Springs, Vol 59 No 1

WINTER 2020

THE INTERNATIONAL MAGAZINE OF SPRING MANUFACTURE

A Publication of the Spring Manufacturers Institute / Vol. 59, No. 1

International Springmaking Springmakers Around the World 32 Exports a Significant Opportunity for Manufacturers 43 International Spring Industry Presents a Mixed Picture 44 Flashback: What’s in a Spec? 53

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President’s Message From Steve Kempf

SMI Executive Committee President: Steve Kempf, Lee Spring Vice President: Bert Goering, Precision Coil Spring Secretary/Treasurer: Gene Huber, Jr., Winamac Coil Spring At Large: Don Jacobson III, Newcomb Spring Past President: Mike Betts, Betts Company Executive Director: Lynne Carr, SMI

SMI Board of Directors

Forging New Partnerships to Increase International Collaboration When I was 23 years old, the company I was working for offered me a position in their Hong Kong office. I accepted the offer and joined a team responsible for the Asia-Pacific region; it was one of the best decisions I’ve ever made. Over the course of my time there, I worked in more than a dozen different countries, visited many others just for exploration and learned more than I could possibly describe here, but one particular experience stands out.

The Indian government was auctioning off licenses to build cellular communications networks, and I was sent there to advise a local company on a valuation and bidding strategy. I worked side by side with the Indian management team. They were highly intelligent, enterprising and open-minded. They were on a road to success. It was impossible not to take note.

At the end of my time in Hong Kong, I received a bonus. I decided to invest it in the people of India and put it all into a fund that invests exclusively in Indian companies. Fast-forward nearly 20 years to 2013, I still held that investment. And with its extremely attractive return, I remained a big believer in the people of India. So, I made a much larger bet on the country by opening a Lee Spring factory in Bengaluru.

Over the past 20 years, Lee Spring has expanded from manufacturing only within the U.S. and a lone international warehouse in the U.K. to a footprint that encompasses 15 locations, including factories in the U.S., U.K., Mexico, China and India and a distribution center in Germany. Revenues from customers outside of the U.S. are now approaching one-third of our total. None of this expansion has been at the expense of our U.S. operations, but rather as an effort to grow within those international markets. In this same period, we have enjoyed significant growth in U.S. revenues, and added two new domestic manufacturing facilities as well.

To be sure, the efforts to expand internationally were underway before my arrival on the scene at Lee Spring, but recognizing the increasingly global nature of business from my personal time abroad, I championed those efforts and committed to invest in further international expansions. Similarly, SMI was already cooperating with like-minded associations in other parts of the world before my presidency. But I have made increasing international collaboration one of the important goals of my limited time leading this organization.

At the end of September, I attended and presented at the 10th International Congress of Spring Industry, arranged by the European Spring Federation (ESF) and hosted by the association of the German spring industry (VDFI). 160 springmakers participated in the conference representing manufacturers from 24 different countries.

In concert with the 2021 SMI Metal Engineering eXpo and Symposia in Las Vegas, we will be hosting the annual International Organization for Standardization (ISO) meeting of the technical committee on springs (TC227). This is the international cooperation that sets standards for the global spring industry.

Forming these relationships will strengthen our U.S. manufacturers, and the global industry as well. It is an exciting time for SMI. We’re forging new partnerships with an eye on the world of international springmaking.

Jennelle Carlier, S3 Wireform • Dave Deerwester, The Yost Superior Co. • David DeVoe, Plymouth Spring • Joe Devany, Betts Company • Linda Froehlich, Ace Wire Spring & Form • Ritchy Froehlich, Ace Wire Spring & Form • Brett Goldberg, International Spring • Agustin Estalayo Ibanez, RPK Mexico SA de CV • Peter Mendel, Kern-Liebers USA • Rob Meyers, RK Trading • Tony Pesaresi, Winamac Coil Spring • Daniel Pierre III, JN Machinery • Chris and Jeff Wharin, Bohne Spring • Tim Zwit, Michigan Spring and Stamping

Springs Magazine Staff Lynne Carr, Advertising Sales, lynne@smihq.org Gary McCoy, Managing Editor, gmccoy@fairwaycommunications.com Dina Sanchez, Assistant Editor, dina@smihq.org Sue Zubek, Art Director, zubekdesign@gmail.com

Springs Magazine Committee Chair, David DeVoe, Plymouth Spring • Reb Banas, Stanley Spring & Stamping • Lynne Carr, SMI • Ritchy Froehlich, Ace Wire Spring & Form • Bud Funk, Fourslide Products • Brett Goldberg, International Spring • Tim Weber, Forming Systems • Europe Liaison: Wolfgang Herrmann, VDFI • Technical Advisor: Dan Sebastian, Honorary Member Advertising sales - Japan Ken Myohdai, Sakura International Inc. Head Office: 3F,4F, ENDO Sakaisuji Bldg., 1-7-3, Bingomachi, Chuo-Ku, Osaka 541-0051, Japan Phone: 81-6-6624-3601 • Fax: 81-6-6624-3602 Tokyo Global Office: 5F Kamei No. 2 Bldg., 2-17-13, Kiba, Koto-Ku, Tokyo, 135-0042, Japan Phone: 81-3-5646-1160 • Fax: 81-3-5646-1161 E-mail: info@sakurain.co.jp Advertising sales - Europe Jennie Franks, Franks & Co. 63 St. Andrew's Road Cambridge United Kingdom CB41DH Phone/Fax: +44-1223-360472 E-mail: franksco@BTopenworld.com Advertising sales - Taiwan Robert Yu, Worldwide Services Co. Ltd. 11F-B, No 540, Sec. 1, Wen Hsin Rd. Taichung, Taiwan Phone: +886-4-2325-1784 • Fax: +886-4-2325-2967 E-mail: stuart@wwstaiwan.com Springs (ISSN 0584-9667) is published quarterly by SMI Business Corp., a subsidiary of the Spring Manufacturers Institute: 2001 Midwest Road, Suite 106, Oak Brook, IL 60523; Phone: (630) 495-8588; Fax: (630) 495-8595; Web site www.smihq.org. Address all correspondence and editorial materials to this address.

The editors and publishers of Springs disclaim all warranties, express or implied, with respect to advertising and editorial content, and with respect to all manufacturing errors, defects or omissions made in connection with advertising or editorial material submitted for publication.

The editors and publishers of Springs disclaim all liability for special or consequential damages resulting from errors, defects or omissions in the manufacturing of this publication, any submission of advertising, editorial or other material for publication in Springs shall constitute an agreement with and acceptance of such limited liability.

The editors and publishers of Springs assume no responsibility for the opinions or facts in signed articles, except to the extent of expressing the view, by the fact of publication, that the subject treated is one which merits attention.

Do not reproduce without written permission.

Cover art created using images from: ©iStockphoto.com/yellowpaul, ©iStockphoto.com/Dekdoyjaidee, ©iStockphoto.com/Csondy

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Contents

32

48

FEATURES

COLUMNS

32 Springmakers Around the World

By Raquel Chole

41 Why Springmakers Should Consider Expanding Operations to Mexico

By Jim Tomei

17 Be Aware Safety Tips

21 Dean of Springs

73 Book Corner

44 International Spring Industry Presents a Mixed Picture

27 Technically Speaking

Types of Tests Used to Characterize Springmaking Materials — Part 1: The Tensile Test

By C. Richard Gordon

By Donald Jacobson III

60 Forecast 2020: Happy Consumers, Slowing Growth

By Phillip M. Perry

4 / SPRINGS / Winter 2020

75 CTE News 77 Inside SMI 80 Committee Connection 81 New Products 83 Advertisers’ Index

53 Flashback

59 G. Donald Jacobson Celebrates 50 Years of Service with Newcomb Spring Corp

67 Springmaker Spotlight

Plymouth Spring at 60: Serving Customer Needs One at a Time

By Gary McCoy

Stress Relaxation and Springs

By Dan Sebastian

What's in a Spec?

by Terry Bartel

Industrial Steel & Wire

Workplace Violence Prevention: Some New Ideas and Resources

By Laura Helmrich-Rhodes

43 Exports a Significant Opportunity for Manufacturers

48 2019 Pittsburgh eXpo Features Education, Exhibits and Exchanges

65 Five Questions

DEPARTMENTS 2 President’s Message

Forging New Partnerships to Increase International Collaboration

7 Global Highlights 12 Regional Spring Association Report

84 Snapshot

David Janowski, AMW Springs

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Global Highlights North America Lee Spring, a global leader in stock and custom springs, announced the acquisition of U.K.-based Longcroft Engineering. Longcroft Engineering is a manufacturer of custom springs operating in Todmorden, Lancashire, U.K. Steve Kempf, CEO of Lee Spring, commented that “the acquisition of Longcroft Engineering expands our capabilities to support continued growth within the U.K. and across the greater European market. Longcroft Engineering has been a key strategic partner of Lee Spring for many years, with a complementary skill set that is a natural fit for the enhancement of our global operations. They are a talented team with broad spring manufacturing experience and particular expertise in short-run prototyping of complex springs made from both wire as well as flat materials.”

Kempf continued, “Longcrof t Engineering will continue to serve customers from their existing facility in Todmorden, plus they will now also have access to a wider range of capabilities through Lee Spring’s global manufacturing operations. This acquisition enhances the offering available to Lee Spring customers worldwide with expanded manufacturing operations located in the U.K.” Western Spring Manufacturing in Hugo, Minnesota, has announced that Matt Haberman joined its team as a lead mechanical engineer July 15, 2019. Haberman, a 1999 graduate from the Milwaukee School of Engineering, came to Western Spring with more than 20 years of engineering experience. The company said in a statement, “Western Spring is excited to have Matt join its growing team and is looking forward to

Pictured (l-to-r): Western Spring owners Ben Altstatt and Alex Altstatt. and lead mechanical engineer Matt Haberman.

utilizing his many facets of expertise to enhance our capabilities for our diverse group of customers.”

Haberman joined management at the 2019 SMI eXpo in Pittsburgh, attending several classes to broaden his understanding of the spring world.

In his first few months with Western Spring, Haberman has made several improvements, which include robotics, catch and count and heat treat processes, just to name a few.

In his spare time, Haberman provides his engineering knowledge for a family-owned sailing business.

Haberman is also busy with family activities, raising two young children.

In addition, he is an experienced sailor with the White Bear Yacht Club and a Senior Alpine National Ski Patrol, sitting on various boards for both.

Haberman says he’s excited to welcome the spring world into his

many activities and looks forward to the challenges that the industry has to offer.

Founded in 1969, Northeast Carbide celebrated its 50th anniversary in 2019.

Northeast Carbide was established to fulfill the need for precision grinding with a focus on the wireforming and spring manufacturing industries.

Through the use of ID/OD grinding, profile and surface grinding, Northeast Carbide has been able to support these industries with wireforming rolls and turks-head rolls, as well as spring tooling, which is produced under the Spring Manufacturers Supply Company (SMSC) brand.

In its ea rly yea rs, Nort heast Carbide experienced rapid growth and quickly outgrew its original location in Meriden, Connecticut. In 1977, a new facility was built at 525

SPRINGS / Winter 2020 / 7

Global Highlights

West Queen Street in Southington, Connecticut, where the company remains. In 2018, Chris Throwe and Andy Cowell purchased Northeast Carbide and continue to build on the company’s rich history with a focus on investment, modernization and growth.

“Looking to the future, Northeast Carbide and Spring Manufacturers Supply Company will grow its partnerships with industry associations, including SMI, NESMA, CASMI and WAI,” said the company in a news release. “Customers will continue to benefit from Northeast Carbide’s engineering and manufacturing expertise, along with personalized customer service. Northeast Carbide thanks its loyal customers for making this milestone possible.”

For more information about Northeast Carbide, Inc., contact Cowell at 860-621-0118 or smsc@nectools.com.

Applied Manufacturing Technologies (AMT), North America’s largest independent automation engineering company supporting manufacturers, robot companies, systems integrators, line builders, and users of robotic automation worldwide, marked the company’s 30-year anniversary in August 2019.

Founded in 1989 by Michael Jacobs, the company has grown to 130 employees, serving U.S. manufacturers from its Orion, Michigan headquarters. AMT has built a tradition

of excellence in providing customers with engineering and design services, and turnkey automation systems.

Over the past three decades, AMT has built a strong partner and vendor network, and developed a loyal and diverse customer base throughout the U.S. “The past four years working with AMT, more specifically with their Advanced Manufacturing Engineering (AME), have been one of the most rewarding experiences I’ve had partnering with a thirdparty engineering firm,” said Mehrdad Mahmoudi, manager of process/product development at Corning Incorporated.

“The AME team’s expertise in new process development and existing process understanding, combined with their ability to design, build and prototype equipment, allows them to evaluate customer needs and requirements to propose the most appropriate solution, ranging from incremental process improvements and LEAN, up to full automation.”

Early in the company’s history, FANUC became both an important customer as well as a key partner, and recently recognized AMT with an award for outstanding growth in robot sales. “We sincerely value our decades-long relationship with AMT. They are widely recognized in industry for excellence in concepting, simulation, engineering, and execution of advanced robotic automation systems,” said Dick Motley, director of FANUC’s Authorized System Integrator group. “Their contributions have improved manufacturing processes and helped maximize productivity for a wide range of customers. We look forward to supporting AMT’s continued growth and success in delivering highvalue automation solutions.”

Jacobs, AMT president and CEO, remarked, “I am grateful to our loyal customers, dedicated partners, and talented employees for helping AMT reach the 30-year milestone. Much has changed in automation technology since we were founded in 1989, but AMT has stayed at the forefront of the industry, and we are committed to maintaining our status as a leading provider of automation and control system solutions.”

To mark the anniversary, the company hosted a private event for employees and their families at Jimmy John’s Field in Utica, Michigan.

The U.S. Depar tment of Commerce has named Harry Moser, founder and president of the Reshoring Initiative, as a member of its new Investment Advisory Council.

The Council will advise the Secretary of Commerce on how government policies and programs affect the United States’ ability to attract and facilitate business investment.

Commerce Secretary Wilbur Harry Moser Ross said, “The Investment Advisory Council will help us further develop, adapt, and expand policies to help U.S. and

8 / SPRINGS / Winter 2020

Global Highlights

international firms recognize there is no better place to do business, grow, succeed and create jobs.”

The Commerce Department’s SelectUSA has been highly successful in attracting FDI (foreign direct investment) to the U.S. SelectUSA is now also responsible for reshoring by U.S. companies. The Reshoring Initiative tracks and drives both trends, which brought 145,000 manufacturing jobs to the U.S. in 2018 and 757,000 since 2010.

Consistent use of the Total Cost of Ownership Estimator® and the Import Substitution Program by companies and the Competitiveness Toolkit by the government would double or triple the size of the trends. The TCO Estimator helps companies “recognize” the benefit of producing in the U.S. for the U.S. market.

