of 2015.

New and Retread Drive Tires: Tread designs: • M726EL or Michelin XDN2 • MegaTrak Retread: Approved for all drive applications.

• Ultra Drive: Approved for Live Haul applications only • Fuel Haulers Do NOT get Retreads, NEW Drives only Casing level / life : • MegaTrak on C1 or C2 if necessary • 7 Years (84 months) or newer per DOT Date Repairs allowed: • See Casing Grading Preferred New Steer Tires • • •

Michelin X LINE ENERGY Z Load Range H for Sleeper Applications Michelin X LINE ENERGY Z Regional / Long Haul Michelin XZE2 Local / Regional

Preferred New Drive Tire: • XDN2 • Bridgestone M726EL (if XDN2 is not available)

Policy, Section I, Page 2 Return to Main Page

Section I. Hogan Tire Policy Sold Unit Tires Tractor and Trailer: Tread designs: • Preferred tread is BDL for Drive and BTL for Trailer Positions Casing level / life: • Accepted Bandag Process casings, no age limit if acceptable for capping C3 or 4th capped casings.

Repairs • Not to exceed $45.00 or the value of the casing.

All Location Trailer Tires: Tread design: • Retread : FCR Trailer.

• New (if needed) Michelin XTA1 Casing level / life: • 8 years (96 months) or newer per DOT date.

C2 or C3 casing (C3 limited to 8yrs (96 months) or newer) C1 if no other options with Hogan approval Repairs allowed: • See Casing Grading Spotter Tires: Tread Design: • BRM All Position.

Casing level / life: • C3 or 4th cap 10 years or newer per DOT date Repairs allowed: • See Casing Grading

Policy, Section I, Page 3 Return to Main Page

Section I. Hogan Tire Policy Associating casings to retreads for inventory purposes

•

All casings with new retreads applied, must have the proper casing part number associated with it.

Whenever charging out, crediting, transferring tires or counting retreaded tires it is important to remember to associate the proper casing as follows:

•

MegaTrak ( Bandag premium drive retread )

= C1 or C2 Casing

•

Ultra Drive (Live Haul drive retread)

= C1 or C2 Casing

•

FCR Trailer (premium trailer retread)

= C1,C2,C3 Casing

•

BDL (Trade Terms retread Drive and Trailer)

= C3 or 4th cap Casing

•

BRM (Spotter cap ALL POSITION)

= C3 or 4th cap Casing

•

Any Yokohama tire/casing is to be treated as a Michelin / Bridgestone grade casing

•

Any Hankook, DoubleCoin, Kelly Springfield or equal quality brand can be ran out on a trailer position if tread applies. Otherwise tire should downgraded to a C2 and capped as a trailer. After one cap it is to be capped as a trade tread only.

•

General Repair Guidelines: •

• • • •

Tires submitted for repair with less than 6/32 tread depth remaining are to be retreaded along with the repair unless otherwise instructed by Hogan management.

Tires submitted for repair with more than 6/32 tread depth remaining are to be repaired only unless otherwise directed by Hogan management.

A light coat of tire paint is acceptable.

No liner sealants are allowed.

Hogan Staff will inspect all RAR tires with Tire Vendor(s) at least once every 30 days.

Policy, Section I, Page 4 Return to Main Page

Section II. Getting Tires “In and Out” of Your Inventory.

Purchase Orders.

An Enrich Purchase Order MUST be created prior to ordering ANY tires to be put into your inventory. This includes the purchase of any New Tires, Retreads, Casings, or Cap & Casings. Upon receipt of these tires, they are to be “Received” in Enrich ASAP. (See Reference I, Page 1 for more details) •

• •

A Vendor Supplied “Retreader Delivery Form” must be obtained for all tires returned from the vendor that have been retreaded, repaired, RAR’d or Scrapped. (See Reference III, Page 1, for more details) The tire Check in – out form will at times contain tires received from road Purchases. (This form shown in Reference III, Page 2 & 3) The Enrich Purchase Order is to be completed as soon as the Vendor Invoice arrives and forwarded to St. Louis for payment.

(Continued on next page)

Section II, Page 1 Return to Main Page

Section II. Transfers from other Locations.

Tires can be transferred to your inventory from another Location.

Any tire transfers must be handled through the Corporate Parts Manager.

Manager at receiving shop Must be notified and must approve transfer before transfer is made.

Special Tire Activity Situations • •

Occasionally, the need to “swap” tires from one unit to another may be presented.

