Industrial Machinery Digest - July, 2019

IndustrialMachineryDigest.com

July 2019

GOING MOBILE

ruising Kitchens Relies on ESAB C Mobile Welders to Feed the Mobile Vending Boom »» Machining Large or Long Parts with a Single Set-up »» Black Belt Training Benefits Companies and Their Customers »» An American Manufacturing Legacy, Still Going Strong

MANUFACTURING SHOWCASE: KENNEDY MANUFACTURING COMPANY Built with Purpose, Built for Life

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18" x 40" Electronic SPECIFICATIONS: Variable-Speed Lathe w/DRO • Swing over bed: 18.11" • Spindle bore: 3.1" INCREDIBLE SPECIAL! • Distance between centers: 40" • Spindle speeds: (EVS), 18 – 1800 RPM • Spindle motor: 10 HP, TEFC induction SB1059F • Voltage/phase: 220V, 3-phase • Machine footprint: 713⁄4" x 1021⁄2" • Approximate shipping weight: 5080 lbs. $ , FEATURES: FREIGHT: $2500 • FAG German bearings, Allen Bradley Controls, Yaskawa Inverter

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Table of Contents

COLUMNS

10

BUSINESS 4.0 Reshoring Success Reshoring Initiative 2018 Data Report: A Record 1389 Companies Announce the Return of 145,000 Jobs

36 FEATURES

24

14

14

MANUFACTURING SHOWCASE Built with Purpose, Built for Life Kennedy Manufacturing Company has been a leader in industrial grade tool storage solutions for over 100 years.

By: Loyd McIntosh

18

By: Nick Boliek

26

TALKING SHOP Mark Soucie President & Owner Ferroloy, Inc.

SAFETY & MAINTENANCE Continuous “Hands Off” Insulation Resistance Testing of Critical Motors

WORKFORCE DEVELOPMENT Black Belt Training Benefits Companies and Their Customers

DEPARTMENTS

By: Deborah A. Froelich

32

NEW TECH

Machining Large or Long Parts with a Single Set-up

36 PROCESS

An American Manufacturing Legacy, Still Going Strong

40

INDUSTRY INSIGHTS Going Mobile Cruising Kitchens Relies on ESAB Mobile Welders to Feed the Mobile Vending Boom

By: Jay Coubrough

6 8 46

FROM THE EDITOR INDUSTRY NEWS ON EXHIBIT WESTEC 2019

50 PRODUCT SHOWCASE 53 SURPLUS BUYING AND SELLING 57 CLASSIFIEDS 58 ADVERTISER INDEX

ON THE COVER

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To support employee craftsmanship in the new shop, Cruising Kitchens expanded its fleet of welding equipment, converting from heavier singleprocess units to compact, portable inverters from ESAB.

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From the Editor As we begin the second half of 2019, it appears the state of American manufacturing is good even in the midst of near chaos. Warnings of a trade war with China, a momentary reprieve in the threatened tariffs against Mexico, and a presidential election that, depending on who wins the election, could result in increased taxes and regulations after a short period of policy in the opposite direction only mean one thing - uncertainty and the need for consistent economic policy, a theme we explore in this issue of Industrial Machinery Digest.

For example, we feature a Q&A with Mark Soucie, President & Owner of Ferroloy, Inc., an iron foundry in Wichita Kansas. Soucie purchased the company as it balanced on the razor's edge of bankruptcy in 2017 and in just two years has the company on a trajectory towards profitability and growth. He credits a large portion on Ferroloy's success to the tax cuts and reduction in punitive regulations that have come out of Washington, D.C. in the last two years, but worries about the pendulum swinging too far in the opposite direction in the near future.

"If our political leaders want to continue to have a strong manufacturing base they're going to have to make it economical to do it," Soucie said during a phone interview from his office recently. "They can make it un-economical through new taxes or punitive regulations." Read the entire interview with Soucie in this month's Talking Shop beginning on page 14.

Included in this issue is the 2018 Reshoring Data Report which shows a record number of companies returning jobs to American shores. In all, 1,389 companies brought 145,000 jobs back to the United States. More information about the Reshoring Initiative can be found beginning on page ten.

Also, in this issue's Workforce Development section beginning on page 26, you'll read about the success Allied Machine is having utilizing Lean Six Sigma education in the company's employee training program. The initiative has not only resulted in more efficient, less-wasteful production environment, but a better work culture as well.

The staff at Industrial Machinery Digest wishes everyone a prosperous second-half of 2019 and we look forward to seeing you at the trade shows later this year.

Sincerely,

SERVING AMERICAN MANUFACTURERS FOR OVER

33 YEARS

William C. Strickland III, Publisher william.strickland@indmacdig.com 800-366-0676 ext. 103 | Fax: 866-826-5918

Nick Boliek, Editor nick@indmacdig.com 800-366-0676 ext. 104 | Fax: 866-826-5918

Loyd McIntosh, Associate Editor assoc.editor@indmacdig.com

Shane Bell, Creative Director sbell@indmacdig.com

SALES

Lisa Hanschu, Sr. Account Executive lisa@indmacdig.com 785-965-9159 | Fax: 785-965-7199

David Marlow, Account Executive David@indmacdig.com 800-366-0676 ext 200

William C. Strickland III, National Sales 205-903-9178 | fax 866-826-5918

Adrienne Gallender, Media Adviser agallender@indmacdig.com 888-407-7737

Susan Strickland, Accounting susan@indmacdig.com 205-542-1098 | Fax: 866-826-5918

Sarah Mayo, Interactive Specialist sarah.mayo@indmacdig.com 800-366-0676 | Fax: 866-826-5918

CIRCULATION & SUBSCRIPTIONS IMD, 3590-B Hwy 31 South, Suite 233, Pelham, AL 35124 circulation@indmacdig.com | Fax: 866-826-5918

REPRINTS

Loyd McIntosh — Associate Editor, Industrial Machinery Digest

To purchase article reprints please call 800-366-0676 ext. 103 or email wstrickland@indmacdig.com

source

LOOKING AHEAD Next Month’s Issue Focus: Cutting to the Point – Bandsaw Performance In August, Industrial Machinery Digest focuses on new bandsaw technology and how automation is making the process more reliable and efficient. Also, we feature Sarcos Robotics, a Utah-based company manufacturing technology that is making lifting heavy payloads safer and, frankly, cooler!

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Industry News 2019 Open House & Training Event is Great Success for Cosen Saws Cosen Saws is excited to have completed their second annual Open House and Training event. The Open House was held at their North American Headquarters in Charlotte, NC. This year, the attendance more than doubled with nearly 100 guests who visited throughout the week. Guests included Cosen distribution and dealers from around the nation, nearly 20 service techs from their national service network, Cosen end-users, Cosen's internal sales network, members of Cosen's sister company Mechalogix, and special guests from Europe and Taiwan.

Additionally, this open house served as a premier to Cosen’s new Circular Series line of saws, with the new CC-100 model being on display and demonstrated.

Several New Feature Areas Announced for Motion + Power Technology Expo Excitement is building for the Motion + Power Technology Expo (MPT Expo), formerly Gear Expo, taking place October 15-17 at the Cobo Center in Detroit, MI. The trade show floor will feature the Fluid Power Pavilion which will have dozens of leading vendors and an Emerging Technology Pavilion with solutions focused on IIoT, Blockchain, 3D Printing, Robotics, Supply Chain, and more. More than 17 of the participating companies are brand new to the event and 10 percent of those are international. The Motion + Power Technology Expo (MPT Expo), formerly Gear

Expo, will bring together over 4,000 professionals looking for technical solutions from more than 300 exhibitors across the supply chain including gear companies, machine tools suppliers and electric drive solutions showcasing new products and services from industry leaders.

European Space Agency awards contract to Siemens and Sonaca The European Space Agency (ESA) has selected Siemens Digital Industries Software to develop aerospace design applications for metal additive manufacturing. The applications will leverage Siemens’ end-to-end software solution for industrial additive manufacturing that combines generative engineering, topology optimization, predictive analytics, process simulation, build preparation and production execution. The two-year long project, named Design4AM, is built on a strong collaboration between Siemens and Sonaca, a specialist in aerospace structures, with financial support from ESA and the Belgian Federal Science Policy Office (Belspo). Additive manufacturing (AM) is an important tool for the space industry because it can meet structural and multidisciplinary requirements for space applications at a much lower weight than conventional space structures made through traditional manufacturing methods.

Okuma Corporation Completes Dream Site 3 Smart Factory Okuma America Corporation, a world leading builder of CNC machine tools, announces the completion of the company’s newest production facility Dream Site 3 (DS3) located in Kani, Japan. This smart factory utilizes cutting-edge technology, robots and IIoT (Industrial Internet of Things) to manufacture vertical and horizontal machining centers and double-column machining centers to support the company’s product line. Okuma is building its smart factories based on the goal of building futuristic factories that interweave automation with skilled techniques.

quality matters. every time.