Moser is excited for the opportunity. “I am honored to join this Council of senior executives from the manufacturing and economic development sectors,” he said. “The Reshoring Initiative has been developing and applying tools to accelerate reshoring and FDI for 10 years. We look forward to sharing information and resources with the other Council members and the Commerce Department leadership.”

A 50-year manufacturing industry veteran and retired president of AgieCharmilles, now known as GF Machining Solutions, 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.

Hap Porter, president and chief operating officer of SEI MetalTek, recently announced several personnel changes.

Ted White, Jr. longtime president of Hardware Products, officially retired from the company in September 2019.

White, an honorary SMI member, began working at the company in 1974. White served on the SMI board of directors, along with chairing the SMI magazine and membership committees.

Porter also announced that Bill Lathrop, president of SEI’s Colonial Spring in Bristol, Connecticut, is the new president at Hardware Products. Lathrop has been with SEI MetalTek since 1999, where he was initially hired to run Triple A Spring. After Colonial/Handee Spring merged with Triple A Spring in 2004, Lathrop was tapped to run the combined company that eventually reverted to its Colonial Spring name in 2006.

Lathrop began his career in the spring industry in 1978 with Associated Spring, and later worked for Economy Spring and Connecticut Spring before joining SEI MetalTek. Replacing Lathrop at Colonial Spring is Scott Solomon, a 40-year veteran of the spring industry who has worked for other notable companies, including Associated Spring, Chestnut Group, Inc. and MW Industries. Solomon earned a B.A. degree from the University of Michigan.

Bill Lathrop

Scott Solomon

“I want to thank Ted for his many years of dedicated service to Hardware Products, SMI, NESMA and the spring industry,” said Porter, a former SMI president. “We wish him the best in retirement. I am thrilled that Bill has taken over the day-to-day operations at Hardware Products after so ably running Colonial Spring. With his deep knowledge and experience in the spring industry, we are thrilled to welcome Scott to the SEI team.”

SEI MetalTek is a privately owned, Dallas-based holding company which acquires and operates diversified manufacturing and service businesses in the metal fabrication,

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Global Highlights

processing and testing industries. In addition to Hardware Products and Colonial Spring, SEI MetalTek owns and operates John M. Dean Co. and Spring Engineers of Houston.

International At the recent staging of wire South America and TUBOTECH in Sao Paulo, Brazil, 186 exhibitors presented innovative machinery, equipment and services on 53,800 square feet of exhibit space. About 13,000 trade visitors took part in the trade fairs, with 95 percent traveling from Brazil, 5 percent from regional neighboring countries such as Chile, Colombia, Argentina, Bolivia, Paraguay, Mexico, Peru and Uruguay as well as from India, Canada and China.

Organized by Messe Düsseldorf and Grupo CIPA, the events offered a meeting platform for regional and international industry experts from the wire, cable and pipe industries.

Messe Düsseldorf is renowned as the organizer of the world’s No. 1 trade fairs for the sectors – wire and Tube, held in Düsseldorf, Germany every two years.

The next staging is scheduled for October 2021 in Sao Paulo. For further information about wire South America and TUBOTECH 2021, contact Messe Düsseldorf North America, Telephone: (312) 781-51 80; Email: info@ mdna.com; Visit www.wire-south-america. com, www.tubotech-online.com and www. mdna.com; Follow us on Twitter at http://twitter.com/mdnachicago

Top: Plenum at the 10th international conference of spring industry in Hamburg. Bottom (pictured l-to-r): Tomi Parmasuo, president of the ESF, Tomas Hedenborg, president of Orgalim and Paul-Bernd Vogtland, president of the VDFI (images courtesy of VDFI).

From Sept. 26 to 28, 2019, the international spring industry as well as representatives of the supplier industry met at the 10th International Congress of the Spring Industry in Hamburg, Germany. The congress was arranged by the European Spring Federation (ESF) and organized by the association of the German spring industry, VDFI. The 160 participants came from 24 countries around the globe.

Fifteen exhibitors used the opportunity to enter into a discussion with participants. Tomi Parmasuo, president of the ESF, moderated a tight program of more than 20 talks. As the key speaker, Tomas Hedenborg, president of Orgalim, spoke about EU industry politics 2030. Challenges are global, geopolitical and economic developments, such as global power shifts – China is expected to be the largest economic power in the world by 2050 – and poor trade and low investments because of protectionism. Further challenges are economic and technological development

10 / SPRINGS / Winter 2020

– when it comes to artificial intelligence (AI), the EU is strongly behind – and social and societal developments, including an aging society — in the year 2030, Europe will be the oldest region of the world – and the lack of qualified employees. Climate and environmental threats are also seen to be among the greatest challenges. Goals would be foreseeable here, as well as stable legal framework conditions, in order to lead the European industry to a climate-neutral economy by 2050.

Following this were short talks from the countries of China, the Czech Republic and Slovakia, France, Germany, India, Italy, Japan, from the northern European countries of Denmark, Finland and Sweden, from Poland, South Korea, Spain, Switzerland, Turkey, the U.K. and the U.S. on their respective economic situation in the spring industry.

In the afternoon, Shigeo Aiba, president of Togo Seisakusyo Corp., reported on the international standardization

Global Highlights

Worldwide delegates to the 2019 ISO TC227 meeting.

activities of the ISO/TC 227 “Springs.” Professor Dr. Ulf Kletzin of Technical University Ilmenau presented for the VDFI research projects that have been implemented on the topic of creep and relaxation behavior of spring steel wires in coil springs. Dr. Uwe-Peter Weigmann of WAFIOS AG reported on the industry 4.0 uses in the wire and spring industry. Pablo Capellán presented the metal additive manufacture (3D printing) of optimus3D. Alexander Busse of the research association on automotive engineering, presented on the topic “E-mobility – Quo vadis? Perspectives of future drive systems.” The talks can be download on the homepage of the ESF at https://www.esf-springs.com.

The joint dinner in the building of the town hall, a part of the Hanseatic tradition in the inner city of Hamburg, presented the opportunity to exchange ideas. The conference ended successfully after a harbor tour and lunch in the Elbe Philharmonic Hall.

The next international conference of the spring industry will take place Oct. 7-9, 2021 in Barcelona, Spain.

initial stages of developing a new ISO standard “Springs – Measurement and Test Parameters – Part 2: Cold Formed Cylindrical Helical Extension Springs.” Both projects will be continued at the next ISO/TC227 meeting scheduled for Sept. 17-18, 2020 in Milano, Italy.

Anyone interested in participating in the ISO standards process should contact either Gordon at c.richard.gordon@ gmail.com or Armstrong at toma@dccoil.com. n

Tom Armstrong, chairman of Duer/Carolina Coil, and Richard Gordon, SMI’s technical director, represented the U.S. at the ISO/TC227 Working Group 2, Working Group 3 and the main committee meetings Nov. 14–15, 2019 in Nagoya, Japan. More than 30 representatives and observers from China, France, Germany, Italy, Japan, Malaysia, Thailand, the U.K. and the U.S. participated in the meetings.

Meetings were hosted by the Japanese Spring Manufacturers Association (JSMA) and held at the Castle Plaza hotel.

The U.S. delegation representing the American National Standards Institute (ANSI) is essential to ensuring that the interests of American spring manufacturers, designers, and consumers are represented in international standards development. SMI serves as the technical advisory group to ANSI for TC227. Working Group 2 is in the final stages of developing a new ISO standard “Springs – Measurement and Test Parameters – Part 1: Cold Formed Cylindrical Helical Compression Springs.” Working Group 3 is in the

SPRINGS / Winter 2020 / 11

©iStockphoto.com/Scott Hirko

Regional Spring Association Report NESMA in Review

By Lucas Karabin, Acme Monaco The New Engla nd Spring a nd Metalstamping Association (NESMA) has enjoyed an exciting exit to the decade, with overall group participation in good standing. Our recent success and focus has centered around replacing the “gray wave.” NESMA had started programs in years past, only to find them rudderless from years of dormancy.

Recognizing members’ concerns, NESMA leaders initiated efforts to establish training courses for fourslide setup and spring coiling setup. This began in 2016, with periodic meetings located both at the Bristol Chamber of Commerce and Bristol Technical Educational Center (Bristol TEC).

State educational consultants participated and advised us, while Sharon Lutkus of Naugatuck Community College (NVCC) helped organize evening noncredit courses hosted at Bristol TEC. Naugatuck Community College has proven to be a good partner for NESMA because of its nationallyrecognized manufacturing programs, which have steadily evolved and

Winding class students at Bristol TEC, October 2019

have turned out sought-after talent.

Courses are presently ongoing for our first winding class. Support has been evident among members at all levels.

NESMA president Lynette Nadeau of Southington Tool helped identify state resources, permitting a sizable cost reduction for the course for all eligible companies. The initial class registered 15 students among area member companies. Trainers Craig Chawner and Sal Darragiati of MW Industries put their autumn Tuesday evenings aside to dig through a

rigorous curriculum, fine-tuned by NESMA board members led by John Dellalana, president of Rowley Spring.

Modern equipment was a concern as Bristol TEC’s mechanical coiler had not been used in some time.

NESMA member FENN Torin of East Berlin, Connecticut brought in a new FZ-10, capable of coiling wire sizes between .008–.023 diameter. Ryan Cutter, president of FENN, was prepared to pay for rigging the equipment, but Northeast Riggers of Plainville, Connecticut, regularly called to area continued

SMI Roadshow at Charleston SESMA Meeting The SMI Roadshow came to the Southeastern Spring Manufacturers Association (SESMA) regional meeting Oct. 23–24, 2019 in Charleston, South Carolina. The event started with a dinner on Oct. 23 at Hank’s Seafood in Charleston.

The business meeting on Oct. 24 began with opening greetings by SESMA president Mike Wright of Helix Spring and Manufacturing, followed

12 / SPRINGS / Winter 2020

by presentations from SMI executive director Lynne Carr, SMI technical director Rick Gordon and SMI technical advisor Gary Van Buren.

Additional presentations were made

by David Purcell of WAFIOS on new technology, and Sergio Gallo of InterWire Products, who provided a steel forecast.

Membership dues and articles of incorporation were presented by Carr and Logan Gibbs of Gibbs.

Following lunch, some of the meeting attendees participated in an off-site golf outing at Snee Country Club in Mt. Pleasant, South Carolina, and dinner at Stars Restaurant in Charleston.

There were 14 attendees who participated in the SESMA meeting, representing: Mid-South Wire, Newcomb Spring, Helix Spring & Manufacturing, InterWire, WAFIOS, Gibbs, Diamond Wire and SMI.

Regional Spring Association Report

shops for new and difficult moves, volunteered their services.

Wire was donated by Gibbs, overseen by NESMA board member Jim Mintun, vice president at Gibbs. Spring Makers Tool Boxes were also generously donated to each student by Alan Ortner, president of North American Spring Tool. NESMA looks forward to a December graduation for the class, and to running the class again in 2020.

NESMA was scheduled to start a fourslide training course in January.

This will also be located at Bristol TEC through Naugatuck Valley Community College’s noncredit program. The fourslide course is in its third year, and NESMA has continued to fill the course in its first two years. Fourslide trainer Rick Selander of Plymouth Spring has polished the curriculum over the past two years and is always looking to grow the class and develop excited, resultsdriven graduates. A group tour of local spring manufacturers has been a traditional part of the course, having visited Plymouth Spring and MW Industries in past sessions.

Outside of t hese init iat ives, NESMA’s Technical Development Committee has focused on next generation recruitment and is working through the school systems as a means of advertising our employment opportunities. As committee chairperson, I wanted to extend a special thanks to members of the 2019 NESMA Technical Development Committee: Al Mangels, Andrea Tarantino, Cristina Stisser, Denise Jankowski, Diane Hunter, Jim Mintun, John Dellalana, Lynette Nadeau, Mark Jurczyk, Dee Babkirk and Sharon Lutkus.

Allianz; gold sponsor WAFIOS; silver sponsors Gibbs and Ulbrich; cart sponsor North American Spring Tool; towel sponsor Spring Manufacturing Supply Company; and of course, Mother Nature, sponsor of a beautiful, dry day.

A private course in the hills of Bristol, Chippanee can challenge amateurs and seasoned players alike with its topography. Scott Kirkpatrick, Radcliff

Wire, was at the course bright and early and insisted on showing events committee chairperson Bob Swanson of United Wire how it’s done by leading the charge in setting up our many sponsorship flags. This, all while giving greens advice and the promise that he would be playing in his kilt if the club’s management would just acquiesce to allow dress code provisions for “Scott

NESMA Events NESMA held its annual golf tournament at Chippanee Golf Club Sept.

16, 2019. We were appreciative of the high turnout, for both the tournament and dinner. Our sponsors were overwhelmingly supportive, making this critical fundraiser a success.

Major sponsors included grand sponsor Thomaston Savings; gift sponsor

SPRINGS / Winter 2020 / 13

Regional Spring Association Report

CASMI Report

By Michael Bandy CASMI Co-Executive Director

SpringWorld 2020 “Kickoff” Event

Participants in the 2019 golf outing are pictured (l-to-r): Justin Swanson, United Wire, Rich Rae, ERA Wire, Bob Swanson, United Wire and Jeff Lawrence, Elkem.

to be a Scot.” We hope to repeat our 2019 success again in September 2020.

NESMA held its annual holiday party at the Farmington (Connecticut) Club on Thursday, Dec. 5, 2019.

This fun annual event featured a disc

jockey, prizes and a dance-off among friendly rivals. Toys for Tots received a monetary donation from the holiday party proceeds. For more information, visit www.nesma-usa.com.

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14 / SPRINGS / Winter 2020

On Oct. 17, 2019, the Chicago Association of Spring Manufacturers, Inc. (CASMI) hosted its SpringWorld 2020 Kickoff Dinner at Maggiano’s Little Italy in Schaumburg, Illinois. It was attended by nearly 70 CASMI members, SpringWorld exhibitors and potential exhibitors. This biennial event signals the beginning of the year leading up to SpringWorld, which takes place Oct. 7-9, 2020, at the Rosemont Convention Center in Rosemont, Illinois.

CASMI board and staff members provided an overview of the upcoming trade show, which is already 82 percent sold.

Regional Spring Association Report

In addition to networking, dinner and show announcements, Mike Veeck, visionary and co-founder of Fun Is Good, presented “Creating Joy and Passion in Your Workplace and Career.”

Companies interested in exhibiting at SpringWorld 2020 should contact CASMI at 630-359-4273, or email dbandy@casmi-springworld.org.

CASMI’s Annual Holiday Party CASMI held its Annual Holiday Party Thursday, Dec. 11, 2019, in a private dining room at Cooper’s Hawk in Arlington Heights, Illinois. Members participated in an informal evening of networking and great food. Members and their guests were asked to contribute a $5 donation at the door, with the proceeds to be given to the Mercy Home for Boys and Girls to assist the less fortunate during the holiday season.