Create a work order, comments should state that tires were swapped with unit number XXXX.

Damaged Tires •

•

Hogan Truck Leasing charges for the damaged tire that is removed from a Hogan Owned vehicle, not the tire that is installed. This includes any Lease Maintenance Units.

Hogan Truck Leasing charges for the tire installed for non-Hogan Owned and/or non-Contractual units. This includes any PM plus units.

(See Reference II, Page 2)

Section II, Page 2 Return to Main Page

Section III. Handling tires “While In” your Inventory

Everything associated with this section is tied in to the Tire Check In-Out Form.

•

Information on all tires going out for recapping or repairing is to be documented on this form. This is a way to track that the Vendor is returning all tires that have been sent to them. (See Reference III, Page 2)

•

In order to give the correct credit for casings coming off of a vehicle, as well as to decide which recap is to be installed by retreader, all casings must be graded. (See Reference III, Pages 3 & 4)

•

Tires and casings preferred storage is to be indoors. If outdoors, under cover is a must as to not be exposed to the elements (rain, snow, direct sun). Tire vendors and cappers must also follow these guidelines.

Section III, Page 1 Return to Main Page

SECTION IV. Monthly Physical Inventory

A tire inventory count is required at the end of every month.

•

Use the Inventory Count Sheet From Enrich to record the on hand quantity of tires that are physically at your location. The Part Number Reference List (back of book) may be used also to assist in monthly inventory.

•

It is preferred that you go to the Tire Vendor’s location to count casings . Note: The Tire Check In and Out Forms must be properly up to date and a visual inspection must be done at the Vendor’s location. Remember, even if our casing is capped at the vendor we do not have the cap in inventory until the recapped tire is delivered with a P.O. Only the casing will need to be counted.

•

When counting retreads, a casing value must be added. (See Reference IV, Page 2)

Section IV, Page 1 Return to Main Page

SECTION V. Over The Road Purchases

Tires Replaced on the Road • • • •

• • • •

•

Whenever a tire is replaced on the road via Hogan Road Rescue, a Service Call report is completed.

Road Rescue then sends a copy of this report to the Domicile Location of the unit involved.

The driver is always instructed to return the tire removed to a Hogan location.

Some Customers may request a Tire Return Receipt upon turning the tire in.

The Tire Return Receipt is completed by recording the Unit # the tire was removed from, the Date returned and the D.O.T. # . The Receipt is signed by the Driver, and the Hogan employee receiving the tire. The top copy of the receipt is issued to the Driver .

The tire must be labeled with the unit number it came off of.

The tire must be inspected to determine cause of removal.

Damaged tires are to be billed back to the customer per Hogan damaged tire billing procedure.

If the tire returned is from a unit that is not domiciled at the Location that received the tire, the “Owning” location manager must be notified of the return and the reason replaced as determined upon inspection.

If the tire is damaged, the Owning Location is to bill tire at it’s value at the time of replacement. If the value cannot be determined, as in the case of 2 sidewalls returned, the location Service Manager will need to review PM sheets and/or work orders, to determine the last known tread depth and bill from that measurement.

The service call report will indicate whether the tire was determined to be damaged at the time of replacement on the road. The labor for tire replacements on the road will be billed to the Customer if the original work order states that the replacement was due to damage. If this is the case, you do not need to do anything about the labor charges. If upon review of the original work order, the labor was not billed to the Customer, you may add the labor charges to the cost of the tire. Do this via the Change Invoice option when Approving the work order. Make sure to note in comments that the cost of the tire includes a labor charge of $ xx.xx.

If after inspection of the tire it is determined that the replacement was NOT due to damage and we have already billed the labor to the Customer, complete and submit a credit/rebill form to reimburse the Customer for these labor charges.

Section V, Page 1 Return to Main Page

Reference I Getting tires “In” your Inventory Detail

Purchase Orders.

To Create a Purchase Order in ‘Enrich; New Michelin Tires go on a Separate p.o. from other tires • • • •

•

• •

Select the “Purchase Order” Button.

Select the “+” key to create a new Purchase Order.

Click “Create Purchase Order” (do not change header type) Select “Inventory” as the Order Type. The Order Date and Due Date will default to today’s date. Make sure that the Warehouse Code showing is yours; change if needed. Prompt and highlight the correct “Vendor” (the system will default the “Pay to Vendor” as the same Vendor that you have selected), change the “Pay to Vendor” if necessary, then press Enter.