Mazak Congratulates Team Penske on 18th Indy 500 Victory Mazak Corporation, a longtime technical sponsor for Team Penske, extends its congratulations to Simon Pagenaud and the entire team for their victory at the 103rd running of the Indianapolis 500. With his team’s 18th victory at its 50th appearance in the Indianapolis 500, Roger Penske’s organization has further secured its place as the winningest team in the race’s history, an achievement due in part to Mazak machine tool technology. Advanced manufacturing equipment plays a crucial role in ensuring engineered components can be designed and produced in time for race day, and Team Penske’s partnership with Mazak has resulted in an enduring competitive advantage.

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Electrical Box Retort Furnace Installed for De-Bindering Ceramic Composites L&L Special Furnace Co., Inc. has shipped and installed a retort box furnace to a worldwide leader of aerospace components in

IMD – The Industry’s Most Extensive Industrial Publication

the southern US. The furnace is used to de-binder ceramic matrix composite components deployed in the aircraft industry. The main function of the furnace is to remove all organics and other materials used in the product prior to placing it in a high-fire vacuum chamber.

This de-bindering process is extremely important and allows for a finished product that is not only very strong but also lightweight.

year’s custom-built 727-cubic inch engine. This is the 31st year of the Sunnen Engine Charity Sweepstakes. All proceeds go to the Victory Junction, a camp for children living with serious medical conditions founded by NASCAR’s Petty family. Last year’s sweepstakes raised more than $102,000, crushing the previous record of $59,000

CNC Machines accepted into Forbes Business Development Council

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Sonny Leonard to Build 2019 Sunnen Engine Charity Sweepstakes Prize Sonny Leonard and the team from Sonny’s World Class Racing, Lynchburg, VA, is building another high-performance engine for the Sunnen Engine Charity Sweepstakes at PRI, following last year’s record-setting success. According to Leonard, this year’s engine, a 762-cubic-inch, 1,400 horsepower beast, is even bigger than last

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Curt Doherty, CEO of CNC Machines, has been accepted into Forbes Business Development Council, an invitation-only community for senior-level sales and business development executives. Curt Doherty was vetted and selected by a review committee based on the depth and diversity of his experience. Criteria for acceptance include a track record of successfully impacting business growth metrics, as well as personal and professional achievements and honors. As an accepted member of the Council, Curt has access to a variety of exclusive opportunities designed to help him reach peak professional influence. Curt will also be invited to work with a professional editorial team to share his expert insights in original business articles on Forbes.com, and to contribute to published Q&A panels alongside other experts.

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IMD 9

Business 4.0

Reshoring Success

Reshoring Initiative 2018 Data Report: A Record 1389 Companies Announce the Return of 145,000 Jobs

I

n 2018 the number of companies reporting new reshoring and foreign direct investment (FDI) was at the highest level in history, up 38 percent from 2017. The combined reshoring and related FDI announcements totaled over 145,000 jobs, the second highest annual rate in history. Including upward revisions of 36,000 jobs in prior years, the total number of manufacturing jobs brought to the United States from offshore is over 757,000 since the manufacturing employment low of 2010.

Allowing for a two-year lag from announcement to hire, the cumulative announcements since 2010 have driven 31 percent of the total increase in U.S. manufacturing jobs during that period and 3.3 percent of total end-of-2018 manufacturing employment of 12.8 million.

The Reshoring Initiative largely attributes the increases to greater U.S. competitiveness due to corporate tax and regulatory cuts. Similar to the previous few years, FDI continued to exceed reshoring in terms of total jobs added, but reshoring has closed most of the gap since 2015.

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The Reshoring Initiative’s 2018 Reshoring Report contains data on U.S. reshoring and FDI by companies that have shifted production or sourcing from offshore to the United States. The report includes cumulative data from 2010 through 2018, as well as projections for 2019. The numbers demonstrate that reshoring and FDI are major contributing factors to the country’s rebounding manufacturing sector.

“We publish this data annually to show companies that their peers are successfully reshoring and that they should reevaluate their sourcing and siting decisions,” said Harry Moser, founder and president of the Reshoring Initiative.

“With 5 million manufacturing jobs still offshore, as measured by our $800 billion/year goods trade deficit, there is potential for much more growth. We call on the administration and Congress to enact policy changes to make the United States competitive again. Our Competitiveness Toolkit is available to help quantify the impact of policy alternatives, including a stronger skilled workforce, continued corporate tax and regulatory reductions as well as a lower U.S. dollar.”

About the Reshoring Initiative Data for this report comes from the Reshoring Initiative Library of more than 6,000 published articles, privately submitted reshoring case studies and privately documented cases. The report provides data and analysis in ten different categories, ranging from the number of manufacturing jobs gained, to reasons cited for reshoring, to a breakdown of data by industry, country, region and state. It also includes data on the nearshoring trend (Canada and Mexico).

A 50-year manufacturing industry veteran and retired President

of GF AgieCharmilles, Harry Moser founded the Reshoring Initiative to move lost jobs back to the U.S. For his efforts with the Reshoring Initiative, he was named to Industry Week magazine’s Manufacturing Hall of Fame in 2010.

Additional information on the Reshoring Initiative and its many sponsoring associations and companies is available at www. reshorenow.org

A Deeper Dive into the 2018 Reshoring Data »» Reshoring and FDI have driven 31 percent of the total increase in U.S. manufacturing jobs since 2010 and 3.3 percent of total U.S. manufacturing employment as of 12/31/18. »» Reshoring from China accounts for 59 percent of all reshoring. »» Although China topped Germany for the greatest number of FDI jobs announced since 2010, China announced 12 percent fewer in 2018 than in 2017.

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»» Quality, freight cost and total cost make up the top offshore drivers of the trend. »» Proximity to market, government incentives, supply chain optimization, higher productivity, skilled workforce, and brand image/made in USA serve as the top domestic drivers. »» Reshoring has been increasing at a similar rate as FDI, indicating that U.S. headquartered companies are starting to understand the U.S. production benefit that foreign companies have seen for the last few years.

Talking Shop

FEATURING:

TALKING SHOP WITH: Mark Soucie — President & Owner, Ferroloy, Inc.

Looking for an investment opportunity after retiring from Koch Industries, Mark Soucie purchased Ferroloy, Inc., an iron foundry manufacturing ductile iron castings and gray iron castings based in Wichita, Kansas. Overly-reliant on supplying equipment for the agricultural machinery industry, Soucie has taken to the struggling business from the brink of bankruptcy to profitability and expansion since acquiring the company in 2017. In this edition of Talking Shop, Soucie discusses the challenges the company faced and what steps he is taking to put Ferroloy on a path to success.

By: Loyd McIntosh

What is the history of Ferroloy?

Ferroloy Foundry was started in 1950 and for the first 50 years of its operation was captive to a company called Easton Corporation. We moved to our current location in 1968. In 2001, The Easton Corporation shut down and Ferroloy Foundry, Inc. turned its focus toward becoming a supplier to the agricultural equipment industry.

Why did you decide to purchase the company?

I had been with Koch Industries for the last 19 years and was a CFO, controller, treasurer there for the various businesses. I got to the point where I wanted to own my business. I came across this opportunity and decided to look into it a little further.

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When I decided to leave Koch I originally intended to invest in several small businesses. What I wanted to do is buy a few small businesses that I could earn a nominal salary and earn profit from value I created through an equity investment.

What were some of the challenges Ferroloy faced when you took over ownership and what changes did you implement to address them?

When I came across this company in January 2017 and they were in financial trouble and near bankruptcy. I made an immediate investment in it and bridged them through a difficult time. Then the owner of the business, Paul Kolbeck, passed away in February 2017, so I ended up buying it from the estate in August

of that year. Part of that process was renegotiating the debt with the bank.

Basically, we were over-reliant on ag machinery, but I felt that the company had an opportunity to diversify and grow. I just felt like we had a good opportunity, a good team, and that I could diversify the company. I had a pretty good idea there were opportunities in other industries and so the first step in the process was hiring a salesperson that had a lot of experience in the industry.

I hired our first salesperson in August 2017 (John Rockey, Vice President of Sales) which made an immediate impact and we began to diversify the business right away.

Over the last two years, we've gone from being 94-percent reliant on ag machinery to right at 75 percent and we're currently growing the business.

What sectors is Ferroloy pursuing and how will that affect the company’s history as an ag machinery supplier?

Our agriculture customers are very important to us, so we're not by any means abandoning that market. We're in Wichita Kansas, so there are several ag equipment OEMs within 90 miles of us that we have worked with for years and will continue to work with. Even though the percentage of our reliance on ag equipment has decreased, we have actually increased our ag equipment business as we’ve experienced growth.

As far expansion goes, the biggest areas has been valves and pumps, some oil and gas, and just general industry. We're kind of in the back yard of the oil business, with refineries within 45 miles of Wichita. We do have oil and gas fields here, but we’re also only five-and-a-half hours from Dallas, so we have some good opportunities to expand our presence in the energy sector as well. The other thing that's happened is other foundries in our area have shut down, so the industry sector has tightened up.

We’ve been able to take advantage of the contracting of the market in our area.

How have the changes you’ve made impacted your current workforce and what are your expectations for future workforce growth and development?

Since I purchased in 2017, we have almost doubled our workforce. We have hired two salespeople and one part-time employee in accounting, but the rest of our hires are all on the production side. Our growth has really been the result of increasing our brand recognition and the efforts of our sales team over the last two years.