Strauss to Headline January Meeting CASMI’s Jan. 15, 2020, Membership Dinner Meeting will feature William A. Strauss, a senior economist and economic advisor in the economic research department at the Federal Reserve Bank of Chicago. His chief responsibilities include analyzing the current performance of the Midwest economy and the manufacturing sector. He produces the monthly Chicago Fed Midwest Manufacturing Index and organizes the Bank’s Economic Outlook Symposium.

Strauss has taught as an adjunct faculty member at Loyola University and Webster University in Chicago. He currently teaches at DePaul University Kellstadt Graduate School of Business and at the University of Chicago Graham School. His research papers include analysis of the manufacturing sector, the Midwest regional economy, the trade-weighted dollar, business cycles and Federal Reserve payments operations.

Strauss is a regular contributor to CASMI events, having provided his

economic outlook for the membership for several years.

CASMI to Host February Event at Manufacturing Technology & Engineering Center CASMI will host a Membership Meeting Thursday, Feb. 20, 2020, at Richard J. Daley College, Manufacturing Technology and Engineering Center (MTEC) in Chicago. This advanced manufacturing training will feature an overview of available programs, tour of the new MTEC facility, and a reception following the program.

The 57,000-square foot facility is equipped to prepare students for careers in engineering and advanced manufacturing, industries that are expected to

bring more than 50,000 jobs to the region over the next 10 years. The new equipment and capabilities at MTEC will enable students to participate in a handson curriculum that prepares them for the technological advancements in the engineering and manufacturing industries.

The facility includes: a manufacturing high bay space, CNC machining equipment and a maker space, classrooms, engineering and manufacturing labs, computer labs and administrative space.

There is a new pedestrian bridge that connects MTEC to the existing Daley College building.

Details on the program are available at www.casmi-springworld.org. n

SPRINGS / Winter 2020 / 15

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Be Aware Safety Tips

Workplace Violence Prevention: Some New Ideas and Resources

By Laura Helmrich-Rhodes, CSP, Ed.D.

©iStockphoto.com/erhui1979

Is OSHA Concerned?

Several spring and wire manufacturer representatives asked me this summer if OSHA is “doing anything with workplace violence?” The answer may be a surprise. Federal OSHA has been addressing workplace violence for decades. I can recall when the famous (“famous” in my world anyway!)

“Recordkeeping Bluebook” (circa late 1980s) required that if someone was in a fist fight at work and broke their glasses, it be considered “recordable.”

Fast forward to today, where workplace violence prevention for health care workers is currently being promulgated. Also, several state-plan OSHAs already have established very specific rules for the prevention of acts of violence, in addition to required action for incidents of workplace bullying and intimidation.

The category of “acts of violence and other injuries” is currently the third-leading cause of fatal occupational injuries in the U.S. According to the Bureau of Labor Statistics (BLS) Census of Fatal Occupational Injuries, of the 5,147 fatal workplace injuries that occurred in the U. S. in 2017, 458 were cases of intentional injury by another person (OSHA, Nov. 2019).

The reality is that those are the cases

we know about. Many injuries due to workplace violence are never reported.

In terms of citations, federal OSHA can cite, and has cited, employers under the General Duty Clause of the Act. This deals with “recognized” hazards.

In other words, if an employer should have taken action to prevent an incident that results in injury or death, they are likely to be cited. Although the focus now is on health care and other highrisk occupations such as night retail, they do have the authority to issue a citation to a general industry employer.

Any injuries, beyond first aid, arising from altercations that occur at work are likely to be OSHA recordable. These

Laura Helmrich-Rhodes, CSP, Ed.D., is an independent regulations compliance consultant to the Spring Manufacturers Institute (SMI). A former member of PA/OSHA Consultation, she is an associate professor in the Safety Sciences Department at Indiana University of Pennsylvania where she teaches graduate and undergraduate classes on topics such as OSHA standards, safety communications, workers’ compensation and human relations. Rhodes is available for safety advice and information. Contact SMI at 630-495-8588 or laurahrhodes@gmail.com.

Many researchers suggest that the investment in employment-based mental health services and in training on crisis intervention and grief management is perhaps more important than simply having a written plan. Identification of employee and manager mental health and substance abuse issues is paramount in preventing known perpetrator violence.

SPRINGS / Winter 2020 / 17

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must be on the OSHA log and have an associated first report (Forms 300 and 301). If your organization is experiencing such events, it is advised that, you must take action to implement a plan of zero tolerance immediately and enforce that policy (see OSHA Enforcement Policy link below).

Employers are urged to make detailed emergency plans for all types of potential events and provide effective training to their workforce. Often overlooked is that portions of those plans need to be highly confidential. In workplace shootings, for example, “the majority of the perpetrators are current or former employees who have access to the buildings, know how to move around them quickly and are familiar with security drills.” For that reason, I suggest that portions of a violence response plan be segmented, and knowledge of certain actions only be known by top, trusted, invested stakeholders.

That idea certainly leads us to the question: “Who is not going to have a mental breakdown within our organization?”

It is nearly impossible to predict; however, many researchers suggest that the investment in employment-based mental health services and in training on crisis intervention and grief management is perhaps more important than simply having a written plan. Identification of employee and manager mental health and substance abuse issues is paramount in preventing known perpetrator violence. In other words, there needs to be a secret plan in addition to the plan shared with the entire company.

Nuts and Bolts of Effective Prevention

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Besides diligent hiring practices, mental health awareness and substance abuse identification, another key protection employers can offer their workers is to establish a zerotolerance policy toward workplace violence. This needs to be in the list of work rules, signed by employees and reviewed annually by supervisors with their teams. This can be a separate workplace violence prevention program, or can be incorporated into your overall safety and health program, employee handbook, or manual of standard operating procedures (OSHA, Nov. 2019).

Most of my clients have an established “visitor policy.”

Obviously, any general liability insurance carrier wants this in place to protect visitors from getting hurt on-site. This assures proper personal protection and keeping visitors away from hazardous work areas. A strict visitor policy can also curb random visits by family members.

The reality is no one knows the domestic troubles employees are suffering through on a daily basis. The Center for Disease Control (CDC) conducted a study in 2015 of “intimate partner stalking and violence.” The findings support the recommendation for an employer to control on-site visitors with a strict policy. Both men and women experience stalking. According to the CDC, most occurrences happen after the age of 25 years old.

Insisting that all visitors enter at a single entry, present positive identification, and be escorted is one effective strategy. Requiring identification of everyone visiting, even government inspectors, is also a must. OSHA actually 15.07.19 16:16

encourages employers to call the local office to confirm an officer’s identification. Furthermore, discussing violence prevention plans with your insurance loss control representative or broker can be beneficial, as they can assist you in assessing premises liability (for example, eliminating roof access and skylight protection) negligent hiring, harassment and discrimination concerns.

During one of our “SMI Summer Roadshows” last year, a member told a story about a homeless man who walked right into the shop, through an open door. This happened twice, the first time to see what was there and the second time to steal what he thought was pure copper (it was copper plated). Surely, there are many stories of unwanted visitors (perhaps a few stray cats or raccoons too?) The point is obvious: Locked doors protect employees from intruders, both known and unknown. Physical risks warrant controls according to OSHA. Specifically, OSHA suggests that by assessing their worksites, employers can identify methods for reducing the likelihood of these types of incidents from occurring. It is unfortunate but a reality that after an incident is not the time to wish action had been taken.

Nearly two million Americans are directly impacted by workplace violence every year. They are bullied, stalked, threatened and, in the most extreme scenario, killed by a disgruntled co-worker, a contractor or even a domestic partner (EHS Today, 2019). OSHA believes that a wellwritten and implemented workplace violence prevention program, combined with engineering controls, administrative controls and training can reduce the incidence of workplace violence (OSHA, Nov. 2019).

The program begins with careful hiring practices, monitoring employee and manager behaviors, a substance abuse program and securing the facility. It doesn’t end there. The program needs attention and continuous improvement, just the same as all product quality and safety programs. Several helpful links are provided below to assist in this effort.

Be sure that all workers know and understand the written policy and comprehend that all claims of workplace violence will be investigated and remedied promptly. n

Employee Training Resources Active Shooter Fact Sheet-Appropriate for employee training https://www.fema.gov/media-library-data/1523561958719-f1eff6bc841d56b7873e018f73a4e024/ActiveShooter_508.pdf Active shooter training video https://youtu.be/5VcSwejU2D0

Sources for Article CDC Survey of Intimate Partner Stalking and Violence (2015) https://www.cdc.gov/violenceprevention/pdf/2015data-brief508.pdf General Liability, Negligent Hiring and Premises Liability Concerns https://www.shrm.org/resourcesandtools/tools-and-samples/ toolkits/pages/workplace-violence-prevention-and-response.aspx Retrieved Nov. 19, 2019 EHS Today Magazine (2019) https://www.ehstoday.com/safety-leadership/ slc-2019-think-and-survive-workplace-violence OSHA Enforcement Policy for Workplace Violence https://www.osha.gov/sites/default/files/enforcement/directives/CPL_0201-058.pdf “Red Flag Behaviors” (Source EHS Today, November 2019) Red flag behaviors include: talking about previous violent acts • depression or withdrawal • increased absenteeism • paranoid thinking • a focus on dangerous weapons • espousing violence on social media

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OSHA Workplace Violence Fact Sheet (Can also be uses as a training handout) https://www.osha.gov/OshDoc/data_General_Facts/factsheet-workplaceviolence.pdf Including employment laws in disaster planning https://www.ehstoday.com/emergency-management/ disaster-planning-should-include-employment-laws

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OSHA’s Workplace Violence Prevention https://www.osha.gov/SLTC/workplaceviolence/

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Dean of Springs

Stress Relaxation and Springs

By Dan Sebastian

I

t is a well-recognized fact in metallurgy that any metal, when subjected Creep Stages to constant stress over long periods of time, will exhibit a phenomenon • Instantaneous: occurs when heat and stress are applied called creep. If you were to tie a load to • Primary creep: starts at a rapid rate and slows with time any metal structure, over time it will get • Secondary creep: has a relatively uniform rate longer. The higher the stress (load) and temperature, the more it will grow. This • Tertiary creep: has an accelerated creep rate and terminates can be seen in its most dramatic fashwhen the material breaks or ruptures. It is associated with ion in the turbine blades of jet engines. both necking and formation of grain boundary voids The blades in the “hot zone” spin at a very high velocity under very high temperatures. Over time, these blades Rupture stretch out and can get large enough to adversely affect the engine operations.

It is believed that a lot of this creep is the result of slippage between the grain Primary ε boundaries. This theory was largely Tertiary confirmed when jet engine manufacSecondary turers developed a process to make a turbine blade out of a single crystal, Instantaneous which greatly extended the life of the blades. The good news is it is predictable and constant, so they are changed t tr on predetermined intervals.

The extensive research into the creep phenomenon has produced some very common characteristics when the material is held at Stress Relaxation in Springs constant temperature and constant stress.

Springmakers must deal with this phenomenon in our own The instantaneous and primary phases are generally special way. Compression, extension and torsion springs believed to be the result of the stress applied and tempera- under constant load will lose their load carrying capability ture, which causes the grain boundaries to align from their (they appear to get weaker). This is very similar to the creep random orientation to an alignment in the direction on the phenomenon, except as the spring loses load, the stress goes applied stress. The temperature provides the energy to the down and the rate of load loss goes down. Predicting the grain boundaries to become more fluid (like oil reducing amount of loss is critical if the spring is going to function as designed over long periods of time. friction forces).

Grain structure in natural state

Grain structure when stress is applied

Dan Sebastian is a former SMI president and currently serves as a technical consultant to the association. He holds a degree in metallurgical engineering from Lehigh University and his industry career spans more than four decades in various technical and management roles. He may be reached by contacting SMI at 630-495-8588.

SPRINGS / Winter 2020 / 21

Relaxation (%)

This is critical in springs used in the hot Time vs. relaxation zone of an engine, pressure relief valves, steam Time in Hrs. valves, oil well blow out protection valves, 0.0% 1 3.5 10 35 100 350 1000 3500 10000 seals and many other applications where the -1.0% spring is under stress for long periods on time.

The SMI “Encyclopedia of Spring Design” and -2.0% other sources provide data on expected load loss for stress and temperatures. This data -3.0% has generally been measured on compres-4.0% sion springs, but stress relaxation occurs in all types of springs (i.e., extension, torsion, -5.0% flat, Belleville, snap rings, garter springs, etc.)

-6.0% Wherever stress and temperature (even ambient) are present, relaxation will occur. At low -7.0% temperatures and moderate to low stresses, relaxation may be minimal, but as stress and temperature increase, the loss and rate of loss % Relaxation will accelerate. The residual stresses present 25.0% can affect the amount and rate of loss.

5°F Like the fatigue data found in most studies, 37 20.0% stress relaxation data is presented based on a standard spring. Much of the data on relaxation was done on compression springs. Like 15.0% engine valve springs, the springs in many test 300°F cases were not subject to residual stress like 10.0% shot peening, heat setting or set-out. Most were stress relieved at temperatures that would 225°F relieve most of the processing stresses. The 5.0% data presented provides an indication of expected relaxation (like fatigue data); to get 0% a very accurate indication of the relaxation for 1 10 100 1000 10000 100000 a specific part, the tests should be conducted with production processed and stressed in application specific conditions. Some compaStress nies will specify a limit to load loss after a set time period. Stress must be above a threshold (dependent on material) to This practice is at best simplistic, as it does not take into cause relaxation to occur. It is also why over time, as relaxconsideration the ongoing rate of load loss (relaxation). ation occurs, the load loss goes down (stress decreases).

One of the most common characteristics of stress relax- Relaxation is like friction, until enough force is applied ation data is that when it is arrayed with load loss on a linear it will not move. scale and time on a logarithmic scale at a specific stress, the data will yield a linear result with a high correlation Material coefficient, indicating very predictable trends. The slope In most materials (especially iron based), the higher the of the line will enable you to make long term predictions. material strength, the greater the resistance to relaxation.

The four dominant variables that effect stress relaxation Some alloys, like high chrome and nickel-based materiare temperature, stress, material selection and heat treat- als, are also more resistant to the relaxation phenomenon. ment. Add these dominant variables to spring processing, which can induce residual stresses that can affect the Heat Treatment amount and rate of relaxation.

The heat treatment applied affects the fundamental mechanical properties of the material. In ferrous based Temperature materials the phase structure is critical.

