PBS Lumber Manufacturing, L.L.C. of Winnfield, reorganized just weeks ago under an acquisition by Freestone Sawmill Partners, LP of Houston, Texas, is already deep into its announced expansion aimed at doubling production of Southern pine lumber.

Through rearranging work schedules, close attention to maintenance, and other management moves, productivity is up from prior levels. New equipment for major expansions is already being delivered, and prepared for installation on the grounds of next-door neighbor 6-C Fabrication, a new Thomas Road operation in Winnfield. A total of $5 million in new investment is planned over two years, to augment the recent $4 million upgrade at PBS just two years ago, the company said in announcing the new partnership in late August.

"We've been impressed by the attitude of the people working at this mill," said Rick Wilson, operations manager. Also on the team sent from headquarters to work at PBS are Art Dawson, administration, Anna Jarowicz, green end manager, Darcy Leffrud, maintenance supervisor, and Erik Nemeck, dry side manager. Each plans to live in the Winn Parish area and will be at the plant daily.

"We've challenged the employees here," said Nemeck. "Every time they break a record, we feed them lunch." On Saturday, October 25, they'll be providing their employees lunch by purchasing them from the Dodson Future Business Leaders' (FBLA) fund raising cook-out.

"It keeps us from having to cook," said Nemeck.

Not only are the employees at PBS being served free lunches, they also received $100 bonus for exceptional work after the first month the new policies were put in place.

"Everything we've accomplished has largely been due to the attitude of the employees," said Wilson. "We told them at the beginning, if we do well, we will share with you," said Wilson, and production continues to rise.

Sawmill production is up 35% from before August. The yield out of each log has risen 7%. Since the resulting lumber is of better quality, sales are up $10 per board feet.

The group had a goal in mind for PBS from the beginning.

"We want to be considered the best place in Winn Parish to work," said Wilson. The company appears to be well on the way to achieving that goal. Their methods are simple and began with intense planning.

"Between us, we have 50 years of experience in this type operation," explained Wilson. Each understood the history of PBS which began operations in 1983 with Sammy Smith, Kiah Bevill and Jimmie Price as partners. The three founders remain as partners in the new company.

A major upgrade had been implemented just before the partnership agreement with Freestone. The group's new plan would take advantage of the equipment the mill already owned, by teaching new intense maintenance methods and making the machines operate at peak levels while producing the highest quality materials possible.

Leffrud began by instituting maintenance schedules, doing preventative maintenance exercises regularly. Additional mechanics were hired to upgrade the physical shape of the machinery.

"We've made no change in what we produce, we're just making it better," said Wilson

Jarowicz began by making sure all departments had communication equipment. Her expertise included making certain the optimizer, a computer guided implement that makes sure the most productive cuts are made out of each log, was working correctly. She put the system in good working order.

"It's just this, our knowledge of the technology that brought us here," said Wilson, adding " and the cash." Freestone has committed to spending several million dollars to make PBS the best sawmill possible.

While Jarowicz improved the optimizer, Nemeck put new policies in place to make the drying kilns even more efficient. First, he modified the kiln schedule.

"Not too many people understand a kiln," Nemeck said. "To them it's just a big, black box."

He explained that the perfect drying process was like an expert cook's best recipe. There's a certain way it has to be done to get it just right, he said.

"There's a lot of potential here in this mill," Nemeck said, of the employees and the equipment.

According to Wilson, PBS is about to break ground on a new site for a planer mill. In the next 3-6 months, they will spend around $2 million in capital outlay.

"We'll probably spend $3 million by the end of the year," he said. Much of that money changes hands in Winn Parish, benefiting everyone. In the future, the hope is to be able put on a third shift, opening up job opportunities for several people at the plant.

"One of the things we're excited about is Six C Fabrications just down the road," Wilson said. "They are an outstanding company."

That company is in the process of refurbishing equipment PBS has purchased to set up in the mill.

"When we get through with this," said owner of Six C, Robin Cummings, "it will be just like new." Enormous pieces of equipment have been laid across the mill yard in order of assembly, and workers are cleaning and examining each piece in minute detail. Then they will refurbish and rebuild it, making any repairs necessary.

Even as the experienced team at PBS works on improving the production at the plant on Thomas Mill Road, they are looking for opportunites to purchase other sawmills.

Even in the tough markets sawmills exist in today, Wilson said: "Sawmills run well can make a nice profit." They are in the process of proving that at PBS.

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