I believe hiring is going to become more and more of a challenge for us in the future because it's tough work and it requires a strong work ethic. I’m not sure our current generation of Americans is interested in this type of work.

We'll invest in automation as automation makes sense for us. We do have CNC grinding, milling and lathe machines and our mold machines are automatic. I do think robotics will play a role in our business

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niche at some point, but the costs are going to have to come down before we make that investment.

How are federal tax cuts and other economic policies coming out of Washington D.C. positively and/or negatively affecting Ferroloy?

We're kind of old-guard industry, so, in my opinion, if our political leaders want to continue to have a strong manufacturing base they're going to have to make it economical to do it. They can make it un-economical through new taxes or punitive regulations. Many

people, think of us as a dirty industry, but we don't produce VEOC emissions, and we're technically a recycler. We take scrap iron and melt it down and reuse it in new applications, so we are front-andcenter a recycler. We do consume a lot of electricity, but we pay our people well and we have great benefits for our employees.

My intent is to reinvest in the business. We now have a positive cash flow and we’re putting money back into the business. I think there is an opportunity for the business to be very profitable, but, as you know, things can happen in Washington that just yank you around. In our industry, consistency is vital.

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IMD 17

Safety & Maintenance

Continuous “Hands Off” Insulation Resistance Testing of Critical Motors

Constant monitoring of critical motors while de-energized prevents failures on startup, reduces unscheduled downtime, saves on major rewinding repairs and increases personnel safety

F

or decades, plant personnel have performed insulation resistance tests with handheld megohmmeters to prevent motor failures that lead to costly unplanned shutdowns, penalties and re-winding repairs.

However, these tests only provide a “snapshot” of motor health.

In a matter of only a few days, motor windings and cables that are exposed to moisture, chemicals, contaminants or vibration can become compromised and fail at startup.

Portable megohmmeters also require electrical technicians to manually disconnect the equipment cables and connect the test leads on potentially energized or damaged equipment to perform the manual testing.

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These tests expose technicians to potential arc flashes when they access the cabinet. In the United States non-fatal arc flash incidents occur approximately 5 to 10 times per day, with fatalities at the rate of approximately one per day.

With so much at risk, plant managers are recognizing the value of continuous megohm monitoring of insulation resistance that initiates the moment the motor is off until it is re-started again.

Armed with this real-time information, maintenance personnel are able to take corrective actions ahead of time to avoid a failure that would interrupt production. By doing so, they can save utilities hundreds of thousands of dollars in repair fees for expensive rewinding, failure-to-produce penalties and lost production time.

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Furthermore, permanently installed automatic testing devices allow for “hands-off” monitoring without having to access cabinets – keeping technicians out of harm’s way.

Motor Protection at Utilities No matter the industry, processing plants rely heavily on motors, though the number and type vary depending on the size of the plant and type of fuel burned. Some plants can have as many as 20-30 critical motors, with five to ten average.

Critical motors are essentially those that could significantly impair the ability to safely meet business objectives or affect production levels if unexpectedly offline. Examples include 480 volt motors up to 13,800 volts that are used to operate compressors, pumps and fans.

Most utilities maintain these motors through time-based preventative maintenance (PM) programs. Insulation resistance tests are typically scheduled on a semi-annual basis; however, given the reduction in personnel at most plants, it may even be less frequent.

Based on these tests, motors may be scheduled to be sent out to repair shops for reconditioning.

Typically, insulation resistance tests are also conducted at the start of annual overhauls or planned outages, to identify any motors that might also need repairs.

Still, despite PM programs, motors that are offline or are frequently cycled can be quickly compromised.

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“We had our fair share of motor failures, and it became quite costly,” says Richard Hohlman, who retired after 37 years working in power generation plants.

“Sometimes the failures can be really expensive,” says Hohlman.

“At that particular plant, we had a couple of Westinghouse two-speed PAM AC induction motors and rewinding one of them would have been a six-figure expense.”

“From an O&M [Operations and Maintenance] perspective, if we can identify a weak motor and avoid the risk of trying to start it up and having it fail, that is a big savings,” adds Hohlman.

To avoid this scenario, Hohlman says he required all critical motors at a Long Island Sound 1500-megawatt plant that were shut down for 24 hours or more to be manually tested with a megohmmeter before being restarted.

“That became an expense in itself, because the tests are often conducted at different hours of the day, at overtime rates,” says Hohlman. “But, by doing it we avoided a number of motor failures.”

Hohlman says a member of his team discovered a continuous testing and monitoring device, the Meg-Alert, and installed it initially on four circulating pumps and several induced draft fans. Later, the devices were also added to several forced draft fans and other critical motors throughout the plant.

The Meg-Alert unit is permanently installed inside the high voltage compartment of the MCC or switchgear and directly connects to the motor or generator windings. The unit senses when

the motor or generator is offline and then performs a continuous dielectric test on the winding insulation until the equipment is re-started.

The unit functions by applying a non-destructive, current limited, DC test voltage to the phase windings and then safely measures any leakage current through the insulation back to ground. The system uses DC voltage levels of 500, 1000, 2,500 or 5,000 volts that meet the IEEE, ABS, ANSI/NETA and ASTM International standards for proper insulation resistance testing voltage based on the operating voltage of the equipment.

The test does not cause any deterioration of the insulation and includes current limiting technology that protects personnel.

“With continuous monitoring, the O&M team is aware at all times of the motor's fitness for duty,” says Hohlman. “Every single time the motor shuts off, if it is for a few seconds, a day, or for the 10 days of an outage, the motor is being tested. And if it goes below a safe level, it alarms immediately and can lock the motor from even starting.”

This stands in stark contrast to the snapshot taken by a megohmmeter at the start of a shutdown. In a matter of a few hours or days, the motor can pick up considerable moisture due to humidity and contamination.

“An electric motor can absorb enough moisture in as little as a few hours in the southern region of the country to damage a motor on start up,” says Ricky Loupe, Electrical and Instrument Manager at a large plant that makes a powdered form of Polyvinyl Chloride (PVC) as well as the primary component ingredient, vinyl chloride.

“There are many rainy days with high humidity down here in the South, and moisture and electricity don’t mix.”

“When a motor is full of moisture and is started, the windings will go to ground and damage the motor,” adds Loupe. “So now you have a critical motor with damaged windings that will cost a significant amount of money to repair.”

An engineer at the time, he and his team conducted an analysis to determine the root cause of the problem and how to prevent it.

After learning more about the Meg-Alert, he purchased one as a trial.

Loupe says it was installed on a 4160V, 1200hp, WP enclosure motor that was used to drive a compressor on a chiller unit.

Based on production requirements, some of the chillers were turned off and only used when needed. This meant the motors on some of the units could sit idle. Prior to running a chiller again, the motors had to be tested using portable megohmmeters.

“Often this work was after hours, due to operations demands and requirements to start them up as quickly as possible,” explains Loupe. “We would have technicians come in on weekends – frequently at overtime rates – just to come and test the motors so they could start them.”

Loupe says with the Meg-Alert units, that information is now available in real-time. He was further convinced after the device, which is connected to the starter, would not allow the motor to turn on due to low megohm resistance readings after a rainy day.

“The Meg-Alert would not allow the motor to start because there was too much moisture in the motor,” explains Loupe. “That, right

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IMD 21

there, paid for the continuous monitoring unit ten times over.”

Today, the plant has Meg-Alerts on all ten chiller motors as well as on four 900hp cooling tower pumps in another area of the plant.

“Hands-Off” Monitoring The continuous monitoring system also allows for a “hands-off” approach that does not require service technicians to access control cabinets to perform a manual insulation resistance test.

Instead and an analog meter outside on the control cabinet door shows the insulation resistance megohms readings in real time. The meter also indicates good, fair and poor insulation levels through a simple “green, yellow, red” color scheme. When predetermined insulation resistance set point levels are reached, indicator lights will turn on to signal an alarm condition and automatic notifications can be sent out to the monitoring network.

Continuous monitoring can also show if the heaters used to maintain thermal temperatures or prevent condensation are working properly.

Most motors utilize heaters to maintain the temperature inside the motor so it doesn’t vary drastically from operating temperature or ambient temperatures outside the unit. If it goes below the dew point, the motor will start picking up condensation while offline.

However, if these heaters fail to operate properly or the circuit breaker is tripped, maintenance personnel may not be aware of it until the motor fails on startup. Although these motor heaters are checked regularly, this can leave critical motors and generators unprotected for weeks or even months.

Preventing Arc Flashes Perhaps more importantly, Loupe says the “hands off” approach reduces employee exposure to potential harm from arc flashes.

“With the continuous insulation resistance monitoring devices, you eliminate the potential harm of arc flashes by not having the technician open cabinets for megohm testing at all,” says Loupe.

Arc flashes are an undesired electric discharge that travels through the air between conductors or from a conductor to a ground. The flash is immediate and can product temperatures four times that of the surface of the sun. The intense heat also causes a sudden expansion of air, which results in a blast wave that can throw workers across rooms and knocked them off ladders.

Arc flash injuries include third degree burns, blindness, hearing loss, nerve damage, and cardiac arrest and even death.