Like creep, as temperature increases, the fluidity between the grain boundaries increases, which causes slippage Spring Processing when under stress. At low temperatures > 2000F (in carbon In the manufacturing of springs, residual stresses occur steels), the slippage is not measurable. The temperature as a result of forming in the “plastic zone;” in some cases affect is also dependent on the residual stress that may those stresses can enhance performance like: be present.

22 / SPRINGS / Winter 2020

• “Set-out” where the spring is pressed solid when the theoretical stress exceeds the torsional limit.

• Shot peening which can impart compressive residual stresses • Initial Tension in extension springs • Coiling Stresses in torsion springs when the stress is applied in the winding direction In these cases, unless the stress relieving is high enough (materially above the relaxation temperature), the processes will cause more relaxation than the same part after stress relieving to reduce non-beneficial stresses.

The relaxation processes can also be reduced by a process called “heat setting.” Heat setting can be divided into three broad methods.

1. Cold Pressing (Set-out): It has been demonstrated that in some cases pressing a spring to solid can give some reduction in stress relaxation. The corrected stress at solid must be in a limited range to achieve the benefit.

2. Hot Pressing and Releasing: Pressing a spring to solid while at an elevated temperature and then releasing can be of some benefit in controlling stress relaxation. This process results in large variations in results because of control issues.

3. Press and Hold at Elevated Temperature: The temperature, stress, and time held at temperature all have significant effects on the reduction of stress relaxation: • The most significant variable is the time held at temperature. The longer the time held at elevated temperature, the greater the relaxation resistance (this allows the spring to pass through the instantaneous phase and part way and or all of the primary phase).

• A higher the difference between the heat setting temperature and the relaxation test temperature will usually improve stress relaxation results.

• The higher difference between the hold at set stress and the relaxation test temperature will improve stress relaxation results.

• There are some studies that indicate that the cooling method and the control of the cooling temperature can affect stress relaxation results.

Research Study on Valve Springs In the 1970s the Associated Springs Research Center was asked to develop a method to predict the relaxation specification for springs that were used by engine manufacturers, who were being forced to meet demands of engines operating at high temperatures as a result of regulations for emissions. A series of curves that are published in the SMI “Encyclopedia of Spring Design,” Figure S-10-page S-12 (compression, extension, garter and torsion springs) based on the then-industry standard of 100 hours of test at temperature. The data satisfied the industry standard but did not provide the information required to predict longer term effects of stress relaxation.

Most engine applications can see heat exposure between 2500F and 2750F, so a series of tests were performed at 3000F on valve quality plain carbon, Cr-V, & Cr-Si material. The stress levels examined were 60 ksi, 100 ksi and 140 ksi. The test samples were locked at the specific stress (fixed length) and the stress relaxation was measured at predetermined intervals from one hour to 900 hours. Several different processing procedures were tested: • Coiled, stress relieved and grounded • Coiled, stress relieved, grounded and set-out to solid • Coiled, stress relieved, grounded and heat set The spring were heated in oil to maximize the thermal exposure at stress and tested at one, eight and 48 hours.

They were then heated in an air oven and tested at 304 and 900 hours. This was the total exposure time needed to get results in almost three orders of magnitude.

In heat setting, a process was used where springs were heated to 4500F (at temperature for approximately five minutes), then compressed slightly above solid and held for 6 to 10 seconds and quenched with water at ambient temperature. All the springs tested had the same configuration.

The data for the cold pressed springs produced mixed results, because all the springs were manufactured to the same design regardless of the material. Upon further examination of the data, there was a modest improvement in relaxation resistance in cold press springs if the theoretical

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Stress relaxation for 8 hours vs. stress 18.0%

n n n n n n

16.0% 14.0% 12.0% 10.0%

ASTM-A230 as Coiled ASTM-A230 as Heat Set ASTM-A232 as Coiled ASTM-A232 as Heat Set ASTM-A877 as Coiled ASTM-A877 as Heat Set

8.0% 6.0% 4.0% 2.0% 0

60 ksi

100 ksi

140 ksi

stress at solid was in controlled limits. In all the materials tested, the torsional elastic limit was between 50 percent and 55 percent of the theoretical ultimate tensile strength. The improvement in relaxation of cold press springs occurred when the theoretical stress at solid was not greater than 20 percent above the torsional elastic limit.

The material improvement in relaxation resistance that accrued with heat setting can be seen in the graph on the next page.

When the same data was analyzed and then plotted with the relaxation percentage in a linear scale and the time at exposure plotted on a log scale, the results were very dramatic but consistent with the creep phenomenon. The accuracy and consistency, as measured by the multiple correlation confidant, was very high > 90 percent. The heat setting practice enables you to move the part through the instances and into or through the primary creep phases depending on the time exposure at stress and temperature.

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Stress relaxation in % vs Hr. to 10% Loss 12,000

>10,000

n n n n n n

>10,000

10,000 8,000 6,000

ASTM-A230 as Coiled ASTM-A230 as Heat Set ASTM-A232 as Coiled ASTM-A232 as Heat Set ASTM-A877 as Coiled ASTM-A877 as Heat Set

4,000 2,000 —

60 ksi

100 ksi

140 ksi

production demands. Quenching the heat set spring under load appears to maximize the position of the part in the primary creep area. Studies in Germany and Japan strongly suggest that controlling the quenching fluid temperature is critical. It should be noted that in the springs tested with the application anticipated, failure was defined as 10 percent load loss from the original applied stress.

Conclusions Stress relaxation in springs is a phenomenon that causes the original installed load to decrease over time. The process is analogous to the creep process in metals at elevated temperature and high stress. Most studies are based on fixed deflection. Most spring applications have varying stress and temperatures, so in those cases, some recovery can and will occur as compared to the standard test data.

It is important to note that stress relaxation can occur even at ambient temperature in very high stress conditions.

Stress relaxation goes through phases of instantaneous, primary, and secondary stages of load loss.

Stress relaxation loss continues to decrease over time because of the decreasing of the stresses.

Min. Tensile Strength (ksi) Starting Calculating Stress ksi x 1,000

8Hrs. Relaxation

If stress relaxation data is arrayed in a load loss versus log of time it will predict load loss with a high degree of confidence.

Specifications that limit a load loss to a specific amount of time are at best superficial, as they do not account for the continuing load loss nor do they take into consideration the slope of the load loss curve.

There is no substitute for actual application testing, but like fatigue data, the data for stress relaxation can give an indication of expected outcomes.

Spring processing is a critical part of the amount of stress relaxation predictions and must be considered in the overall performance expectation. In general, the higher the stress relieving temperature, the better the relaxation resistance.

Acknowledgements This paper would not have been possible without the support and encouragement of the team at Associated Spring. I would like to individually thank: H. Perry Smith, director of research (retired), Charles Larson, chief metallurgist (retired), and Jason Sicotte, NPD engineering manager. Along with all the technicians and employees who made and tested the springs. n 11

(2,000)

ASTM 230

ASTM 232

ASTM 877

212

235

271

Slope % Load loss/Log(hrs.)

Est. Time for 10% relaxation

Stress as % of min.

Tensile

8Hrs. Relaxation

Slope % Load loss/Log(hrs.)

Est. Time for 10% relaxation

Stress as % of min.

Tensile

8Hrs. Relaxation

Slope % Load loss/Log(hrs.)

Est. Time for 10% relaxation

Stress as % of min.

Tensile

Coiled, Ground, & Stress Relieved

60 100 140 60 100 140

2.03%

0.153

6,006.54

28.3%

0.20%

0.078

13,358.97

25.5%

1.10%

0.045

20,575.56

22.1%

7.71%

0.475

1,282.11

47.2%

3.92%

0.251

3,223.11

42.6%

3.23%

0.175

4,668.57

36.9%

17.44%

0.874

( 51.49)

66.0%

13.12%

0.553

235.08

59.6%

9.89%

0.428

824.77

51.7%

Coiled, Ground, Stress Relieved, &

Heat Set

0.29%

0.053

19,113.21

28.3%

1.81%

0.105

8,600.00

25.5%

1.03%

0.062

15,274.19

22.1%

3.94%

0.331

2,631.42

47.2%

2.72%

0.251

3,701.20

42.6%

1.08%

0.069

13,724.64

36.9%

11.45%

1.104

668.48

66.0%

5.20%

0.464

1,834.05

59.6%

3.20%

0.262

3,396.95

51.7%

Note: 1) Stress Relieving temperature was based on the material 2) The 60 ksi data because of the low relaxation % in early times (< 48 hrs.) was difficult to measure accurately yield multiple correlation coefficient with a median of < 32% the multiple correlation coefficient for 100 & 140 ksi were > 93% 3) Heat Setting was done at a constant height and held for 8 to 12 seconds then quenched under load 4) The est. time to have a relaxation is approx. and any calculation over 10,000 hrs. were reported as > 10,000

SPRINGS / Winter 2020 / 25

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Technically Speaking

Types of Tests Used to Characterize Springmaking Materials — Part 1: The Tensile Test

By C. Richard Gordon

A

s promised in my last Springs column (Fall 2019), this article will discuss one of the basic types of tests used to characterize springmaking materials.

There are several tests which can be used to characterize springmaking materials. This is the first article in a series on the subject. This article includes presentation materials from a Testing and Properties class that I have taught for a number of years for the Wire Association International as part of their Fundamentals of Wire Manufacturing program.

Overview In general, the testing of materials represents an important part of all quality work. It can include the control of: 1) incoming raw materials, 2) materials and/or components in production, and 3) produced materials and/or components before delivery.

Many different techniques are used, including: 1) chemical analysis, 2) microscopy, 3) nondestructive testing, 4) mechanical tests such as tensile strength, hardness, and fatigue and 5) technological tests such as bending, torsion, coiling, wrapping, and weldability.

In this series of articles, I will focus on mechanical and technological tests used to characterize springmaking materials. In this article, we will start with the tensile test.

As springmakers, we specify a wire size (diameter), grade, and tensile strength based on the spring design criteria and applicable specifications/standards. For example, if our spring design calls for the use of 0.080 in. diameter type 1 music spring wire, the ASTM specification A228, Standard Specification for Steel Wire, Music Spring Quality, shows the tensile strength range for this product is 282–312 ksi (1 ksi = 1,000 psi). We rely on our wire supplier to provide that material. We might check the conformance to the specification through a review of the material certification test report. We may do incoming material testing to confirm the test report values or periodically have audit testing done by an outside test laboratory to audit conformance. If we want to measure it, here is how to do it.

Footnote As the SMI technical committee was preparing the two SMI videos, Spring Design 101 – Fundamentals of Spring Making Materials and Spring Design 103 – Overview of

(a)

(b)

(c)

Figure 1 Schematic representation of elastic deformation2: (a) before loading, (b) loaded, and (c) after the load is removed.

Spring Making Materials (posted on the SMI website at www.smihq.org), the group suggested that basic material properties such as tensile strength and modulus of elasticity were the most important properties. How the properties are determined or measured was a subject which should be addressed in a technical article in Springs magazine.

Tensile Test The typical tensile test is a destructive test, in which we apply a pulling or tensile force to a test specimen until it breaks.

It is one of the most fundamental types of mechanical tests that can be performed on the material. It is widely used to provide basic design information on the strength of materials and as an acceptance test for the specification of materials. It

Rick Gordon is the technical director for SMI. He is available to help SMI members and non-members with metallurgical challenges such as fatigue life, corrosion, material and process-related problems. He is also available to help manage and oversee processes related to failure analysis. This includes sourcing reputable testing labs throughout North America, forwarding member requests to the appropriate lab and reporting results and recommendations.

He can be reached at c.richard.gordon@gmail. com or 574-514-9367.

SPRINGS / Winter 2020 / 27

(a)

(b)

(c)

Stress (s)

Figure 2 Schematic representation of plastic deformation2.

is simple, relatively inexpensive and fully standardized. It is used to establish operational load limits of materials. It tells us many things about the material in addition to strength.

In order to understand the tensile test, it is important to understand that metals behave elastically and plastically.

What we mean by elastic deformation is shown schematically in Figure 1. An unloaded sample is shown on the left.

In the center, a load “P” is applied to the sample and this sample extends a certain length, indicated by the small “e.”

When the load is removed, the sample returns to its original length. This is what we mean by elastic deformation.

Plastic or permanent is shown schematically in Figure 2. As in the previous figure, the unloaded sample is shown on the left. In the center, a load “P” is applied to the sample and this sample extends a certain length, indicated by the small “etotal.”

When the load is removed, the sample does not return to its original length but is longer. The increase in length represents the plastic or permanent deformation. The elastic component of the total elongation is also shown. In a spring, this is what is observed as spring back during spring forming.

As stated previously, the tensile test tells us many things about the material in addition to strength. By strength, we are typically referring to tensile strength or ultimate tensile strength. Other information includes yield strength, modulus of elasticity, percent elongation, percent reduction of area, and toughness.

As we begin our study, we need to define several parameters.

• Engineering stress (s) is defined as the force per

Strain (e)

unit area or load (P) in the units of pounds force or kilograms divided by the sample original crosssectional area (Ao) with units square inches or square millimeters.

Figure 3 Engineering stress - strain curve3.

s = P / Ao

• Engineering strain (e), which is equal to the final sample length (lf ) minus the initial sample length (lo) that quantity divided by the original sample length (lo). e = [(lf - lo) / lo]

• Permanent elongation (PE), or elongation after fracture, is the engineering strain expressed as a percentage.

PE (%) = [(lf - lo) / lo] x 100

• Reduction of area (ROA) is one minus the quantity Figure 4 Dimensions for standard round tensile specimen4.

of the final area (Af ) divided by the initial area (Ao), expressed as a percentage.

ROA (%) = (1 – (Af / Ao)) x 100

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Figure 3 shows an engineering stress - strain curve with several parameters defined. The point X identifies where the sample fractured.

Terms shown in the figure are described below.

Young’s modulus, or the modulus of elasticity (E), is the slope of the linear portion of the stress strain curve. Young’s modulus is a mechanical property of linear elastic solid materials. It defines the relationship between stress (force per unit area) and strain (proportional deformation) in a material. For those interested in history, Young’s modulus is named after the 19th-century British scientist Thomas Young.

The proportional limit defines the point where the deformation behavior is no longer linear and the sample begins to deform plastically. The point where linearity ceases can be difficult to determine.

The yield strength is defined as the stress at which plastic deformation starts to occur while the material is loaded. The departure from the linear elastic region can be difficult to detect, and thus the offset method is used to determine the yield strength. An offset is specified as a percent of strain and for many materials 0.2 percent offset is typically used.

The tensile strength is the point of maximum load or stress that the specimen sustains during the test. The ultimate tensile strength may or may not equal the fracture stress.

This all depends on the type of material being tested. That is, whether the material is brittle or ductile. Tensile strength is measured in units of force per unit area. In the SI system, the units are Newtons per square meter (N/m²) (or pascals (Pa)).