Enter the Tire Part Number, use the tab key to move to the quantity field (or position your mouse on the field and left click) enter the quantity, tab or move via the mouse to the “Per Unit” field and enter the estimated cost. Press Enter. Line one will disappear from the screen and go to line two. Continue to enter part numbers and quantities for all the tires you want to buy from this vendor. To double check all that you have entered, press the “ ” Change button. If all is OK, (change if necessary and press enter), press the Red “X” to exit.

The bottom of the screen will show the PO number that you just created.

Highlight the line that has that PO number on it and press the “ ” Line Item Process Button, then the “Process” button.

To Receive your Tires; • • • • • •

Find and highlight the P.O..

Press the “Line Items Receipts” Button.

Enter the quantity received for each item listed.

Enter Delivery Receipt Number Under “Packing Slip” at top left of screen.

Press the “Post” (mailbox) button, and the “Post Receipt” button.

You may or may not print barcode labels.

Your tires are now in your Inventory.

Reference I, Page 1 Return to Main Page

Reference II. Getting Tires “In and Out” of Your Inventory.

Miscellaneous Tire Work and Repairs Procedure to enter an invoice that only has Misc. Tire Work (Lot Checks, Tire Cage Work, Repairs on Tires while at a Vendor or Scrap Charges).

• • • • • • • • • • • • • • • • • •

Create a new P.O. from P.O. screen by clicking + sign as usual Click “Create Purchase Order” Click dot next to “Miscellaneous” to create a Misc. P.O. Select proper vendor Hit enter Enter line description (i.e. Lot check, tire repairs ) Tab and enter “EA” for unit of measure Tab and enter Qty. of one Tab and enter total invoice amount Press enter. This will fill in all other fields except G/L and place cursor in G/L field.

Click “Prompt” icon or press the “F4” key for prompt.

Press tab key once to “Account Description” field.

Enter your location code (i.e. 01,16, 25) Press enter This will bring up G/L accounts for your shop. Page down and select “Tires-Misc” by double clicking line (making sure it begins with your location code).

Press Enter, line two will be displayed.

Red X out of P.O. Process p.o. as a regular p.o. from this point forward.

Tire repairs are not to be included in the price of a tire. Tire repairs should always be entered as a misc p.o if on a separate invoice or as a Special Charge if combined with a tire invoice.

Reference II, Page 1 Return to Main Page

Reference II. BILLING DAMAGED TIRES Hogan Owned Units: •

• •

•

Any tire that is to be billed to the Customer must first be removed from the Unit, which will put it into your inventory. Value the tire for what it would be if it had not been damaged. This will be done on a “Skip” line as normal.

Now create a second line and make this line “Billable”.

Charge any labor associated with the damaged tire on this line. Go to the parts screen and charge the tire out that you credited in step one above. Make sure that you are entering this on the Billable Line. This will take the tire back out of your inventory, and charge it back to the Customer.

IF a sublet is involved, such as a Vendor is doing the labor portion of the job, a line must be created for the sublet, as you are not able to charge out parts and have a sublet on the same line.

Non-Hogan Owned Units: • •

• •

•

A tire sold to a Customer is charged directly to the unit via the work order.

Always check with the Customer for instructions on what to do with their tire (s) removed from the vehicle.

In the case that a tire (s) of value is removed from a Customer owned unit, the tire may be returned to the customer at their request. In this case the off tires would not be placed on a parts line on the work order, however this should be noted in the comments section.

If the tire removed is of value and the customer would like a credit consideration the following would apply: If the tire is of value but of no use to Hogan: The tire can be issued to the Tire vendor for credit consideration. Credit received from the vendor should be issued to the customer via a sublet work order creation. This tire would not be noted on the work order as a tire removed. You must track this separately.

If the tire is within Hogan tire program specifications: Tell the Customer that we will credit them for the tires that came off, but if upon inspection of the tire using the tire manufactures sophisticated Equipment, the tire is deemed unserviceable, it will be charged back to them.

Discuss with Area Manager the customers we will buy casings from.

Reference II, Page 2 Return to Main Page

Reference III. Handling tires “While In” your Inventory TIRE CHECK IN-OUT FORM This form is used to record all tires removed from vehicles and should be completed as follows: • Vendor: Record name of vendor tires are sent to for service.

• Date: Record the date this form is used.

• Location: Record the Hogan shop location number.

Beginning from left to right: • Unit #: Record the unit number the tire was removed from.

• DOT: Record the last 4 digits (as previously explained) of the tire DOT number.