Among the potential causes of an arc flash listed by NFPA 70E includes “improper use of test equipment.” Although de-energizing

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equipment before testing and wearing appropriate personal protective equipment (PPE) is recommended, the best solution is to eliminate the need to access the control cabinets at all to perform insulation resistance tests.

In addition to the risk of arc flashes, Loupe has witnessed another potential risk firsthand that can occur if a motor shorts out within feet of an employee.

In the plant, personnel are only about five feet away from the motor when starting the chiller. If the motor shorts out, it can make a huge noise and throw out a mass of sparks.

“With continuous insulation resistance monitoring, you don’t have an employee in harm’s way if the motor fails on startup,” says Loupe. “The device prevents that safety concern as well.”

For more information, contact Meg-Alert at www.megalert.com; phone (800) 778-5689; or at 8766 Frank Drive, Minocqua, WI 54548.

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Manufacturing Showcase

Built with Purpose, Built for Life Kennedy Manufacturing Company has been a leader in industrial grade tool storage solutions for over 100 years.

By: Nick Boliek

I

n 1911, Howard Kennedy recognized a problem. Working as an engineer on the Pennsylvania Railroad in Fort Wayne, Indiana wasn’t easy work. On top of the hardships and often dangerous labor that he and other workers faced, there was also the need to maintain, store, and protect the tools and gear used on a daily basis. At this time, standard leather suitcases were the norm, but did not adequately protect from the rigors of railroad travel.

“Howard Kennedy was discouraged by his and colleagues’ belongings, tools, and instrumentation getting ruined or misplaced,” explains Shannon Mason, sales operations manager of Kennedy.

From a small garage, Kennedy designed his own metal suitcase for himself out of galvanized sheet metal. This was the birth of what would become the foundation of Kennedy tool

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24 IMD JULY 2019

IMD – The Industry’s Most Extensive Industrial Publication

storage equipment products. Two years later, Kennedy relocated to Van Wert, Ohio.

To this day, Kennedy has been proudly manufacturing many of their industrial grade steel tool chests, roller cabinets, side cabinets and visual tool control right here in the United States. Their products can be found in use by MRO and metalworking professionals in the aerospace, automotive, construction, energy, fleet maintenance, medical/pharmaceutical industries.

Features of Kennedy’s popular Signature Series Machinists’ and Mechanics’ Chest include a high security tubular locking system, heavy-duty friction drawer slides, drop front panel that conceals and secures, and hand felted, wool-lined drawers that protect precision tools. The friction drawer slides set Kennedy apart from most tool storage system manufacturers that utilize ball bearings. This is especially important for end users who may be restricted from utilizing products that contain ball bearings, such as in the aerospace manufacturers like Boeing and Delta.

Kennedy recognizes that the importance of supporting the future of manufacturing.

Recently, the company donated three complete combination units to Lanier Tech in Georgia, which had expanded their facility with a new CNC machine shop. Lanier Tech offers precision machining and manufacturing programs that give students the training

and opportunities they need to excel in the machining and metalworking world.

“In the last 15 years, we have lost a lot of manufacturing in this country, and the hardest hit part of that was the machinist world,” says Craig Martin, vice president of sales and marketing for Kennedy. “The only way it can come back is have the people to support it and get back into the trade.”

For more information, visit buykennedy.com

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INDUSTRIAL MACHINERY DIGEST.COM1/28/19

AM 11:13

Workforce Development

Black Belt Training Benefits Companies and Their Customers Allied Machine invests in large-scale Lean Six Sigma education for continuous improvement.

By: Deborah A. Froelich

W

hy do companies like 3M, GE, Ford, and even a 78-year old, family-owned cutting tool manufacturer like Allied Machine & Engineering continue to invest in black belt training? After all, it’s time consuming, expensive, and pulls valuable employees from their daily commitments. Not to mention, it’s particularly rigorous and certification is not guaranteed. Investing in Lean Six Sigma’s black belt training is intimidating, but businesses committed to educating employees in key roles throughout their organization see long-term benefits in customer satisfaction, work culture, and their efficiency.

Lean Six Sigma methods are rooted in process improvement systems like Total Quality Management (TQM) and evolved over time.

Motorola’s Bill Smith coined the term in the early 1980’s. The name originates from a statistical measure, and the goal is to consistently produce no more than 3.4 defects per million opportunities (DPMO).

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26 IMD JULY 2019

Initially Lean Six Sigma was used exclusively in parts manufacturing, but over time companies like 3M and GE started using it in other areas too. In the 2000’s, companies began combining the quality improvement systems of Six Sigma with the waste reduction methods of Lean Manufacturing, creating the term Lean Six Sigma. As defects are reduced, waste is reduced, so the two practices complement each other well.

The methods worked so well, that by 2009, 82% of Fortune 100 businesses had implemented Lean Six Sigma practices into their business strategies.

With such successful businesses using Lean Six Sigma tactics, executive leadership at Allied Machine understood the importance of educating key players to shape the continuous improvement culture and sustain process excellence. Black belt training was the perfect solution.

Executive vice president Steve Stokey participated in black belt training alongside employees. He said, “I chose to go through the training to be able to lead the cultural shift at Allied. It is vital that I hold the organization accountable to effectively use the tools to continuously improve our business. By learning the nomenclature, understanding the software, and working on a black belt project with my team, I am living the change process with them.”

Throughout black belt training, the facilitators instructed candidates in advanced Lean Six Sigma, covering the DMAIC (define, measure, analyze, improve, control) methodology, the unique nomenclature, analysis software, data-driven techniques for process improvement and more. Higher level procedures are covered and practiced in the final week of classroom instruction.

Once classroom sessions conclude, trainees lead a black belt project that must make a significant financial impact and support strategic initiatives. The project is the proving ground for all the skills covered during classroom sessions and generally takes at least three to six months to complete.

Trainees submit their project to the certification trainer for review and if approved, they are certified as a black belt.

Not all participants achieve this status.

Ross Randazzo, the director of operational excellence at Allied Machine, notes that “Black belt training not only identifies potential leaders in our workforce, but it also identifies areas for improvement, even in existing leaders too.” Along with processes and products, this training also provides continuous improvement opportunities for an organization’s workforce.

So how does the training help an organization’s customers?

The hierarchy of Lean Six Sigma certification is represented by various belt colors. Each color encompasses various skill sets, roles, and duties.

There are many tools that exist within each segment of the DMAIC method. Here are several applied to Six Sigma projects by Allied’s candidates as they pursued their certification.

Organizing black belt training for leadership roles across various departments is no small feat, but in the end, it benefits the most vital component to an organization’s success and longevity--its customer. It systematically defines a roadmap to match the voice of the process with the voice of the people. In other words, it teaches how to listen to customers and align internal quality standards to meet the end-user’s needs.

In the 1990s, Ford Motor was struggling with low productivity, environmental issues, and very low customer satisfaction rates.

In response, they began a consumer-driven Six Sigma focus. Ford poured through surveys and feedback to target the top 25 critical customer concerns for each vehicle line and developed a process improvement strategy to address each. Their hard work drastically improved customer satisfaction ratings, according to Quality Digest.

By setting standards that mirrored their customer’s expectations and monitoring processes to consistently meet them, Ford demonstrated the value of their customer’s feedback and restored credibility.

INDUSTRIAL MACHINERY DIGEST.COM

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Lean Six Sigma certification conveys that an organization is fiercely devoted to producing and delivering the best products and services on time, every time. According to classroom facilitator S. Skillman, “Customers receive higher quality goods in a faster time frame with better reaction to problems.”

Six Sigma offers six ways to benefit customers #1 Communication Customers deserve to be heard and communication is a critical component of Lean Six Sigma. Understanding a customer’s requirements and making them your own is a mantra repeated throughout training. The terminology used in Lean Six Sigma is well-known and provides a common language for businesses and their customers. It puts an emphasis on gathering the right information from clients in order to shape internal quality standards.

#2: Trust End-users also want to trust their suppliers. Lack of transparency, inconsistent compliance, and varying lead times chip away at vendor relationships. By training employees in the data-driven processes, organizations like Allied Machine have documentation that can provide compliance visibility to their customers. Tracking and archiving data through control systems and analysis software allows employees to react quicker to significant variances and reinforces customer trust.

Originally Taiichi Ohno, a chief engineer at Toyota, created seven areas of potential waste (a.k.a. Muda) while developing Toyota’s lean production system. The eighth waste was added in the 1990’s when Toyota’s method was adopted in the West.

#3 Quality

#4 Innovative Products and Services

John Frazier, a master black belt and manufacturing manager for Allied Machine, stated, “When customers realize a company invests in Lean Six Sigma training and is ISO certified, it gives them confidence. They understand this supplier is going to pursue excellence in everything they offer.” Companies using Lean Six Sigma’s structured, data-driven methods are truly dedicated to quality and, more importantly, define quality through the eyes of their customers.

Streamlined processes also help new products get to market faster.

Black belts are certified experts in identifying and reducing the eight deadly wastes often found in manufacturing. Whether identifying bottlenecks, removing unnecessary movements, or eliminating creep from project meetings, Lean Six Sigma methodology helps businesses navigate process developments smoothly and delivers innovations to customers quicker.