The Imperial, or English system, units are pounds-force per square inch (lbf/in² or PSI), however engineers in the U.S. typically use units of ksi, which is a thousand psi.

As the material is stretched during the tensile test, the cross section is reduced uniformly up to the point of maximum stress. This is the referred to as uniform strain. Beyond this point, the stress begins to decrease, and localized necking or reduction in the section diameter is observed. This continues until the sample fractures.

And finally, the total strain to fracture is shown.

Tensile Test Samples For tensile testing, full size may be used or samples can be machined to the dimensions as shown in Figure 4.

A 2-inch (50mm) gauge length is standard and the bar is machined in the parallel section to ½ in. in diameter.

For many wire products, full section testing is done and no machining is required. Straight wire samples are required for tensile testing. For wires produced with a cast, care must be taken to straighten the samples by gentle bending before testing as this can affect such properties as yield strength and elongation.

Representative gripping fixtures for wire products are shown in Figure 5.

Ductility is the ability of the material to deform plastically without fracturing, and is usually measured by elongation or reduction of area in a tensile test5.

Figure 5 Wedge type (left) and snubbing type wraparound grips (right) for wire tensile testing4.

Plasticity is the behavior of materials in the strain region beyond the elastic range.

While there are several measures of plasticity, 0.2 percent offset yield strength is the measure of choice for plasticity because of the relative ease in measuring it.

Tensile Testing Machines There are two types of tensile test machines: electromechanical (screw driven) and servo hydraulic. An electromechanical machine is shown in Figure 6. This machine uses an electric motor, gear reduction system and two screws to move the crosshead up or down. A range of crosshead speeds can be achieved by changing the speed of the motor. Servo hydraulic machines are a cost-effective way of generating high forces.

Different sizes of test machines are available depending on the sample testing needs. A list of equipment suppliers is shown at the end of the article.

Initial Diameter (Do) The initial sample diameter (Do) is an important parameter and is typically measured using a handheld micrometer or laser micrometer. With the handheld micrometer, the maximum and minimum dimensions are measured at a position on the cross section and averaged. With the laser micrometer, typically 32 measurements are made around the wire circumference in order to calculate the average diameter.

Elongation For determining permanent elongation (elongation after fracture) in low carbon steel samples, indentation marks are placed on the sample that correspond to the gage length specified. For high carbon steels, samples are not indented because punch indentations would serve as stress risers and the location for the final fracture but may be marked using non-mechanical means (e.g. paint markers).

SPRINGS / Winter 2020 / 29

Once the tensile test is completed, calipers are used to measure the reduced diameter for reduction of area calculation.

The following example is provided to show the difference in tensile test properties for different grades of material. In this example, 7/16-inch diameter hot rolled wire rods were selected; low carbon (1008) and high carbon (1080V [vanadium]) steel rod samples were tested using a servo hydraulic testing machine with a 120,000 lb. load cell.

Tensile strength data is shown in Table 1.

Remembering the tensile strength is the peak load divided by the original cross-sectional area, the tensile strength of the 1080V material is significantly higher than the 1008.

The reduction of area value is significantly higher for the 1008 steel. Permanent elongation is only determined for the 1008, as punch indentations in high carbon steel would serve as stress risers and location for the final fracture as previously noted.

Data for calculating reduction of area and permanent elongation is shown in Table 2.

The chemical composition for each steel from Table 1 and 2 is shown in Table 3.

Higher strength is primarily a result of steel chemistry: carbon, manganese, silicon and vanadium composition differences (higher composition values result in higher tensile strength values). Differences in the hot rolled rod cooling practices used for each grade also affect tensile strength.

Figure 6 A schematic of an electromechanical tensile machine3.

Table 1 Tensile test data and properties of low and high carbon hot rolled wire rod.

Table 3 Steel chemical composition data.

Grade

1008

Element

Chemical Analysis (wt%)

1080V

Grade

1008

1080V

Size (in.)

7/16

7/16

0.4447

0.4427

C

0.06

0.81

0.1553

0.1539

Mn

0.38

0.67

9051

27194

P

0.008

0.007

Tensile Strength (psi)

58280

176700

S

0.014

0.010

Reduction of Area (%)

77.2

30

Si

0.13

0.23

30

NA

Cu

0.15

0.18

Ni

0.06

0.08

Diameter (in.)

Area - (in.2) Peak Load (lbs.)

Total Elongation (%)

Table 2 Additional tensile test data Grade

1008

1080V

Diameter (in.)

0.4447

0.4427

After Test Diameter (in.)

0.2125

0.371

77.2

30

Pretest Punch Length (in.)

4

NA

Posttest Punch Length (in.)

5.2005

NA

Permanent Elongation (%)

30

NA

Reduction of Area (%)

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Cr

0.04

0.06

Mo

0.017

0.021

Al

0.003

0.003

V

0.002

0.071

N

0.0086

0.0078

B

0.0002

0.0001

Figure 7 Schematics of the clip-on, sensor arm and video extensometers7 stress high carbon steel strongest

medium carbon steel toughest

low carbon steel most ductile

strain

Figure 8 Schematic of tensile test stress – strain data for three materials8.

Toughness 5,6,8 is the ability of the material to absorb energy in the plastic range. For a material to be tough, it must display both strength and ductility. It is the ability of the material to withstand stress above the yield point without fracturing, and is represented by the total area under the stress strain curve up to the point of fracture. Figure 8 shows stress strain data for three materials.

In this example, toughness is highest for the medium carbon steel sample.

Tensile Testing Standards Extensometers In order to determine yielding behavior, extensometers are used. There are two types: contact and noncontact.

Figure 7 shows schematics of two contact and one non-contact extensometers that can be used: clip on the left, sensor arm in the middle and video extensometer on the right. For the most sophisticated applications, a non-contact laser extensometer using the principles of laser interferometry can be used.

Sources of Error in Tensile Testing Sources of error in tensile testing include: extensometer issues, grips, tensile specimens themselves, crosshead separation speed and worn machine components.

• ASTM A370–19: Standard Test Methods and Definitions for Mechanical Testing of Steel Products • ASTM E8/E8M–16a: Standard Test Methods for Tension Testing of Metallic Materials • ASTM E6–15e2: Standard Terminology Relating to Methods of Mechanical Testing • ISO 6892-1: 2016: Metallic Materials—Tensile Testing — Part 1: Method of Test at Room Temperature

For More Information Tensile testing equipment company websites have a wealth of information.

• http://www.ametektest.com/ • http://www.instron.us • https://www.larsonsystems.com/ • http://www.mts.com

• • • •

http://www.ssi.shimadzu.com/ www.starrett.com/springs http://www.tiniusolsen.com/ http://www.zwick.com/

Moving Forward Wire coiling, wrapping and torsion tests are planned for future articles. n

References

1. Gordon, C.R., Ferrous Testing & Properties, Fundamentals of Wire Manufacturing, WAI, Fall 2019.

2. Chandler, H., Metallurgy for the NonMetallurgist, (1998), ASM International, Materials Park, OH. 3. Shemenski R.M., “Fundamentals – Testing & Properties,” WAI, 2004 & 2008 4. ASTM A370-19e1 Standard Test Methods and Definitions for Mechanical Testing of Steel Products.

5. Dieter, G.E., Mechanical Metallurgy, (1976) McGraw-Hill, USA. 6. Callister, W.D. Jr. and Rethwisch, D.G., Fundamentals of Materials Science and Engineering, (3rd Ed.), (2008) John Wiley & Sons, Inc., Hoboken, NJ. 7. Becker, W. and M. Dripke, M., Choosing the Right Extensometer for Every Materials Testing Application, Advanced Materials and Processes, Vol. 169, No. 4, (2011), p.17-21.

8. Sebastian, D., Tensile Strength and Fatigue Life, Springs, Spring 2018, p.

19.

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As springmakers, we are often tasked with providing the most critical moving parts of an assembly, components that actually define the movement, function or capability of the system, yet our components are often the afterthought project. As component engineers and designers, we are regularly responsible for making a system functional after all other components are die cast or molded, with few options for modification to accommodate the physical characteristics of the metal formed part. However, springmakers save the day on a regular basis here in North America. The same is true around the globe. These scenarios seem to be fairly universal, and weâ&#x20AC;&#x2122;ve asked springmakers from around the world to share their stories.

Springmakers Around the World

By Raquel Chole

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Rugócenter Kft Újszilvás, Hungary

Judit Sándorné Graj is the business architect for her family business, and that title should give readers the idea that they have a unique business model for the company. Her parents, Sándor Graj and his wife, Júlia Sándorné Graj, started the business in 1982 as a cooperative (an association of people united to meet a common business outcome through a jointly-owned enterprise) to make agricultural machine components.

In 1997, with a much expanded product line but only six employees, Rugócenter Kft became an independent business entity, owned at first by Judit’s father and run by her mother after his death in 1999. The company currently has 26 employees, including Judit and her sister, Andrea, as well as members of their extended family. It continues to be a matriarchy with Júlia at the helm, flanked by her able daughters. While the administrative side is run by the women of the family, the engineering side is made up of male colleagues.

While over half of their business is still agricultural machine components, the Graj family has made a strong effort to diversify markets with the result a small foray into automotive, appliance and a strong presence in miscellaneous

One of their most memorable applications was in a newspaper advertisement. It used a compression spring that was put between two pages of the Cosmopolitan newspaper in Hungary. When the paper was opened, the spring pushed what is a paper show out at the reader. applications as contrasting as eyeglass springs, bicycles, baby carriages and pruning shears, hearths and shutters.

Júlia hopes their newest market to conquer will be medical; they recently sent samples for trial to a U.S. company.

If approved that, it would expand their markets served as well as their geographic reach.

One of their most memorable applications was in a newspaper advertisement.

It used a compression spring that was put between two pages of the Cosmopolitan newspaper in Hungary. When the paper was opened, the spring pushed a paper show out at the reader.

According to Júlia, parts currently ship to Slovakia, Serbia, Ireland, Germany, Switzerland and Romania.

Within Hungary, they have partner companies that assemble their components into products that ship globally.

Hungary has been part of the European Union (EU) since 2004. One exporting challenge for Rugócenter Kft is that they are required to make customs clearance for their products shipping outside of the EU. Júlia intends to increase their export volume from the current 15 percent by utilizing excess machine capacity. Having the export procedures securely in place will make that increase less challenging from the paperwork standpoint. As Rugócenter Kft increases their exports, the growth is enabled by their current expertise in export documentation.

The Village of Újszilvás is located southeast of Budapest in Central Hungary. It is known for having a culture of local family businesses that have found export success. The village has experienced rapid success and an economic upturn, and was rewarded with a European Village Renewal Award, honoring the town as being a sustainable and holistic village development of excellent quality.

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European Springs & Pressings LTD

Headquarters in Cornwall, Great Britain, U.K. with a global presence In addition to manufacturing for their core automotive and industrial markets, European Springs & Pressing has ended up with a variety of unusual, niche projects over the years, including an installation on the façade of the Tate Modern Museum in London with a spring mechanism serving as an anti-climb zone. A second niche project they did was for Liberty of London, using springs to display fashion products as part of an artistic installation to support beautiful couture accessories in their display windows.

Mike Gibbs is the managing director for European Springs & Pressings in Cornwall. Their latest showpiece project involved the conversion of the 2012 London Olympic Parks Football Stadium into the West Ham Football Club Stadium. When the stadium was sold to West Ham, the football club wanted to hang banners that would protect spectators from the elements and at the same time, display the West Ham logos and team colors.

Brexit, according to Gibbs, has created an uncertainty in the economy that bridges all potential markets. “People aren’t sure if they want to invest in the U.K. There is a lack of confidence and much insecurity. It has resulted in a halt to some investments.”

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The end result was some large tensioning springs used to hang the banners. “We designed them from scratch,” says Gibbs. “We worked with an architecture firm that designs these type of big banner awnings for major installations.”

While these are the sexy spring projects, European Springs & Pressings is heavily involved in the automotive aftermarket for the bread and butter of their operation, with an emphasis on aftermarket suspension springs.

Gibbs notes that, for Europeans, it is a less taxing market to enter, since the European market tends to have lighter vehicles and typically use 14 mm wire for suspension springs; whereas the U.S. market needs to service cars that are weightier and, as a result, demands a meatier suspension spring made from 20 mm wire or better. As a result, the barrier to entry in the U.S. market can be more substantial. The 20 mm wire size requires bigger equipment and heftier wire, resulting in a more significant investment for springmakers eager to enter that supply chain.

For U.K. manufacturers, Brexit (the “B word”) has been a limiting factor in their expansion and sales. Brexit, according to Gibbs, has created an uncertainty in the economy that bridges all potential markets. “People aren’t sure if they want to invest in the U.K. There is a lack of confidence and much insecurity. It has resulted in a halt to some investments.”

Fortunately for European Springs & Pressings, they have a global presence, which has resulted in more stability for their business. “We’re all over the world,” explains Gibbs. “We are a global group with a local supply.

Brexit will not have the same impact on us as it might have on a springmaker with just a U.K. location. Our locations service the region where they

are located, so the location in Cornwall serves southwestern England; the India location serves customers based in that region.”

“For the U.K. locations, if they put a taxation or impose red tape on goods crossing the border into Europe, that could have an impact. For example, as OEMs decide where they will build the next Mini or Nissan vehicle, they have to consider Brexit and how that may impact their cost structure or their ability to import components and export vehicles going forward,” says Gibbs.

“There is no upside to Brexit in the short term,” laments Gibbs. “Maybe in the long term — five to 10 years from now. On the bright side, though, we have a broad portfolio. We’re in everything: trains, medical and aerospace, which protects us from a downturn in any specific market.

“We are able to make prototypes, which often leads to production jobs.

In addition, we have a catalog business. While the goal is to supply small volume parts without needing to provide engineered products at this level, a definite benefit is that we can often supply a catalog part an engineer can use in testing, and that relationship often leads to a longterm role in supplying high-volume parts once the product design is perfected,” explains Gibbs. The catalog has two versions: an online edition as well as a paper edition. “People may only need one or two pieces of a component to experiment with. Later that can lead to a production project and we’re here to help with that.” Clearly proud of the efficiency, Gibbs notes that the European Springs & Pressings catalog is quite extensive; however, they pride themselves on being able to deliver parts in 24 hours, even though not all parts are “on the shelf.”

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Lee Spring

Headquarters in Brooklyn, New York with a global presence Steve Kempf is the dynamic CEO of Lee Spring. Based in Brooklyn, they have manufacturing and distribution outlets around the globe. Since the early 1960s, they had a distribution facility in the U.K., serving the European market. Twenty years ago, they opened a manufacturing operation in Mexico, and the past 15 years have seen their manufacturing expand into Suzhou, China, and more recently Tianjin, China, Bengaluru, India and their distribution extends to a facility in Germany, bringing their total to seven U.S. locations and seven global locations.