• Tread Type: Record the EXISTING tread type on the face of the tire removed.

Example: XZA3, MEGATRAK, TFCR, G399, etc…..

• 32S: Record the Tread depth of the tire removed.

• Removed for: Record the reason tire was removed.

• DEST.: Record the destination of the tire.

Example: MEGATRAK, Repair, TFCR, Scrap, etc….

• Claim#: Record the claim number supplied by the vendor receiving tires for service.

Example: 4210 – 1 • Part#: Record the Enrich part number for the tire removed (as shown on the “Part Number Reference List”).

As tires are received back from the vendor indicate as such on this form.

Tires RAR’d must be charged back to the unit originally removed from as indicated to the far left of this form.

Damaged tires must be billed to the responsible Customer after proper notification.

Reference III, Page 1 Return to Main Page

Tire Check In and Out From Vendor Date___/___/___ Unit #

DOT#

Vendor Tread Type

32nds

Location__________________ Reason Removed

Dest.

Claim #

Part #

Reference III, Page 2 Return to Main Page

Reference III. Handling tires “While In” your Inventory GRADING CASINGS •

Casings are graded to assist in determining what type of retread is allowed and which casing part number should be applied.

•

Casings are assigned life numbers that accumulate as the casing is retreaded.

• • • • • •

A Virgin casing (not previously retreaded) has a casing life number of 1.

A worn out one time retreaded casing has a life number of 2.

A worn out second time retreaded casing has a life number of 3 A virgin casing is considered a C1 part number A One time retreaded casing is considered a C2 part number.

A twice-retreaded or third retreaded casing is considered a C3 part number C1 Casing Specs: Never been capped, 5yrs. (60 months) old or newer, 4 nail holes maximum and repair edges cannot touch, no repairs larger than B-20, Spot and bead repairs only if no plies exposed.

C2 Drive Casing Specs: Virgin or once capped casing, 7 yrs. (84 month) old or newer, 4 nail holes maximum and repair edges cannot touch, no repairs larger than B-20, Spot and bead repairs only if no plies exposed.

C2 Trailer Casing Specs: Virgin or once capped casing, 8 yrs. (96 month) old or newer, 4 nail holes maximum and repair edges cannot touch. 4 repair per tire allowed no larger than a B-20, and One additional Major repair allowed per tire no larger than a B-40. Spot and bead repairs only if no plies exposed.

C3 Trailer Casing Specs: 8 yrs. (96 month) age limit as long as it is acceptable to cap and repairs not to exceed $45.00. 4 nail holes maximum and repair edges cannot touch. 4 repair per tire allowed no larger than a B-20, and One additional Major repair allowed per tire no larger than a B-40. Spot and bead repairs only if no plies exposed.

C3 Spotter Casing: 3rd or 4th capped casing 10 yrs. (120 month) age limit as long as it is acceptable to cap and repairs not to exceed $45.00.

C3 Trade Casing Specs: 3rd or 4th capped casing. No age limit as long as it is acceptable to cap and repairs not to exceed $45.00. Utilization on trade units, non-Hogan applications.

Reference III, Page 3

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Reference III. HANDLING TIRES

Tire Check In and Out From Vendor Date___/___/___ Unit #

Vendor

Location__________________

DOT#

Tread Type

32nds

Reason Removed

Dest.

Claim #

L-2569

1201

XZA3

4

Normal Wear

Megatrak

123-1

L-9401

429

Megatrak

16

Flat RRO

Repair

124-1

122050

488

XDN2

4

Normal Wear

TFCR

125-1

L-1300

1201

G399

18

Run Flat

Scrap

126-1

Example

Reference III, Page 4 Return to Main Page

Reference IV. Monthly Physical Inventory Tire Inventory Count In Enrich System • • • • • • • • • • • •

• • • • • • • • • • •

•

Total each Enrich Part Number for entry into the Enrich Inventory count.

Verify that all Tire Parts on Open Work Orders are Fully Issued and Returns Posted.

Verify that all Purchase Orders have the Quantities Fully Received.

In the Enrich System click on EMMS. Click on Material (located top of screen).

Click on Item Administration.

Click on Count.

Click on the ADD (+) Button.

In the Description area type in your Location Name or Number and the word TIRES. Make sure DATE is the last day of the month the tires are counted for. Count Type = C. Warehouse = Location Number Item Category = TIRES (Note) All tires should have the Item Category field populated with “Tires” which makes it no longer necessary to enter “from” and “to” row shelf bin numbers.