#5 Improved Environmental Impact

Rear Admiral Grace Murray Hopper, esteemed computer scientist known for her work on programming languages such as COBOL, spoke often on the dangers of fearing change and the power of adaptability. This quote is taken from an interview in Information Week, March 9, 1987.

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28 IMD JULY 2019

Customers concerned about the environment can look to manufacturers practicing Lean Six Sigma too. Reducing energy consumption, minimizing material waste, and streamlining processes all make positive impacts on the environment.

According to the EPA, 3M reduced volatile air emissions by 61% from 2000 to 2005 through Lean process improvements.

The EPA has even developed a Leanguide specifically for environmental professionals. Emphasis on reducing specific waste groups helps provide a safer work environment, competitive pricing on products for customers and a healthier community for all.

#6 Shorter Lead Times In order to improve reliability, organizations are always looking to improve delivery times. Black belts exercise critical thinking skills and mentor staff to proactively streamline processes so that customers receive orders faster. Employees are encouraged to think about how they can make a significant difference, whether it’s reduced movements in a particular work cell, improved inventory maintenance, or a simplified system for packaging.

How can companies avoid stumbling blocks along the Lean Six Sigma path?

Integrating Lean Six Sigma into a company’s culture is not an easy journey. Time and resources are obstacles for successful deployment, but other intangibles also stunt integration, including fear of change and lack of leadership buy-in.

Egos can cripple a continuous improvement culture. Jacob Miller is a master black belt and the director of product and process development. He’s been working at Allied Machine for 13 years and understands people struggle with the fear of change. Miller advises, “We have to get over ‘this is the way we’ve always done it’ and realize it’s going to make things easier for everyone involved in implementing processes.”

As for buy-in from management in the organization, if they don’t believe in the power of data-driven decisions and process improvements, they’ll never reap the full benefits of Lean Six Sigma.

Ownership and the executive board ultimately set the tone for the

company’s culture and are responsible for dedicating resources and removing road blocks along the way. It’s imperative that leaders define the goals, understand the tools, and create a strategy for top-down deployment.

Investing in Lean Six Sigma black belt training is just good business, for its customers, its people, and the company.

World-wide, businesses know what to expect from a company that adheres to this process. Executive Vice President Mike Stokey summarizes the importance of investing in black belt training: “There are plenty of cutting tool manufacturers out there competing to gain the market’s attention. We know our people need to be trained at the Olympic level of waste reduction and quality control if we’re to continue winning their business and their loyalty.”

ABOUT ALLIED MACHINE & ENGINEERING Allied Machine & Engineering is a leading manufacturer of holemaking and finishing tooling systems. Allied devotes its advanced engineering and manufacturing capabilities to creating the widest selection of valueadded tooling available to metal-cutting industries around the world.

Our tooling solutions deliver the lowest cost-per-hole in a wide range of drilling, reaming, threading, boring, and burnishing applications. Located in Dover, Ohio, Allied’s precision holemaking technologies provide end users worldwide with the highest level of performance. Precision engineering and expert application support makes Allied the first and best choice for solving complex metal-cutting challenges.

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INDUSTRIAL MACHINERY DIGEST.COM9/20/18

AM 10:50

ABRASIVE POWER TOOLS AND PROCESS SOLUTIONS

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Original Dynabrade Building, 1969

For 50 years, Dynabrade has earned a reputation and position of leadership in the innovative design and manufacturing of unique portable abrasive power tools, accessories and dust collection. With our total systems solutions, we are able to meet the needs of many industries.

OUR HISTORY Dynabrade began in 1969 with one inspired idea. Walter Welsch, Dynabrade’s founder, developed the first Dynafile® Abrasive Belt Tool as a method of improving the task of hand filing metals and other hard surfaces. Thanks to his innovative, entrepreneurial spirit, Dynabrade thrives to this day. We are continuously upgrading the products offered, through extensive research and development based on market needs.

Early Photo of Walter Welsch, u Founder of Dynabrade

Evolution of the Dynafile® Abrasive Belt Tool q

OUR FUTURE Dynabrade is a local company with a global presence. Our tools are sold by hundreds of distributors worldwide in over 90 countries. We support our international efforts at our headquarters, as well as with subsidiaries in Europe (Luxembourg) and India (Mumbai).

We help supply many industries like automotive manufacturing, aerospace, woodworking, metalworking and wind energy to name just a few. With salesmen worldwide and no-obligation demonstrations on any product in our line, we truly strive to listen, to observe, and to optimize.

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New Technology

Machining Large or Long Parts with a Single Set-up

H

eadquartered in Wapakoneta, Ohio, FlexCNC and FlexArm have been manufacturing CNC machines as well as tapping arms, die grinding arms, torque arms, assembly and part manipulators, and more, since 1984. The company has globally expanded its sales, with more than 600 customers worldwide, and now operates out of a new 50,000 square foot facility.

The latest addition to their lineup of machining centers for large or long parts – like structural steel beam – in a single set-up is the FlexBEAM line. With an open bed design that measures 40-feet by two-feet, this new model can machine parts up to 40 feet in length. Alternately, the long open bed, coupled with the movable safety light curtain, allows multiple set-ups, so that while the FlexBEAM is machining one part, another can be loaded, or offloaded.

This dramatically increases the productivity of the machine’s uptime. The open design provides unrestricted access which makes loading and unloading easier and faster. In addition to structural steel beams, FlexBEAM machines are ideal for the machining of long products like tube, or pipe, cutting keyways, and more.

The FlexBEAM has a monoblock welded steel frame with high rigidity and a t-slot machine bed. It features 3-axis interpolation, scribing, automatic hydraulic workholding and automatic tool touch-off.

In addition, a laser zero detector is standard, as is 6 x ATC, a hand pendant, and network with ethernet cable.

Control on the FlexBEAM is simple yet powerful, with conversational and ISO G&M-code programming for versatile 3-axis CNC machining along with an optional 4th axis. Equipped with a color touch screen control, 40 GB of program storage, and 50 programmable zero points. Programs can be loaded through USB or through and ethernet connection. Extensive training is provided, both in-plant and on-site.

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IMD – The Industry’s Most Extensive Industrial Publication

C-Series Vertical Machining Centers FlexCNC’s C-Series vertical machining centers drill, mill, tap and bevel large or long parts in a single set-up. With a 2-foot bed width and lengths from 10 to 80 feet, the C-Series is ideal for machining of long products like tube, or pipe, cutting keyways, and more.

The C-Series features a monoblock welded steel frame with high rigidity and a t-slot machine bed. Spindle taper of CT or BT 40 are available, at 6000 RPM, with a max torque capability of 184 ft/lbs.

Standard unit runs on 480V and includes mobile light-curtain safety barriers, frame with chip conveyor and t-slotted table, flood coolant pump and tank, and automatic tool calibrator. The 12” color touch screen is water-resistant and durable enough to provide years of service. Oversized double hung precision linear guideways ensure smooth and precise movement on all axes. All moving parts are self-lubricating on all axes.

A programmable servo motor drives the spindle, while a 10-compartment automatic tool change ensures capacity for virtually any application.

The C-Series is available in bed sizes from 10 feet to 80 feet, with custom length beds available to suit specific requirements.

Boring different hole sizes daily?

WE HAVE A KIT FOR THAT. Kits aren’t made for everyone, but if you work on different projects from day to day, you need to be prepared for the work tomorrow will bring.

G-Series Standard Edition Vertical Machining Centers FlexCNC’s G-Series vertical machining centers for face milling, helical milling, rough milling, drilling and more, of large or long parts in a single set-up. The Standard Edition model 20-06 SE boasts a 20-foot by six-foot bed, to machine parts up to 20-feet in length. Alternately, the long open bed, coupled with the movable safety light curtain, allows multiple set-ups, so that while the 20-06 SE is machining one part, another can be loaded (or offloaded).

The 20-06 SE features a monoblock welded steel frame with high rigidity and a t-slot machine bed. Spindle taper of CT 40, at 6,000 RPM, with a max torque capability of 74 ft/lbs. (with 18 HP upgrade). This proven product line features maximum travel rate of 1200 in/min along the x axis, 1000 in/min along the y axis and 165 in/min along the z axis. Z-Axis travel is 19” max. Spindle nose to table distance from 5.5” to 25.0”.

Boring holes doesn’t have to be boring.

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IMD 33

Standard unit runs on 480V and includes mobile light-curtain safety barriers, frame with chip conveyor and t-slotted table, flood coolant pump and tank, and automatic tool calibrator. The 12” color touch screen is water-resistant and durable. Oversized double hung precision linear guideways ensure smooth and precise movement on all axes. All moving parts are self-lubricating on all axes. A programmable servo motor drives the spindle, while a 10-compartment automatic tool change ensures capacity for virtually any application.

Control on the FlexCNC is simple yet powerful, with conversational and ISO G&M-code programming for versatile 3-axis CNC machining along with an optional 4th axis. Equipped with a color touch screen control, 40 GB of program storage, and 50 programmable zero points. Programs can be loaded through USB or through and ethernet connection. Extensive training is provided, both in-plant and on-site.

Built in the Wapakoneta, OH factory, the G-series 20-06 SE sells for $258,995. Leadtime for these standard machines is just 12-16 weeks. Delivery, installation, training, and two-year warranty available for just $9500. In addition to standard models, FlexCNC can customize a machine to suit specific parameters – including length and width, raised gantry, open machine bed, and double fourth axis.