All of these were “greenfield” developments rather than acquisitions, and all were established at the behest of a single or small handful of large customers needing a trusted vendor in that location.

“We are very broadbased,” says Kempf. Lee Spring parts are in exercise equipment and consumer products among others. They are not heavy in

36 / SPRINGS / Winter 2020

any particular industry — ­ diversified to the point that no single industry approaches 10 percent of their revenue.

In terms of specialties, Lee Spring positions itself to be more on the product development and engineering side, according to Kempf. “A high percentage of our people are engineers, and we work with customers at an early stage to develop parts and stick with them through the production process. We are on the R&D and product development side to ensure form, fit, function and manufacturability. But that does mean that we might do 50 R&D projects for the single one that becomes a big runner,” says Kempf. “Although it’s true that 49 of the orders die on the vine, our ultimate goal is that one long runner. As a result, in terms of projects, we do more short runs than long, but in machine hours, the long runs take the most machine time.”

In answer to a customer need, Lee Spring developed a plastic composite

spring that is formed by injection molding.

While it will not replace metal springs by any means, plastic can be very useful in an environment that relies on nonmetallic components. The cost of making an injection mold versus coiling is prohibitive, unless it is for a certain niche where metal does not serve the process well. “It’s a great solution for some customers,” says Kempf. “For the customers we serve, it helped them eliminate all metal elements from their product.”

Examples of uses for this type of spring would include in MRI machines, where metal would interfere with the MRI functionality, and underwater tsunami detection equipment, for which anticorrosion materials are critical. “This product has found a home and a loyal following with anyone able to use it,” says Kempf.

With regard to the global growth and expansion of Lee Spring at a time when other springmakers were sticking to a domestic strategy for the most part,

Kempf says: “We are pretty proud of our global strategy and our ability to serve our customers in the four corners of the world.

“The most important thing about domestic or international springmaking is the people,” says Kempf, “getting people to build and manage these facilities who are high quality and trustworthy.”

Kempf explains how having trusted partners on the ground is significant: “Having a physical presence tomorrow in China is not possible. For us, using locals in all locations is best; however, we do frequent visits by (people from) our New York headquarters to help with best practices. We send operations and engineering teams from our headquarters to ensure best practices across the businesses, but we do sales locally since each plant serves a local market.” Kempf’s vision is that each location can come up with good solutions and share these, feeling that the true return on investment comes with developing regional customers.

“We view ourselves as problem solvers for customers no matter what their spring problem is, so we are not constrained in our approach. We will solve their problems,” says Kempf. “Ninety percent of our sales force started as engineers, which means they are able to work directly with our customers to engineer solutions.”

What is next on the horizon? Kempf says it will be “wherever good people will lead us.” The Longcraft Engineering facility in England was an acquisition and Lee Spring’s newest addition to the company profile. “We had already partnered with them for years as a supplier to our U.K. customers. We found we really enjoyed working with each other, in part because they complement our product lines and capabilities so well,” says Kempf. The Longcraft team has some additional capability in forming flat materials. Recognizing their deeper experience in this area, Kempf has a team of people over there

right now to learn from Longcraft’s best practices in forming, as well as to learn about how they have been able to tool up for short runs. Kempf wants to understand the acumen in tooling and die knowledge that allows Longcraft to make short runs to modest quantities of high quality parts with complex cuts and shapes.

Kempf enjoys the universality of solutions presented by a well-crafted component, and he talks with pride about how the functionality of a part can impact our days in a positive, helpful way: “I rode my bike in to work today and it has two springs under the seat to keep my ride smooth. The electric toothbrush my wife brushed with last night also has our parts in it,” he explains. “We’re in some really popular Pilates exercise equipment, Crayola marker paint tips and an airplane seat.

We impact people’s lives and comfort every day.”

Hagens Spring Group Støvring, Denmark

Henrik Hagens is CEO of Hagens Spring Group, the third generation to lead the company since his grandfather founded it in 1945. It all started because his grandfather was a natural entrepreneur and could sense a good business option when it presented itself. When someone asked him to figure out how to make some springs, he was hooked and began his new business, which at that time was called Hagens Fjedre A/S. Later his son took over and now his grandson, Henrik, is at the helm.

Hagens Spring Group expanded into China in 2011 and recently purchased a metalforming spring company in Sweden. They serve almost all markets, focused on medium to large volume projects. Agriculture was the primary market in the early days, since that was a fundamental market in that part of the world then, a common need critical to the countries that now form the EU in the early days after World War II. Now

SPRINGS / Winter 2020 / 37

38 / SPRINGS / Winter 2020

they have expanded to include automotive, food handling, medical, valve pump components, home and garden, and rail.

With that breadth of markets, it is no surprise that their wire size ranges from .2mm to 22mm in diameter. The company’s high volume parts include springs for medical devices and the medium volume is typically parts made from heavy duty wire.

“The customer drives the markets we enter,” Hagens explained, regarding the Hagens Spring Group’s position in servicing clients. “We first supplied automotive when we bought a company in Sweden. We want to grow globally in different segments because our company is stronger when we are diverse.”

Hagens Spring Groups exports mostly to Western and Eastern Europe from the Scandinavian locations and services Asian countries from China.

Their exports to the U.S. and Mexico are minor at this stage, and any dealings tend to be at the first or second tier of the supply chain for customers dealing with companies in North America.

“The business world is more and more global thinking. The differences in doing business will be fewer in the future because the trend is that there are similar ways of acting and thinking that are making most companies act in terms of global concepts,” explains Hagens.

“Even in a global economy, the relationships between people are always key.”

For the future, being a family company in the third generation portends good opportunities for growth. According to Hagens, that’s because the history of the company affords the players a level of competence gained by growing up in the business and a set of shared values passed on from generation to generation. “Our challenge now is to grow. You must be able to grow in the loop, dependent on the family’s ability to sustain the business, without an outside investor.”

Hagens sees it as his responsibility to gain a profitable position in the marketplace that is controlled and focused.

“Some companies can grow readily through investors. We need to grow through earnings within our current business,” says Hagens.

“I want the company to grow, and as long as I have some years ahead of me I still have some time to think about this, so I don’t need to find an immediate succession solution,” he explains.

Hagens is the only family member currently involved in the business and says it’s too early to determine if his children will be interested in carrying the standard forward because they are still getting their education.

“I think the values our customers treasure key in on quality, reliability and the way we service them,” explained Hagens of the company’s success through the years as a supplier. “When we make an agreement, we stick to it. We want long lasting cooperation, and that is why customers stay with us for many years.

Open communication is key to this.

“My father and grandfather had the same values. I adopted them from my father, and he got them from his father; however, each generation tries to do it better than the one before. At the deepest level, these values go back to the foundation of the company,” concludes Hagens.

working with customers routinely to increase cycle life.

The company began 68 years ago when it was founded by Thomas Marsh. McJannett describes him as a bit of a tinkerer: “He worked on mechanizing things, and he grew the business over a number of years. We still have some of the wireforming machines he created. Some machines that we still use from his early efforts are to make sinuous springs for furniture.” Called “bow” springs Down Under, these components are about 1.5 feet long and can be made on the equipment Marsh designed

at a rate of 12 pieces per minute. Around 30 years ago, Marsh’s son took over the business. He recently put the company under new management, which is how McJannett entered the business. Like most Australian springmakers, he came at it as an outsider, since metalforming is not a ubiquitous career option in that region of the world. He is enjoying the challenges that come with his move to springmaking.

“What makes our business successful is that we’re able to work very closely with our customers. Working with them to help with design develops a stickiness

“The differences in doing business will be fewer in the future because the trend is that there are similar ways of acting and thinking that are making most companies act in terms of global concepts,” explains Hagens.

“Even in a global economy, the relationships between people are always key.”

Marsh Spring

Brisbane, Queensland, Australia Adam McJannett is the general manager of Marsh Springs. The nature of being a springmaker in Australia is that the country is simply not a big market, due to the nature of manufacturing in general there — mostly small volume since the population of the country is fairly small (25 million people). Because the market is small, they have a broad depth of products to sustain business. A large percentage of their business is garage door springs. Beyond that, they make water pump components, and some automotive parts in addition to serving a variety of miscellaneous markets,

SPRINGS / Winter 2020 / 39

“During the high season, we’d run those machines 24/7,” says McJannett. At some point their volumes started to erode, and practically overnight nearly all the production of that product moved to Asia. The asset is that they now recognize the early warning signs of such an exodus and will work very hard to ensure they are not caught by surprise by something like this in the future.

40 / SPRINGS / Winter 2020

for that customer to stay with us,” explains McJannett.

For Marsh Springs, there have been some pivotal changes in their product mix that have shaped the markets they currently serve. Years ago, they made millions of trampoline springs. “During the high season, we’d run those machines 24/7,” says McJannett. At some point their volumes started to erode, and practically overnight nearly all the production of that product moved to Asia. The asset is that they now recognize the early warning signs of such an exodus and will work very hard to ensure they are not caught by surprise by something like this in the future. “We still supply Olympic-standard trampoline parts, but that volume is nothing like the volume we experienced making ordinary trampoline springs for recreational use. On the positive side, adding garage door springs has provided major growth for Marsh.”

It is noteworthy that the two major markets McJannett describes are for highrisk applications. They manage this risk by ensuring a robust quality system that has rarely delivered product with issues to customers.

The automotive market looks very different in Australia to what North American suppliers expect to see in their region. Marsh makes some components that go into Ford F250s in the U.S.. They also make a formed strip component that goes into an automotive mirror. “We also export to Thailand because our competitor could not bend the legs on a spring in one shot,” says McJannett. “We’ve got some really good people who can come up with ways to make things.” At the end of the day, though, automotive is all but gone in Australia. The last automakers are closing up shop, according to McJannett. The challenge for the Marsh team is to move on from that, find its new market niche and create other revenue streams. “We brought in a dip spin painting plant to provide additional services and we constantly ask the questions: ‘What other services can we offer? How can we add more value?’”

“Realistically, we can’t compete for the business of a client that needs 5 million pieces in ‘X’ amount of time with a part that doesn’t change.” Getting material quickly to produce mega quantities is a challenge, and it is tough to compete simply on the basis

of price with nearby Asia on parts that are strictly high-volume runs sans design input.

There is a mill in Australia, and Marsh relies on them for a variety of materials.

“They get rod and draw it down to supply us,” says McJannett. For more specialized material, they look to Kiswire and DSR in Korea and some others, citing the care these suppliers take with the raw material to produce high quality wire as being a strong asset for forming high quality componentry.

One outcome of the trade situation between the U.S. and other countries has been an uptick in business to serve tariffimpacted areas, since Australia has been kept out of that fray.

While the U.S. is experiencing issues with finding qualified labor, in Australia the labor pool is much smaller, and there are very few manufacturers and even fewer spring companies. As a result, everyone McJannett hires is new to springmaking, so there is a steep learning curve for new employees. There used to be a lot of smaller players, but over the years they’ve been acquired or closed up shop. Besides Marsh, there is no springmaker of any impactful size in Brisbane. “We’ve done five acquisitions over the past few years. Part of it is that these companies go up for sale. If you don’t know springs you are not going to buy a spring business, so that has enabled us to grow,” says McJannett. “It’s part of our strategy for having a profitable, diversified, well-run business.”

The common thread for all these springmakers operating around the world is building a business based on their ability to service customers from concept to production, solving problems, discovering innovations. In every case, this has led to long term supplier/ customer relationships that have a strong foundation in the engineering process, from inception and continual improvement to processes and component functionality, that have fostered customer loyalty based on high levels of focused service on the part of these springmakers. n Raquel Chole is a frequent contributor to Springs magazine, with 23 years of experience in the industry spent in the U.S., Mexico and China. As someone who loves a good spring application, she was charmed by this not-to-be-missed page of clever uses by the http://www.rugocenter.hu/ index.php/en/spring-magic. Be sure to check it out.

ŠiStockphoto.com/naruedom

Why Springmakers Should Consider Expanding Operations to Mexico

By Jim Tomei

I

n January 2016, the Swedish-based spring wire manufacturer Suzuki Garphyttan officially kicked off their Mexico expansion project. For the eight months preceding, we had been traveling to various states within Mexico, speaking with local government officials, investigating more than 35 potential industrial sites and building the case for expansion with the board of directors in Japan. This was the culmination of 18 months of prework aimed at lowering the transportation costs of wire shipped to multiple spring companies in Mexico.

We obtained valuable advice from springmakers already located in Mexico, especially from SMI member Thomas Pimmler and his staff in Aguascalientes, Mexico. Since the majority of our customers were centered around the

Queretaro and Guanajuato states, and it was easy air travel direct from Texas to these locations, one of our first team trips was to the city of Queretaro, Mexico. It was not what we expected: The cities and locations were beautiful, growing and investing their new wealth, every major manufacturer of products in the world was here in new production facilities, and the climate was perfectly suited to year-round manufacturing with few extremes in temperature.

Finding the right place for your business in Mexico is critical. You need access to a good workforce, but in the best areas the land is more expensive, and the employee turnover can be high because of hiring competition. We found the best way to avoid these problems was to locate a minimal distance away from the major cities. Most of the foreign

SPRINGS / Winter 2020 / 41

companies build in an industrial park rather than along a building a family-like culture is the goal. The workers are street. This arrangement gives the security of reliable power unionized, but you can pick the union you want early in the and water, and there are numerous new industrial parks process and they are extremely easy to work with, primarily opening all the time. The real estate appreciates rapidly. In concerned with making sure everyone is treated according the two years since negotiations took place, the price we to the law. Most of the springmakers I spoke to in Mexico paid for the land in our park rose by 58 percent. There is lamented that good setup men were difficult to find, as they an abundance of investment money, so leasing are here in the U.S., so they would often bring is a good option if you want to lower capital people from their home companies to work for extended contracts. investments.

All the local One of the most difficult things we New growth has slowed slightly this encountered was importing our raw year as investors are more cautious governments offer incenon world trade, but that has led to material. Finding the right logistics tives to entice you to locate better deals for land. All the local partner is critical for getting the to their state. These incentives governments offer incentives to proper tariff codes, or you end up paying high, unreimbursed entice you to locate to their state. depend upon the size of the planned costs. Luckily there is a lot of These incentives depend upon workforce, but generally they offer the size of the planned workforce, steel going both ways across the reimbursement for employee but generally they offer reimburseborder so there are many people to ment for employee training and help direct you to the right compatraining and limited reimlimited reimbursement for capital nies. There is a value added tax of 16 bursement for capital investments. percent (recently lowered by half for investments.

