High Quality Pools Expand to Second Manufacturing Site
October, 2006 : Rocky Mount, NC, USA
The demand for high quality fiberglass swimming pools and Blue Hawaiian Fiberglass Pools outstanding reputation has necessitated the opening of a second manufacturing plant to meet their demand.
The high quality of a Blue Hawaiian pool comes from a well-trained workforce and strict control of the manufacturing process. An essential component of process control is the use of consistent Vipel® F010 vinyl ester and Altek® H834 unsaturated polyester from AOC.
The majority of Blue Hawaiian Fiberglass Pools sales are to the Eastern United States and Canada, but the company has shipped as far away as Germany. Blue Hawaiian headquarters and its original plant are in Largo, Florida. The new plant being built in Rocky Mount, North Carolina, will significantly reduce transportation costs for pools shipped to several states and Canada.
New facility, same quality
The new plant will continue a management philosophy that emphasizes professional training. New workers are trained by Largo Plant Operations Manager Nick Williams, who is a Certified Composites Technician - Instructor (CCT-I), the highest professional accreditation earned through the American Composites Manufacturers Association. As a CCT-I professional, Williams qualifies, mentors, schools and tests Blue Hawaiian workers to become Certified Composites Technicians.
"Our high quality also gets a boost from low worker turnover," explained Company President and CEO Roger Erdelac. "We make every worker feel like a part of the organization, and we promote from within. For example, the individual selected to manage the new North Carolina plant started out with us as a fiberglass laminator, became CCT-certified and worked his way up."
Complementing the dedicated workforce is a highly disciplined system for controlling the manufacturing process. Pool production starts with mold preparation and application of a pigmented gel coat. To keep moisture from causing gel coat blisters, workers next spray-up a barrier skin coat of chopped glass fibers in Vipel F010 bisphenol A epoxy vinyl ester.
The final layer is a hand lay-up bulk laminate using Altek H834 resin to impregnate fiberglass chopped strand mat and woven roving. Resin-impregnated combination mat is added to specific locations needing extra strength.
AOC resin consistency
Plant Operations Manager Williams pointed out how the consistency of AOC resins plays a key role in maintaining high levels of end-product quality. "The consistency of the previous supplier’s bulk resin was so bad that we had to keep retraining our workers," he said. "They had to learn how to adapt to the latest shipment.
"Since we switched to the Altek resin, every shipment we get is just like the one we got before," Williams added. "We know what’s going to happen, so we’re able to run our process without making adjustments. Our experience with the Altek bulk resin was so positive that we switched to the Vipel product for our barrier resin."
"Batch-to-batch consistency has always been a hallmark of AOC resin production," said Emilio Oramas, AOC Business Manager - Open Mold Reinforced. "It all starts with proprietary computer controls that eliminate the potential for human error at each step of the manufacturing process.
"The quality management systems of all AOC-owned facilities are certified as meeting the world-class requirements of ISO 9001:2000," he said. "Furthermore, every AOC plant embraces Six Sigma - Lean which uses statistical data and teamwork to improve productivity and elevate product quality."
About Blue Hawaiian Fiberglass Pools
Headquartered in Largo, Florida, Blue Hawaiian Fiberglass Pools is a premiere manufacturer of FRP composite pools. The company’s pools can include such features as built-in spa, swim jets, children’s wading area, sun tanning ledge and a wet patio. Blue Hawaiian Fiberglass Swimming Pools offer 66 award-winning designs, including designs that are unique enough to be awarded a U.S. Patent. For more information on Blue Hawaiian Fiberglass Pools designs and benefits, including a limited 35-year warranty, phone 727.535.5677 or 888.840.7699, or go to www.bluehawaiianfiberglasspools.com.
About AOC
AOC is a leading global supplier of resins, gel coats, colorants, additives and synergistic systems for composites and cast polymers. AOC products are manufactured in facilities strategically located in North America, Europe and Asia. AOC-owned manufacturing plants are ISO 9001:2000-certified, use proprietary technology to ensure resin batch-to-batch consistency, and follow Six Sigma-Lean principles for improved efficiency. For more information on AOC resins and technology for closed molding, e-mail Emilio Oramas by e-mailing eoramas@aoc-resins.com, or phoning 901.854.7255. or visit www.aoc-resins.com on the Internet.