For additional information

FLEXCNC

705 Commerce Drive Wapakoneta, OH 45895-9239

www.flexmachinetools.com flexarm@flexarminc.com

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(800) 837-2503.

INDUSTRIAL MACHINERY DIGEST.COM

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IMD 35

Process

An American Manufacturing Legacy, Still Going Strong

M

eet the family-owned overhead crane manufacturer that got its start in the founder’s garage, and today stands as one of the few remaining all-American crane builders. Each crane, from gearboxes to cabs, is engineered and built in the same Oak Creek, Wisconsin facility. While many other manufacturers have benefitted from widespread outsourcing, Zenar Corporation still thrives on keeping the entire operation all under one roof.

What Makes a Zenar Crane ‘American-Made’?

Most of the heavy machinery bought and sold today is assembled in America, not truly made in the way that most Americans envision the concept. In the overhead crane industry alone, a majority of all cranes are assembled in the states from parts fabricated or bought

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all over the world, despite officially touting the FTC’s “Made in America” label. Zenar’s cranes are a rare exception to that trend. All of the overhead cranes produced by Zenar Corporation are built in their Oak Creek, Wisconsin facility from beginning to end.

When the custom overhead crane manufacturer first opened for business out of a garage in 1972, the original founders never thought their operation would grow into the major crane authority it is today.

They had a unique passion for pursuing unparalleled precision in both design and fabrication -- and their tenacity paid off. Decades later, the founders' children and grandchildren are still at the helm of Zenar Corporation, where truly American manufacturing is both a family tradition and a competitive advantage.

Today, no visitor to the 120,000 square foot facility would guess Zenar Corporation’s humble beginnings. With the dedication of

IMD – The Industry’s Most Extensive Industrial Publication

a large team of expert craftsman, Zenar designs and builds some of the most advanced overhead material handling systems in the nation. Holding true to their roots, the Zenar team still controls the entire crane build process, just like they’ve done since the 1970s. This unique ability to monitor the quality control of each part is what allows Zenar’s final product to outstrip the competition - both in performance and longevity.

Not only does the founding family have extensive experience in designing and fabricating overhead cranes, so does the entire Zenar team. Employee turnover is low at Zenar, and most of the employees welding and fabricating crane parts have been at the company for a long time.

Each employee not only knows their craft, they know cranes, and it’s difficult for competitors to reproduce what dozens of crane experts at every level can do.

That’s the bottom line for why Zenar continues to fabricate their own cranes and crane parts from start to finish. Their team’s attention to detail, quality control, and unmatched expertise simply can’t be outsourced.

MARK YOUR CALENDAR

How Zenar Builds Cranes the American Way When Zenar sets out to build a crane from start to finish, they mean ‘start to finish.’ The first stage in a crane build begins with a custom design developed by Zenar’s engineers or the customers specifications. Beyond supplying travel speed and payload requirements, customers can rely entirely on Zenar

OCTOBER 8–10, 2019

Exposition Center at Wisconsin State Fair Park • Milwaukee, WI

Connections to Technology, Talent & Resources

A tradition since 1989 – where manufacturing leaders meet!

The 16th biennial WIMTS has been re-tooled and is no longer simply a machine tool show. It will now feature manufacturing’s hottest new technologies—additive mfg, automated, energy & environmental efficiency, IIoT, nanotechnology, robotics and more. Also in the spotlight will be plastics, welding, production, machining, tool & die, stamping, conveyors, packaging, electronics, foundry, fabrication, metrology and more.

Labor Enhancement Initiatives will be emphasized. Numerous Workshops, Industry Seminars and Industry Association Events & Meetings are also scheduled throughout the three-day event.

FREE Admission Online: www.WIMTS.com

WISCONSIN’S LARGEST MANUFACTURING EVENT WILL HIGHLIGHT: • Hands-on Demonstrations of Machines and Tools under Power • Tuesday Wisconsin Manufacturers & Commerce (WMC) Luncheon • Tuesday Afternoon “Connection Reception” Networking Event with Student Competitors attending with resumes • Wednesday Manufacturing Summit Breakfast • Welding Pavilion with Individual Student Competitions • Automation & Robotics Lab with Student Team Competitions

Questions? Contact Cheryl Luck at 262-367-5500 or Cheryl@EpiShows.com INDUSTRIAL MACHINERY DIGEST.COM

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Corporation’s engineering expertise, though a few of the many customers actually come to the table with specifications for Zenar to work off of. The sheer amount of industry experience at Zenar gives them the ability to develop an advanced material handling solution for just about any need.

Once a design is finalized and materials are purchased, each department gets to work building their piece of the puzzle.

Operation managers work to schedule the workflow. Cranes of similar size or with similar components are grouped together so that work is more efficient, and cranes are also scheduled so that they are ready for assembly at the same time. While the fabrication department begins work on trolleys and end trucks, the girder department starts on girders or beams.

Zenar Corporation also cross-trains its staff to prevent work stoppage and disruptions. With an entire team of multi-skilled crane experts, maintaining workflow doesn’t depend on any single individual. Any welder or fitter can sub into a different department at a moment’s notice, and that keeps projects on time and on budget.

When each part of a crane is completed, the entire piece of machinery is assembled on the main floor, and rigorously tested.

Final testing at Zenar is a necessary quality control measure, but it’s not the first line of defense against product defects. Management expects their cranes to operate as they should during final testing, because every department works under the same standards and the same unified vision. With their “do it right the first time” approach, any errors are caught early on in the build process and addressed long before assembly.

Employee engagement is also one of the ways Zenar keeps its entire team upholding the same performance and quality standards.

At weekly meetings, managers talk about which cranes are on the floor so that each assembler, electrician, fabricator, welder, and machinist knows which crane their hard work is contributing to. Despite a high volume of crane orders and multiple cranes in production at one time, every team member knows which crane they are working on.

When every team member can see their role in creating such an impressive final product, they’re more likely to feel fulfilled in what they do and invest in their work. That personal investment translates to higher standards, better quality, and better final results for Zenar and its customers.

Zenar Builds Success for Its Employees Aside from the American-made cranes themselves, one of the most quintessentially American aspects of Zenar is its workplace culture.

Executive management believes that potential can be discovered anywhere, and that mentality opens doors for those willing to work hard enough.

Each employee is taught that they are only limited by their own ambition, and that working hard to achieve success is more than just a dream at Zenar Corporation. Management, including the Vice President, walks around the facility several times a day and looks for stand-out team members going the extra mile. As a result, entry level employees can eventually find themselves managing entire departments if they can demonstrate the skill and drive to serve in that capacity.

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With an open-door policy and owners who knows everyone by name, management’s inclusive mentorship keeps employees at every level passionate about progressing in their roles as builders of industry-leading cranes. As a matter of fact, learning is a part of the job for everyone at Zenar. Not only are processes and products continuously improved, so are the individual skills of each engineer and tradesperson.

Sometimes, promising talent is sent back to school to obtain further credentials, while others are regularly instructed in the latest technology coming to Zenar’s shop floor. This environment keeps Zenar employees striving to grow both as professionals and as a team. Zenar’s focus on personal improvement and education doesn’t stop with their employees.

They are actively involved in their community by participating in education programs that allow high school students to get hands on manufacturing experience.

According to the Vice President, “Keeping everyone improving and excited about what they’re doing here is key to our success. At the end of the day, everyone knows that the couplings, gears, and hoists they’ve worked on are going to be a part of one of the highest quality custom cranes in the country. Which is something to be proud of.”

And that’s what really sets Zenar apart from the competition: enduring pride in American craftsmanship.

For more information, visit www.zenarcrane.com

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Industry Insight

James Flatman, shop manager, recently converted Cruising Kitchens new shop over to a fleet of compact, portable inverters from ESAB.

Going Mobile

Cruising Kitchens Relies on ESAB Mobile Welders to Feed the Mobile Vending Boom By: Jay Coubrough, ESAB Welding & Cutting Products

N

o surprise that there’s a flourishing bandwagon of people jumping from brick and mortar businesses into mobile products and services: offices, restaurants, shelters, vendors of any kind. If you can put it on wheels, chances are Cruising Kitchens, San Antonio, Texas, has built it. In fact, Cruising Kitchens probably built the bandwagon.

“Six years ago, our president and CEO, Cameron Davies, built his first food truck right before the big boom in the Austin and San Antonio area,” says James Flatman, shop manager, Cruising Kitchens.

“He got his feet wet in the market before it really took off. There have been a lot of competitors that have come and gone, but Cruising Kitchens has just continued to grow.” And grow it has. In the last year

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and a half, the shop went from 10,000 sq. ft. to 68,000 sq. ft. and 70 employees located in a shop minutes from the San Antonio airport.

“We’re dealing with step vans, trailers, intermodal shipping containers, and each truck has a mix of stainless steel, aluminum and structural steel,” says Flatman. “From the fabrication side, we have MIG, Stick and TIG going into every truck.”

Making it Happen Especially in the food truck industry, social media makes the difference between a cult-like following and a lonely parking lot.