Safety, of course, is everyoneâ&#x20AC;&#x2122;s first the border states to stimulate growth) that question. As it turns out there is ample you must pay for all your imports; however this is eventually returned when offset with the online information to determine the least secure areas, which tend to be near the borders where the cartels tax applied on sales. You can avoid this cash flow issue by are prevalent. The three states of Guanajuato, Aguascali- importing under the IMMEX program for foreign entities, entes, and Queretaro were high on our list because of their but this requires extensive inventory control systems if you safety record and the abundance of springmakers. Quere- are unsure where the springs will end up. taro boasts the lowest crime rate in Mexico, and up to 50,000 A final unexpected benefit to springmakers is the chance people move there each year for the access to jobs, security to expand their sales markets. The density of worldwide for the family, and good schools. The main city of Santiago companies in this area is outstanding, and many of these de Queretaro has a population of around 1 million. I can companies use springs in their products. You can meet confirm that numerous times while walking alone through people from all these companies in your industrial park the downtown streets of Queretaro, after a late dinner, I felt and in the ex-pat social clubs, so the networking opporsafer than I do in many American cities. tunities are numerous. And the advantage of lower labor Two of the main unexpected advantages of opening in costs, combined with new equipment, allows for aggressive Mexico are the work ethic and technical ability of the work- pricing when bidding for new jobs. force. Understandably the labor is cheaper than here; we One year after our grand opening celebration in April discovered that when you added in benefits and offered 2017, Suzuki Garphyttan Mexico was operating at full higher pay to attract more technical people, our total labor planned production levels and investing for additional costs were about 40 percent lower than the U.S. What you growth. I personally spent over three-and-a-half years either get for that is remarkable. Most of the employees have trade in travel or full-time work in Mexico, and I enthusiastically school experience and often are educated in lean manufac- recommend this as a viable option to anyone in our industry turing principles and ISO and IATF quality systems. We looking to expand operations. n sent our lead operators around the world to train at our other sites, and every other site manager commented on Jim Tomei is currently working as a consultant how impressed they were with our team. in the spring wire industry. His most recent Every U.S. company manager that I met while in Mexico, position was a two year contract to build and startup a state-of-the-art valve quality wire from a variety of manufacturing industries, mentioned that plant in Mexico for springs. Tomei has over they were happy to get employees without drug problems 28 years of experience in the wire industry (as that is a big issue in some regions) who were reliable including as general manager of production every day. You have to be alert to keep these employees; facilities in the steel wire, and stainless and with large companies from all over the world, there are a nickel aerospace markets. Tomei holds a masterâ&#x20AC;&#x2122;s degree in metallurgical engineering from lot of opportunities for good people to leave. However, we the University of Illinois at Chicago. He can be found that many want to be involved with a startup and reached at jamesgt12@gmail.com. help develop a company that will last for generations, so

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Exports a Significant Opportunity for Manufacturers

M

anufacturing and supply chain expert Lisa Anderson, president of LMA Consulting Group Inc., sees exports as a significant opportunity for manufacturers to grow and future proof their business.

“As manufacturers work on customizing products and meeting ever-changing delivery expectations, it’s equally important to consider where the customer is located, and their drivers. In today’s manufacturing world, exports are a significant opportunity for manufacturers to grow and diversify their business. In fact, statistics show that 95 percent of consumers are outside of the United States, and most countries see U.S. exports as highly desirable. That’s staggering and significant,” Anderson commented in a recent news release.

LMA Consulting Group works with manufacturers and distributors on strategy and end-to-end supply chain transformation to maximize the customer experience and enable profitable, scalable, dramatic business growth.

Culture, the end user, product use, legal requirements and other factors vary from country to country. These and other aspects must be considered to ensure a resilient supply chain.

“There is tremendous opportunity to continue to expand beyond our borders. But that means that not only must sales, operations, new product development and finance be on the same page, but also international partners and advisors. And the end goal must be the same: to maximize the customer experience in the most efficient and effective manner for growth, scale and profits,” Anderson said.

Manufacturers contributed $2.38 trillion to the U.S. economy. The National Association for Manufacturers reports that for every $1 spent in manufacturing, another $1.82 is added.

“Despite reports to the contrary, manufacturing is growing and is significant. U.S. manufacturing alone would be the eighth largest economy in the world,” Anderson adds.

Over the past 28 years, U.S.-manufactured goods exports have quadrupled. Over the next decade, 4.6 million manufacturing jobs will be needed. Latest statistics show that in 2017, the 249,962 manufacturers in the U.S. accounted for $2,244.3 billion (11.6 percent) of the total U.S. output and employed 8.5 percent of the U.S. workforce.

“Despite what people hear about robotics and artificial intelligence (AI) taking over manufacturing jobs, manufacturers will continue to be a key employer. The jobs may change, but the need for talent will not,” Anderson said. n

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International Spring Industry Presents a Mixed Picture

If you want to know what’s going on in the international spring industry, there’s no better place to learn than the International Congress of Spring Industry. The 10th gathering of the group took place in Hamburg, Germany from Sept. 26–28, 2019.

The Congress brought together 160 participants from 24 countries from around the globe.

The event took place under the auspices of the European Spring Federation (ESF) and was organized by the association for the German spring industry, Verband der Federmindustrie (VDFI).

One of the main challenges in the Nordic countries is the lack of skilled labor

Political instability remains a challenge in Italy, with 11 governments in 20 years.

China: the spring industry's overall growth rate is about 7 percent

India has a young and trained workforce with an average age of 29 years

South Africa: the spring industry is at low of ±50% of capacity due to a very subdued economy. ©iStockphoto.com/Anson_iStock

44 / SPRINGS / Winter 2020

Representatives from several countries made presentations about the economic climate of the spring industry in their region. SMI president Steve Kempf presented on the state of the U.S. spring industry.

Here are some of the highlights of the presentations.

China Angelo Zheng represented the China Spring Specialty Association (CSSA).

Zheng is the general manager of Yangzhou Donva Hardware Spring Co. Ltd. He said the overall spring industry represents customers in more than 10,000 industries and about 200,000 people. Zheng said there are 205 CSSA members and the industryâ&#x20AC;&#x2122;s overall growth rate is around 7 percent.

He said 80 percent of the spring industry is located in economically

The greatest challenge for the spring industry in Japan is business succession

developed coastal areas including the cities of Zhuji, Wenzhou and Dongguan.

Zheng explained that the main markets where springs are being supplied include automobile manufacturing, motorcycle manufacturing and the maintenance market. He predicted future growth in the railway system (high-speed and city metro trains), construction machinery, nuclear power, wind power, aerospace, ships, military, medical equipment, instrumentation and electronic products.

The Czech Republic and Slovakia There are eight companies who belong to the Czech and Slovak spring association. The Czech Republic totals 20 spring companies.

The Czech and Slovak spring industry has a long tradition in production and technological processes. The majority of association members are small and midsize companies. Companies who are not part of the association represent those who produce hot formed springs and foreign capital companies.

The outlook for the Czech and Slovak spring industry for the first nine months of 2019 was for a slowdown and a decline, due to problems in the automotive industry. In addition

to automotive industry concerns, it was reported that other challenges for the near future in the Czech and Slovak spring industry include finding enough people/skilled workers, the level of automatization and the globalization of business.

France Representing 200 member companies, FIM Ressorts is the French federation of spring manufacturers. The spring industry in France has had an average annual growth over the past eight years of around 3 percent. The association reports that growth has slowed down after an exceptional year in 2017 of around 13 percent growth. The latest report from 2018 showed a more normal growth rate of 4.4 percent.

Overall, the spring industry has performed better than the general French industry since 2011. In particular, FIM Ressorts reports that the spring industry has done even better than the French automotive industry.

French gross domestic product growth is expected to reach 1.3 percent in 2019 and 2020. For spring manufacturers, sales growth was expected to be from 0 to 2 percent, with a note of caution for the last quarter of 2019 and for 2020.

FIM Ressorts notes there are many remaining headwinds, including the automotive industry undergoing a revolution with engine electrification; uncertainties and instability around Brexit; trade tensions between the U.S. and China and the probability of tensions coming later between the U.S. and the European Union; tensions over raw materials (nickel prices have grown by 50 percent from June); and geopolitical tensions in Persian Gulf with its potential impact on oil prices.

Germany Presenting on the â&#x20AC;&#x153;Economic Situation of the Spring Industry in Germanyâ&#x20AC;? was Paul-Bernd Vogtland, chairman of the managing board of the VDFI and an executive partner in the VDF Federn

SPRINGS / Winter 2020 / 45

Group. “The current general production environment and forecast looks rather cloudy,” declared Vogtland.

He said the future expectations in business are similar to the beginning of the economic crisis in 2008-2009.

Vogtland said the origin of the recession/crisis is different this time. “The weak demand in the automotive industry will take approximately three years.” Vogtland said the members of the VDFI have bad expectations for the near future.

He said a big challenge ahead is an effort to adjust costs to declining business prospects and to do it quickly.

“How fast can so-called ‘fixed costs’ be reduced so that they are no longer fixed?” he said. “How can inventories be quickly reduced? Productivity usually falls in this situation, so how can skilled workers be held?”

Vogtland said liquidity becomes crucial.

“Although there has been a significant drop in orders, material prices have changed little,” he explained.

“Many hope that prices will fall even more sharply due to lower demand.”

In terms of the labor market in Germany, Vogtland said the cost of one hour’s work is still rising. “This is due to increases through (labor) negotiations, but also due to increases in non-wage labor costs.” He said the economic downturn tends to calm the labor market.

Vogtland said the biggest market for springs is the automotive sector at 50 percent, followed by machine building at 25 percent and the electrical/ electronics market at 20 percent.

He said the biggest trade barriers include the current trade war and the related punitive custom tariffs.

India A look at the spring industry in India was provided by the Indian Spring Manufacturers Association (ISMA).

ISMA was formed in Jan. 2019 and has already grown to 50 members.

ISMA reports that India has a young and trained workforce with an average age of 29 years. They also report that 95 percent of the Indian spring companies are family owned and that the majority of the companies are exporting worldwide. “The Indian spring manufacturing industry offers a great opportunity for contract manufacturing and collaborating,” said ISMA in its report.

Current challenges included a slowdown in automotive demand, higher interest rates, increased manufacturing costs, standardization of tolerances and a constant fluctuation of demand and changing schedules.

It was noted by ISMA that India is the fourth largest automotive economy in the world with exports of 14.2 percent. In addition, India is the third largest electricity producer.

Italy Francesco Silvestri is the director of ANCCEM, the spring industry association in Italy. He said current short-term challenges are driven by political instability, both in Europe due to elections and Brexit, and in disputes between the U.S. and the rest of the world. Silvestri said mid- and long-term effects are more focused on

Remaining headwinds [affecting France are] the automotive industry undergoing a revolution with engine electrification; uncertainties and instability around Brexit; trade tensions between the U.S. and China and the probability of tensions coming later between the U.S. and the European Union; tensions over raw materials (nickel prices have grown by 50 percent from June); and geopolitical tensions in Persian Gulf with its potential impact on oil prices.

46 / SPRINGS / Winter 2020

innovations in the automotive sector, including new mobility technology and electric vehicles.

In terms of the spring industry in Italy, the 2018 market showed good growth over 2017 at an increase of 4 percent. Silvestri said the first part of 2019 was headed toward a decrease, especially for those who are linked to the automotive sector.

Overall, Silvestri said the Italian economy is showing a slight decrease in GDP, which is line with the rest of the EU. He said Italy still faces a lot of political instability. “Unfortunately, this is going to be a habit, considering that in the last 20 years we have had 11 different governments.”

Silvestri said the next elections are in 2022 and that there is some uncertainty regarding the populist parties who won the previous elections, and whether they will continue to prevail. “This situation (instability) still impacts on economical and industrial politics, leaving industries in an unstable environment.”

Japan The Japan Spring Manufacturers Association (JSMA) has 214 regular members, which are defined as metal spring manufacturers with manufacturing operations in Japan. The association also has 38 associate members.

Japan has a projected GDP growth of 0.9 percent for 2019, compared to a world output of 3.2 percent. The greatest challenge for the spring industry in Japan is business succession. The number of spring companies has gone from 672 to in 2007 to 524 in 2016.

Spring products manufactured in Japan in terms of sales is led by flat springs at 45 percent, wire springs at 33 percent, torsion, coil and leaf springs all at 7 percent and washer springs at 1 percent.

Nordic Countries A consolidated report of the Nordic region was presented that included the countries of Denmark, Finland and Sweden. The market situation is stable in those countries, while order flow is still good. Economic forecasts

are slightly pessimistic, primarily because customers are cautious due to a possible slow down.

Like other regions, one of the main challenges is a lack of skilled labor.

There are also challenges due to pressure from customers to cut costs and extend longer payment terms.

Risks cited included political ones from the trade war between the U.S. and China, Brexit and local politics.

Another risk is in the automotive market due to technology. Raw material prices and the availability of materials continue to be a challenge due to prices being at a high level.

“The challenges are to work as lean and efficient as possible. The opportunities are few, beside looking for more efficiencies in production and personnel.”

Poland

Spain

Poland has no spring association, so data is hard to gather, according to a report presented by Metapol Sp. The number of spring manufacturers in the country is estimated at 20 that are described as mainly small- to mediumsize companies.

The current economic situation in Poland is very strong, despite the current global economic slowdown. The annual growth rate has averaged 4.2 percent per annum between 1992–2019. Poland is steadily catching up with Western Europe and has become the seventh largest economy in the EU. “The strength and resilience of the Polish economy can be attributed to its large domestic market,” according to the report. “A vibrant entrepreneurial landscape of small- and mediumsized enterprises, benefiting from a large domestic market and strong competitive advantages in neighboring European countries, is also an important source of growth.”

The biggest challenges for the spring industry in Spain include uncertainty in the automotive market, the world trade situation, Brexit and political instability. That’s according to Carolina Alonso, general secretary for ASEMU, the association for the spring industry in Spain.

The market price for materials within the automotive sector is steady or even dropping. In other sectors it is steady, said Alonso. In addition, labor costs have increased slightly, most of this linked to normal increases due to inflation. In general, Spain has the highest electricity costs in comparison the rest of Europe.

The automotive sector is the most important market for springs, with Spain ranked as the second largest car manufacturer in Europe. Other important sectors are mechanical, medical, aeronautical and railway.

Spain’s biggest and most important exports are mainly to other European countries, explained Alonso.

What are the biggest trade barriers?

“So far it has not been a big issue for springs, we hope to remain similar,” explained Alonso. “In the case of raw materials, there have recently been some disturbances due to trade barriers to steel.”

South Africa Emil Maritsch, CEO of the Spring Manufacturers of South Africa, provided this report on his country’s situation via email.

“Due to a very subdued economy in R.S.A., the spring industry is at low of ±50% of capacity but less affected than many other industries. Capital investment is low or nonexistent, as we don’t know when the economy will turn to the better; at present, the outlook is bleak.

The vote to leave the EU in June 2016 has cost the U.K. about 800 million pounds ($1 billion) per week, or about 2 percent of total economic output.