Verify that all information is correct.

Press Enter Key. Screen will display “ Building Records “.

When completed, Screen will Display “Count Definition (number) Created.

Click on the Blue Arrow located at the top of the screen to Enter Inventory Count.

The inventory count screen will consist of Tire Part Numbers located to the Left.

The Quantity of the “Frozen Book “ Value will be displayed next to the Part Number.

Enter actual counts in the column Actual Count.

Verify that all count numbers are correct after entering, press enter key.

Click on the RED X to leave the Count Entry Screen.

Print a variance report by positioning your mouse on the “Variance” button and left clicking your mouse. The report will print to your printer. Use this report as a tool to find any missing tires, or mistakes made during counting or entering. Go back to the entry screen and make any changes necessary.

To CLOSE the Count Click on the Close Count Button located at the top of the screen. (Image of person walking through door). Enter “Tires” for the Adj code.

Reference IV, Page 1 Return to Main Page

Reference IV. Monthly Physical Inventory Accounting for Casings A casing is associated (included) with every retreaded tire in inventory.

When counting retreaded tires in inventory, the same number of casings Must be added to the casing total count.

All casings still at the Retread Plant must also be included in the total count.

Example: If there is 10-MegaTrak in inventory, there are 10-C1 or C2 casings also.

If in addition, the vendor still has 20-C1 casings not yet returned to the location, these must be added to the Total inventory count: 10-C1 casings on MegaTrak retreads + 20 C1’s at vendor = 30 C1 casings total.

The same applies to C2 and C3 casings in respect to the correct tread design which they are associated with.

Examples: MEGATRAK = C1 or C2 casing ULTRA DRIVE = C1 or C2 casing TFCR = C1,C2 or C3 casing BRM = C3 casing BTL = C3 casing BDL = C3 casing Casings are not included when counting or using used retreaded tires.

Reference IV, Page 2 Return to Main Page

Load Range “G” Label Example. Notice “LRG” on the Label

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Load Range “H” Label Example. Notice “LRH” on the Label

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Hogan Tire Management Part Number Reference List Part Num ber New Steer

Tires Listed are 22.5 & 24.5 Sizes

03885

X Line Multi Energy Z Long Haul "G"

66205

X Line Multi Energy Z Long Haul "H"

03168

X Multi Energy Z Load Range H Regional Steer

XZE2

Michelin Steer Tire

R268

Bridgestone Steer Tire

R283A

Bridgestone Steer Tire

G399A

Goodyear Steer Tire

S/Other

Any Steer Tire Not Commonly used

New Drive XDN2

Michelin Drive Tire

XONE

Michelin Drive Tire 445/50/22.5 Wide Base

M726EL

Bridgestone Drive Tire

D/Other

Any Drive Tire Not Commonly Used

New Trailer XTA1

Michelin Trlr Tire

R197

Bridgestone Trlr Tire

XONEXTE

Michelin Trailer Tire 445/50/55.2 Wide Base

T/Other

Any Trlr Tire Not Commonly Used

Drive Recaps MegaTrak

Drive Cap C1 or C2

Ultra Drive

Live Haul Drive Cap C1 or C2

BDL

Trade Cap C3

BRM

Spotter All Position Cap C2 or C3

BDR-UWB

Wide Base Drive Cap

DC/Other

Any Drive Cap Not Commonly Used

Trailer Recaps TFCR

Bandag Premium Trlr Cap C1 ,C2 or C3

BTR-UWB

Wide Base Trailer Cap

BTL

Trade Cap C3 or 4th cap casing

TC/Other

Any Trlr Cap Not Commonly Used

Used Tires S/U

Steer Tire Used

D/U

Drive Tire Used

T/U

Trailer Tire Used

DR/U

Drive Recap Used

TR/U

Trailer Recap Used

Casings C1 or C1WB (w ide base)

Virgin Casing

C2

Once Capped Casing

C3

Tw ice Capped Casing

Light and Med Duty

Sizes other than 22.5 and 24.5

TS/Other

Steer Tires

TD/Other

Drive Tires

TS/OtherU

Steer Tires Used

TD/OtherU

Drive Tires Used

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Steer Tire Pressure and Load Range Chart

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DRIVE CAPS

ULTRA DRIVE 26/32

MEGA TREK 26/32

BDL TRADE CAP 20/32

TRAILER CAPS

BTL TRADE CAP 11/32

FCR TRAILER 11/32

SPOTTER CAP

BRM Spotter Cap 26/32

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