These small businesses owners need to inform their customers about where they’ll set up for the day, as well as promote daily specials.

IMD – The Industry’s Most Extensive Industrial Publication

For Cruising Kitchens, on the other hand, social media allows customers to see the build process along the way. In addition, they have an open-door policy. Customers can come in to see their product being built, fabricated and put together. Those who are out of state or the country get the same experience on social media.

The company works with high profile customers like the U.S. Army and renowned chef, restaurateur and T.V. personality Gordon Ramsey and understands the value of exposure.

“Being in a bigger facility opens up the capabilities of what we’re able to produce, and people can see James Flatman uses the AC TIG output of the Rebel 205ic to TIG weld a water tank. that,” says Flatman. “We built Gordon Ramsey’s Hell on Wheels unit for his T.V. show, 24 Hours to Hell and for audiovisual equipment or, by pulling out the computer hardware, Back, and we’re working with the U.S. Army so they can it becomes a walk-in cooler just by turning the refrigeration unit provide healthier eating options for the troops.” on. The hydraulic pump and electrical panel generator are held in Hell on Wheels is more than a mobile kitchen; it’s an the front box — the heart of the unit. There are also two 55-in. flat extraordinarily well-equipped hi-tech rig built to go anywhere. screen televisions, one on each side of the jumbotron, for playing “It started off as a 30-ft. shipping container mounted to a lowboy additional footage. “It’s definitely a take-anywhere setup that draws a trailer,” says Flatman. “It has a hydraulically-controlled stage and awning big crowd,” says Flatman. as well as an 18-ft.-wide by 8-ft.-high jumbotron on the roof. It’s all on In addition to building mobile kitchens, Cruising Kitchens builds one pendent operated by one pump, so they can pull up to wherever dining halls for oil fields and rigs for colleges, zoos, food banks they need to be and set it up in five minutes with two people.” and nightclubs. Weight Watchers recently commissioned Cruising The inside has two complete state-of-the-art kitchens. The back Kitchens for a unit that went on tour with DJ Khaled. half is multi-purpose; the box on the back can be a command center

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42 IMD JULY 2019

“Were at a point where if a customer can come up with an idea, we are capable of making it happen,” says Flatman.

For completing rigs and putting on the finishing touches, Cruising Kitchens has upholstery, maintenance and printing shops on site. If a truck is used, it gets a full once over in the maintenance shop before a build begins.

Interiors can be re-upholstered to match company logos, and at the print shop, trucks are wrapped with vinyl after design and printing are completed.

Vehicle wraps may be simple or could contain colorchanging vinyl placed over graphics that are printed on clear vinyl. Graphics for signs, storefronts, tradeshows and more are printed on a flatbed printer that can print a 4- by 8-ft. sheet of plastic, aluminum or stainless in about 90 seconds. The company offers a complete marketing package that includes t-shirts and hats.

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Cruising Kitchens is always up for a challenge. Bidding against other companies only strengthens its range of build and fabrication capabilities.

“What set up apart from the other companies in contention for Hell on Wheels was the hydraulic system for the stage and awning and the jumbotron itself,” says Flatman. “Other companies weren’t comfortable dealing with these things. We like a challenge and are not scared of trying something new.”

Perhaps its largest advantage over competitors is the company’s attention to detail. Flatman attributes much of this to his sheet metal workers and fabricators.

“They go above and beyond to make sure seams are flawless and we don’t have to caulk gaps. Everything meets up as it should, or they start over. They take pride in their work and it shows in the end product.”

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Mobile Flexibility To support employee craftsmanship in the new shop, Cruising Kitchens expanded its fleet of welding equipment, converting from heavier single-process units to compact, portable inverters from ESAB. Equipped added includes six Rebel™ EMP 235ic multiprocess (250-amp MIG-Stick-DC TIG) units, two Rebel EMP 205ic AC/DC all-process units. one ET 220i AC/DC TIG/Stick unit for larger TIG aluminum projects (e.g., long welds on ¼-in. material) and a Thermal Dynamics® Cutmaster® 60i manual plasma cutter.

Mounted on carts with cylinder racks, the inverters units quickly wheel from one end of the shop to the other, while their lightweight (even the 250-amp units only weigh 53 lbs.) allows the welder-fabricator to carry the unit inside a truck or container if needed.

“We’re not having to forklift bigger units into place or move units over to a person’s area,” says Flatman. “Also,

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IMD 43

a guy can knock out some stainless steel trim, then bounce over to another unit to weld out an aluminum water tank and then move over to a shipping container for structural steel work on the inside.”

Prior to moving into the larger space, Cruising Kitchens landed a big contract for a shipping container build, for which the company contemplated purchasing separate MIG and TIG welders in order to complete the project on time. However, Flatman had heard about Rebel’s multi-process capabilities.

“We inquired about the Rebel welders and got a response in 30 minutes,” says Flatman. “At the time, ESAB was really the only company that had a true multi-process machine.”

While compact multiple process inverters had been available, they sacrificed performance in one or more modes or with different types of Stick electrodes (e.g., they could run an E7018 or an E6010 acceptably, but not both).

Cruising Kitchens brought in the multi-process welder and were “blown away by it,” says Flatman.

“Rebel MIG welds beautifully, the TIG side of it is phenomenal, and Stick welding is even better,” says Flatman. “It runs so quietly when you’re Stick welding, you question whether it’s on until you get used to it.”

Cruising Kitchens met its needs for a heavier TIG aluminum with the ET 220i, which has a 200-amp output at 45 percent duty cycle on 1-ph primary power. A water-cooled torch enables continuous welding while keeping the torch comfortable, while ability to adjust AC output frequency and balance control keeps the arc focused.

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Power Wheel® planetary gear drives allow greater flexibility than conventional power train systems and often eliminate the need for drive shafts, axles and chain drives. The many Auburn models, styles and sizes meet a wide range of mobile and industrial applications. Powered drives provide outputs to 180,000 lb/in, max. speeds to 5000 rpm. With up to 98% power transfer efficiency, Auburn Gear Power Wheel® drives are significantly more efficient than many other types of drives, including differential design planetaries. The rugged, compact design of these drives saves space and provides for long service life. All models can be furnished with parking brakes.

wheel drives: For off-road mobile equipment propelled by pneumatic tires, tracks and rollers. shaft drives: Meet the power requirements for conveyors, augers, mixers and swing drives. spindle drives: Perfect for vehicles with small diameter drive wheels requiring flange mounts. swing drives: Designed for applications that require 180º or 360º rotation. non-powered: Normally used where dead wheels/axles are required. kit assemblies: Power Wheel models are available in “kits” containing only those components needed for the application. parking brakes: Takes less space than a bolt-on package, allows final drive and brake from a single source.

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44 IMD JULY 2019

“It’s hands down one of the nicest TIG machines I’ve used on aluminum because of its arc control,” says Flatman.

In addition, the Cruising Kitchen recently added two all-process Rebel 205s, which adds AC TIG capabilities for aluminum, as well as DC TIG, Stick, MIG and Flux-Cored capabilities.

“When you have guys who are TIG welding aluminum water tanks but also MIG welding framework for generators and Stick welding framework for shipping containers, it’s nice that they have their own machine to roll around the shop,” says Flatman. “It gives them ownership to knock out any job thrown at them.”

Equipment investment aside, the process of switching out machines and learning new products and setup has been relatively simple. “The machines are incredibly user-friendly. The big digital display on the front walks you through everything,” says Flatman.

“We’ve had very few questions or concerns.”

ABOUT ESAB ESAB is a world leader in the production of welding and cutting equipment and consumables. Their innovative, world-renowned equipment and solutions are developed with input from their customers and built with the expertise and heritage of a global manufacturing leader.

For more information, visit www.esabna.com

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On Exhibit

WESTEC 2019 DATES: SEPTEMBER 24-26, 2019 Long Beach Convention & Entertainment Center | Long Beach, California WESTEC, the leading California manufacturing trade show, has been providing solutions to manufacturing challenges for 55 years. Attendees will have the chance to experience hands-on interaction with the newest technologies in close to 60 manufacturing technology categories, including; aerospace manufacturing, CNC Machining, Waterjet, Advanced Materials, 3D printing, and much more. »» For more information, visit www.westeconline.com.

EXHIBITOR HIGHLIGHTS..................................................................................

BOOTH: 2145

Allied Features Their Newest IC Drill – 4TEX Allied Machine & Engineering will highlight their indexable drill, 4TEX, designed to excel in holemaking applications with inclined surfaces, interrupted cuts, high temperature alloys, or stainless steels. The company states it outperforms other standard drills by delivering higher penetration rates in light duty machines and is ideal for making shallow 2xD, 3xD, and 4xD holes in the 0.472” – 1.850” (12mm – 47mm) range. Additional flute space (1.6X larger than typical IC drills) coupled with dual twisted coolant outlets increase penetration rates by enhancing coolant flow and generating excellent chip evacuation. »» For more information, visit www.alliedmachine.com/4TEX BOOTH: 1745

Easy Index Cutter Heads with BIG KAISER’s Contact Grip BIG KAISER introduces the Fullcut Mill Contact Grip, an endmill that permits easy indexing of cutter heads while maintaining excellent rigidity and accuracy. With the addition of the Fullcut Radius Mill (FRM) and the Ball End Mill (BE), the Fullcut Mill Contact Grip series now features four connection sizes and seven cutter types. The unique dual Contact Grip of the Fullcut Mill Contact Grip is a threaded coupling system that achieves machining capacity close to that of integrated types. The taper and flange face make close contact for solid connection and one holder allows selection from multiple heads. »» For more information, visit www.bigkaiser.com BOOTH: 956

High Capacity Powered Pallet Truck from Combilift The Combi-PPT is a high-performance pedestrian operated powered pallet truck with a range of capacities up to 35,000 lbs. which enables the safe and secure transportation of very heavy loads without the need for a ride-on forklift. The features, which include Combilift’s unique, patented multi-position tiller arm and design ensure optimum visibility of the load and surroundings for the operator and guarantee maximum safety in areas where other personnel may be present, in busy production plants for example. Its maneuverability enables efficient and productive operation in confined spaces. »» For more information, visit www.combilift.com

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IMD – The Industry’s Most Extensive Industrial Publication

BOOTH: 2008

Dynabrade’s 2.8 HP Rebel Series Heavy Duty Right Angle Grinders And Sanders Dynabrade line of American made air tools are ideal for use in heavy abuse work environments including Foundries, Shipyards and Steel Plants. 7 inch and 9 inch Diameter Depressed Center Wheel Grinders are offered. 7 inch Models at 8,500 RPM and 9 inch Models at 6,500 RPM. Each model accepts Type 27 reinforced Depressed Center Grinding Wheels. These Grinders are for fast weld and stock removal, heavy metal grinding and rust and scale removal. 7 inch and 9 inch Diameter Disc Sanders are ideal for sanding and blending various materials including metal, stainless steel and various composites. »» For more information, visit www.dynabrade.com BOOTH: 745

Formdrill: Thermal Drilling Experts Thermal drilling is a process that uses friction to produce bushings in metal tubing and flat stock. The combined rotational and downward force of our special Thermal Drilling tool bit creates frictional heat. Temperatures can reach 900 C for the tool, and 700 C for the work piece.

The material is transformed into a "super-plastic" state, allowing the tool to displace material and form a bushing. These bushings are ideal for threaded applications, as the number and strength of threads is significantly increased. It is an excellent alternative to weld nuts or threaded inserts. »» For more information, visit www.formdrill-usa.com

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IMD 47

BOOTH: 849

Go Green with Hydraulic Drive Technology Green Hydraulic Power is in partnership with MJC Engineering & Technology, Inc. They provide a full turnkey solution, which may include, system integration, engineering solutions, software technology and programming. ​When compared to conventional hydraulic power systems Green Hydraulic Power units can result into up to 80% energy savings, noise emission reduced by 20 db(a), and a higher machine yield. Furthermore, GHP units require lower horsepower, and the units generate less heat with little to no cooling needed. These Industry 4.0 ready hydraulic drives also result in a smaller carbon footprint. »» For more information, visit www.greenhydraulicpower.com BOOTH: 1303

Mastercam 2020 Released Mastercam 2020 continues to increase productivity and programming efficiency, while reducing overall production costs, with a series of automated 2D through 5-axis toolpath improvements.

The new 3D Blend toolpath delivers a smooth, precision surface finish, and provides stock and holder checking. 3D tooling has also seen many usability improvements such as 3D tool icons in tool lists and stop-on-contact functionality when mating insert to holder. Mastercam 2020 increases efficiency and reduces job setup time and the preparation needed for part machining and programming. This includes the ability to filter inserts and holders by attributes as well as the ability to track associativity. »» For more information, visit www.mastercam.com BOOTH: 851

Scotchman Industries Introduces 3 New Ironworker Options and Features Light-up your Scotchman ironworker. These new, low profile LED work lights are available on all current models located in the following workstations: PF45, 5014-ET, 50514-EC, 6509, 9012,12012, all Dual Operator (DO) models, F185, and ShearMaster. Optional retrofit kits are available for infield retrofitting to existing Scotchman Ironworkers. Additionally, jog motor control is now available on the Scotchman 50-ton ironworker. The Snap Ring Removal Tool for #20 punches makes an otherwise tedious task fast and easy. Sold separately or included with the purchase of a #20 Punch and Die Package. »» For more information, visit www.scotchman.com BOOTH: 2244

Suhner Robot Solutions for Fully-Automated Manufacturing Suhner Industrial Products now offers a number of powerful machine tools that can be mounted directly on the robot arm and ready for continuous use. The Suhner power-pack robot machine tools are compatible with all robot manufacturers, making them versatile for demanding high-performance applications. This allows operations that were previously not suitable for automation, to now be automated.

Tools are available for brushing, polishing, filing, belt sanding or tool spindles and are easily integrated. Applications for the new robot tools range from automotive manufacturing to deburring operations, stainless steel machining to drilling and tapping operations and all areas of manufacturing and operations. »» For more information, visit www.suhner.com/en/

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BOOTH: 1456

FZ40 Compact – A Space-Saving Portal Milling Machine for High-Speed Machining Zimmermann’s FZ40 compact is especially suitable for machining workpieces made of steel, cast iron and titanium. The machine features the powerful new VH60 2-axis milling head with a spindle power of 63 kW, a spindle speed of 15,000 rpm and a torque of 300 Nm. It is available with the HSK-A100 tool holder. The FZ40 can hold workpieces weighing as much as 16 metric tons. Owing to its particularly high performance and stability, the FZ40 Compact can machine steel components quickly and economically on 5 axes. It achieves short throughput times, high availability and high precision. »» For more information, visit www.f-zimmermann.com/us/

IMD Quarterly Read More about Zimmermann’s FZ40 and other solutions in the Q-2 edition of Industrial Machinery Digest Quarterly at www.industrialmachinerydigest.com

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INDUSTRIAL MACHINERY DIGEST.COM

PM 5/31/19 12:34

Product Showcase

PRODUCTSHOWCASE WANT TO BE FEATURED? Send your latest product information to editorial@indmacdig.com

IMD's Monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers.

Heavy Duty HEPA Vacuum For 30 Gallon Drums EXAIR’s new 30 Gallon Heavy Duty HEPA Vac is a powerful, HEPA quality, industrial vacuum cleaner. It has been engineered to filter contaminants to HEPA requirements in dusty environments requiring frequent cleaning. It is extremely quiet at 82 dBA (half the noise of electric vacs), making it suitable for a wide variety of environments.

An economical, easily maintained pre-filter stops larger particles, while the HEPA filter handles the smaller matter. All filters are tested for minimum 99.97% filtration at the 0.3 micron level to meet HEPA standards in strict accordance to IEST-RP-CC-007. »» For more information, visit www.exair.com

Introducing the Grizzly Model T28522 24" Pan and Box Brake

No. 824 is a 500°F (260°C), modified universal oven from Grieve, currently used for housing a vertical conveyor system at the customer’s facility. Nine KW installed in Nichrome wire heating elements, while a 600 CFM, 1/2 HP recirculating blower provides universal airflow to the workload. This Grieve modified universal oven features 4” insulated walls, aluminum steel exterior, Type 430 stainless steel interior and two (2) 20” wide x 5-1/2” high conveyor access doors installed in oven door. Additional features include safety equipment for handling flammable solvents, including explosion venting door hardware.

Grizzly Industrial is excited to announce the Grizzly Model T28522 24" Pan and Box Brake. Machine highlights include bend sheet metal up to 24" wide, with a 0–135° brake range and 3⁄8" minimum reverse bend, and five removable fingers for box forming and other special bending operations. The Maximum height of pan/box sides is two inches. The T28522 weights approximately 84 lbs.

Maximum thickness for mild steel: half-width: 18 gauge, full-width: 20 gauge. The Model T28522 is available for $299.95 and is covered by a one-year warranty.

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500°F Modified Universal Oven from Grieve

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IMD – The Industry’s Most Extensive Industrial Publication

Coxreels® Upgraded Multi-Lobe Seals Coxreels is proud to announce a seal upgrade to the nitrile 1.5-inch and 2-inch inline swivels with advanced multi-lobe sealing technology. The enhanced seals are designed to maximize seal integrity, improve overall seal performance, and maximize seal life.

In-depth testing has shown that the performance of the multi-lobe seals exceeds that of the standard O-ring, cup, and T-seals for large capacity fluid handling and high-volume delivery in both high-and low-pressure applications. Additionally, the new seal geometry has a better resistance to compression set, which is a leading cause of premature seal failure. »» For more information, visit www.coxreels.com

Form 3 and Form 3L - Built on the Next Generation of 3D Printing Technology Formlabs has announced the addition of two new advanced professional Low Force Stereolithography (LFS) 3D printers to its hardware lineup: Form 3 and Form 3L. Benefits of the LFS process include incredible detail and surface finish, pinpoint precision, and nonstop printing.The powerful LFS print process behind the Form 3 is built to scale: Form 3L simultaneously uses two Light Processing Units (LPUs) to bring large format 3D printing in-house. Form 3L offers five times the build volume and two times the laser power of the Form 3 to print large parts fast. »» For more information, visit www.formlabs.com

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IMD 51

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