Switzerland In Switzerland it is reported that the currency of the Swiss Franc is continuously appreciating, especially against

the euro. In the labor market, the unemployment rate remains below 3 percent and the hourly rate of pay is among the highest in the world. In addition, the tax situation and labor laws in Switzerland are favorable for enterprises.

Bigger companies, i.e., the spring customers, have focused on high value goods and services, during strong currency appreciations that took place in 2012 and 2015. A lot of Swiss companies outsourced their manufacturing both to China and southeast Europe.

What are the biggest challenges for the Swiss spring industry? “Old customers disappear while new industrial companies come on the market; this means a constant change in customer base.” The report said production in the country is more on a small scale, while larger productions often are moved to low cost countries.

For spring manufacturers in Switzerland, the price for well-trained people remains high because of the country’s low unemployment rate.

U.K. The report on the U.K. was delivered by the William Hughes Group and primarily focused on the impact of Brexit. The vote to leave the EU in June 2016 has cost the U.K. about 800 million pounds ($1 billion) per week, or about 2 percent of total economic output, said Bank of England policymaker Gertjan Vlieghe.

The pound is down more than 10 percent against the euro since Britain voted to leave the EU. That’s increased the cost of imported goods and services, boosting inflation and eroding purchasing power for consumers.

It was also noted that the U.K. has experienced the longest continuous decline in foreign direct investment since records began, with a 10 percent reduction in projects, and a £1.5 billion reduction in capital investment between 2016 and 2017.

To download all presentations made at the International Congress of Spring Industry, including the economic climate on the spring industry in each country, visit: https://www.esf-springs. com/archives/1181. n

SPRINGS / Winter 2020 / 47

2019 Pittsburgh eXpo Features Education, Exhibits and Exchanges

48 / SPRINGS / Winter 2020

T

he third staging of the SMI Metal Engineering eXpo was held during unseasonably warm weather in Pittsburgh from Oct. 1-3, 2019 at the David L. Lawrence Convention Center. The 2019 eXpo marked the third time the event has been held, featuring exhibits from leading suppliers to the spring and metalforming industry.

“The SMI eXpo in Pittsburgh was a great success for the association and incredibly valuable for both Lee Spring as a company, as well as for me personally,” said SMI president Steve Kempf, who is the CEO of Brooklyn, New York-based Lee Spring Company. “With more companies represented than ever before, and with the key decision makers from those companies in attendance, the eXpo provided broad exposure for the exhibitors.”

Planning for the 2019 eXpo was led by chairs Chris M. Fazio, general manager, Pittsburgh plant, Diamond Wire Spring; Kelley L. Christy, director of sales/marketing and I.T., Diamond Wire Spring; and Daniel Pierre III, president of JN Machinery in East Dundee, Illinois.

“This was the first time the eXpo was held in a location where there were not as many nearby springmakers,” explained Pierre. “We were happy to see operators from the

“Because of the show and the strong offerings of the equipment suppliers, we know who to call when we have a customer problem to solve.”

local companies and show them features of our machines, but the majority of the attendees were definitely CEOs and upper management.”

Pierre said this type of attendee allowed his company to focus its discussions on where they are heading in terms of new machinery and new features.

“It also provided an opportunity to learn what our customers’ future needs are,” said Pierre. “JN will take this information to plan for the future. In this sense, for JN, the 2019 eXpo was more about future growth of our company rather than being a sales show.”

The event provided opportunities to network with industry colleagues during the opening night reception sponsored

by SMI Oct. 1, and during the off-site event at the Senator John Heinz History Center Oct. 2, sponsored by Industrial Steel & Wire.

“The 2019 eXpo was a showcase of advancements in technology, machinery and software,” said Fazio. “There was plenty of interaction and networking, which allowed for folks to make new contacts while strengthening existing business and personal relationships.”

Education in the Spotlight Kempf said the technical symposia, already a highlight of the eXpo, attracted an even larger audience than the events in Charlotte and Hartford. More than 20 sessions were held on business trends and best practices, manufacturing technology and innovation, and materials and testing.

Sessions took place in the morning prior to the start of the eXpo Wednesday, Oct. 2, and Thursday, Oct. 3.

Kempf said Lee Spring brought representatives from each of its manufacturing locations (17 attendees in all) together for the event.

“We divided and conquered to cover all of the symposia sessions, and then shared insights with one another,” explained Kempf. “We also covered the entire exhibition, compared notes and even made a few purchases right off the show floor. In the evenings, we also enjoyed the great city and the amazing weather that greeted us.”

“I also personally gained from the time spent with all those from Lee Spring, as well as the abundant opportunities for industry networking, highlighted by the wonderful evening at the Heinz Center,” said Kempf.

SPRINGS / Winter 2020 / 49

"What I was first blown away by was the openness and sharing of information from other springmakers. We all have common problems and sharing solutions in a competitive industry was really great to see."

“Whether you were an exhibitor or vendor, the diverse educational tracks were informative and instructive to all participants,” added Fazio. “The show was a true culmination of the many contributions from SMI, its trade show partner, Tradeshow Logic, and the commitment from the exhibitors, sponsors and to all those folks that traveled and supported the show; all of this combined to make Pittsburgh a valuable and knowledge-filled event.”

Providing a Spark for New Attendees The eXpo regularly attracts many first-time attendees, including Jennelle Carlier, production manager at S3 Wireform in Swift Current, Saskatchewan.

“What I was first blown away by was the openness and sharing of information from other springmakers,” Carlier commented. “We all have common problems and sharing solutions in a competitive industry was really great to see.”

“We brought six people to the show and they were impressed with the technology on display,” said first-time attendee Matt Kennedy, NPD engineer in Corry, Pennsylvania for Associated Spring. “We work closely with our

50 / SPRINGS / Winter 2020

suppliers, but we don’t often get to see their latest projects because we’re too busy working on day-to-day issues.”

Kennedy said it is important to stay up-to-date, to know how improvements in CNC equipment and software are changing the industry. “Because of the show and the strong offerings of the equipment suppliers, we know who to call when we have a customer problem to solve.”

Carlier agrees that the eXpo is a great way to see firsthand how automated machines can improve efficiency, to meet suppliers face-to-face and to discover new products.

She also appreciated the value of the technical symposia.

“The sessions in the morning were very informative and got the wheels turning,” said Carlier. “The networking in the evening was a perfect way for a newcomer to be welcomed and introduced to other members. I definitely felt included.”

Overall, Carlier said attending the event was worthwhile to her as a first-time attendee. “The contacts I made have proven to be invaluable as I have already reached out for help. The answers and support I have already received is very helpful,” she concluded.

Spring Design 201 Course Debuts in Pittsburgh The Spring Design 201 course “Compression Spring Design” was presented for the first time by Gary Van Buren, SMI technical advisor, just before the start of the 2019 SMI Metal Engineering eXpo in Pittsburgh. The class was facilitated by Rick Gordon, SMI technical director.

Technical committee members Gene Huber, Jr., Winamac Coil Spring Inc. and Don Jacobson III, Newcomb Spring of Tennessee also attended the training session and worked with small groups on data input during the ASD7 software training part of the course.

Huber also provided grade 302 stainless steel springs of different designs: constant pitch, variable pitch, hourglass, conical and barrel, which were used as teaching tools for the class.

The 201 training module was written by Jacobson and was reviewed and refined by the SMI technical committee.

Fourteen students from 11 companies attended the class. Many positive comments were received from students, as well as favorable ratings in the formal class evaluations.

Jennelle Carlier, production manager at S3 Wireform Inc. in Swift Current, Saskatchewan, attended the eXpo for the first time and was a student in 201 training course.

“I was excited to attend the spring design course,” said Carlier. “There isn’t much out there available for design training. The face-to-face training for me was very valuable, providing answers from real experts.

We will be using the training material available on the SMI website for training purposes here at our facility.”

Improvements to the training module will be included in the next class offering, based on input from students and team members who participated in the class. A focus group was formed to implement these improvements.

“The first offering of the Spring Design 201 course proved to be a great success,” said Huber. “It not only fulfilled its purpose of teaching basic spring design principles, but also proved to be an excellent forum for the exchange of ideas.”

2021 eXpo Heads to Las Vegas “A huge thank you to all those who worked so hard to make the 2019 eXpo such a triumph,” concluded Kempf. “The SMI staff, led by Lynne Carr; the SMI trade show committee, led by Chris Fazio, Kelley Christy and Daniel Pierre III; the team from Tradeshow Logic led by Bobby Bergeron, and really, everyone in the industry who make it such a special community to work within.”

The 2021 SMI Metal Engineering eXpo will be held Sept. 28–30, 2021 at the South Point Resort and Casino in Las Vegas. The facility consists of a 24-story hotel tower, casino and 90,000 sq. ft. convention center, located on a 60-acre site along Las Vegas Boulevard, just 10 minutes from the Las Vegas Strip.

“I am really looking forward to Las Vegas in 2021,” said Kempf.

For more information and to access presentations from the 2019 eXpo, visit www.metalengineeringexpo.com. n

Gary Van Buren

He added, “The SMI technical committee thanks all those who participated and helped to make this a successful first offering.”

Plans are underway to offer the Spring Design 201 course just before the West Coast Spring Manufacturers Association 2020 Tabletop meeting, scheduled for the end of February.

SMI Thanks eXpo Sponsors VISIONARY SPONSOR:

“We are grateful for the incredible support from our 2019 eXpo sponsors,” said SMI executive director Lynne Carr.

GOLD SPONSORS:

PLATINUM SPONSORS: SILVER SPONSOR:

SPRINGS / Winter 2020 / 51

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Flashback

What’s in a Spec?

(Editor’s note: In this edition, we republish an article that originally appeared in the April 2006 of Springs that addresses a frequentlyasked-about topic regarding material specifications. The article specifically addresses what springmakers need to know about material specifications and how to modify them to meet customer requirements.)

By Terry Bartel Ph.D. Charter Steel Incorporated

Specifications are an integral part of our lives.

All images in this article ©iStockphoto.com/ilyast

Whether or not we realize it, every one of us uses, or is affected by, specifications in many ways every day. Nearly everything we use, touch, eat, wear or look at was produced using directions that can be loosely construed as a specification.

In the most general sense, a specification is merely a grouping of information that defines the basic parameters required to produce the desired end product.

As springmakers or material suppliers, when we think of specifications, we will most often think of a drawing with dimensions, spring loads or rates, and associated tolerances, material names, a list of properties, elemental contents, reference documents, testing methods and other such items. Many of us have dealt with these items so long that when we look at a specification, we can automatically visualize the spring and what it does, or the material type and its performance characteristics.

But what really should be in a specification, and how should it be constructed to make certain that the desired end product meets its intended use? If you think about this, you quickly realize that this simple thought is the basis for success, frustration or, at the worst, failure. A way of driving this point home is to think about the last time you purchased something that stated on the box “some assembly required” and the success that you had in following those instructions.

A specification is like that set of instructions. If all of the information (both written and drawn) that you needed was included and clearly presented, you were successful in assembling the toy, barbecue grill or whatever. If, however, those instructions were not complete, clear and concisely presented, you were either frustrated or failed in the assembly process.

SPRINGS / Winter 2020 / 53

What follows is aimed at giving you an idea of the information to be included in a material specification so that you receive a product that allows you to manufacture a spring to meet your customer’s needs and expectations. We will start with a brief discussion of the specification formats used by international organizations, and then we’ll talk about specification content. Finally, we’ll proceed on to the reasoning behind the inclusion of specific information in a specification.

Although we will be discussing material specifications, much of the same reasoning can be applied to specifications for almost any end product.

National Specification Formats In the United States, the most commonly encountered specifications are SAE AMS (Society of Automotive Engineers Aerospace Materials Specifications) and ASTM International formerly known as American Society for Testing and Materials. Elsewhere, DIN (Deutsches Institut für Normung), EN (European Norm) and ISO (International Standards Organization) are more common. Each of these organizations is an independent standard/specification generator, and all are very powerful and highly recognized around the world. Although there has been much discussion regarding the desirability of harmonizing these independent specifications, there is little hope at this time of any of these organizations relinquishing any of their power. For our purposes here, all of these organizations

do have one thing in common: They have very structured formats for their specifications and standards. With this uniformity of format, the user always knows where to find specific information.

If these specifications provide you with the material you need, use them. If you discover that your needs are not met, then you should build on them (and their general format) to create a material specification that meets your needs.

The basic formats are somewhat along the following lines and in the order presented: • Scope: The scope is an overview. It tells the user what to expect and clarifies use. It can be very useful for defining limits of use.

• Referenced (Applicable) Documents: This section lists all documents that are referenced throughout the body of the specification or standard. Generally, the following three pieces of information are provided for each document as a minimum: document author (source), identifying number and title. Occasionally, the contact information for the source document is included.

One rule to follow: Don’t include a document in this section if it is not referenced, as this adds confusion to interpretation of needs.

• Introductory Material: Not all specifications contain this section. It generally includes such items as ordering information, general requirements and manufacturing information. In addition, material condition

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may be included here, or it may be under Technical Requirements if very specific needs are stated.

• Technical Requirements: This is the real meat of any specification, as it defines the specific requirements for a material. These will include (as applicable): condition if more specific in nature, material chemistry, melting practice, mechanical properties (tensile and yield strengths, elongation, reduction of area, hardness, creep and stress-rupture—both before and after any aging heat treatments), required heat treatments and applicable atmospheres, any special metallurgical requirements (grain size, microstructural uniformity, phase percentage and so forth), and finish. Depending upon how the specification is structured, this section may also contain material sizes and tolerances. This is a very good place to include any specific word or process definitions that are important to the understanding of the specification. It is this section that truly defines the needs of the product.

• Quality: This section has quite often been written with just a “general workmanship or quality” attitude. This is beginning to change, however, and a lot more requirements are being added to this section. It should include any specific testing and reporting needs that must be addressed. Among them would be responsibility for inspection, any additional testing (including sampling) or inspection that is desired, and what is to be reported on the raw material certification. Resampling, retesting or rejection are also usually addressed in this section.

• Delivery: Such items as packaging, shipping preparation and labeling are included in this section. Many times, this information is included on the purchase order and not in the body of the specification.

Although you will find other headings, those listed above provide the basis for most of the specifications created by the internationally recognized organizations. Again, if these meet your needs, use them. Why create additional work and system maintenance problems for your organization?

Time and resources are becoming more and more scarce as international competition increases.

Your Own Specification If existing specifications do not meet your needs, then you must create at least some form of your own specification. Internationally recognized specifications may not contain all of the requirements that you need to produce your product. You may have additional technical requirements that are not included in these specifications, you may want to clarify specific points, or you may wish to stipulate sampling and testing methods.

Second, an internationally recognized specification may not exist for your needs or the material in question.

The latter is quite prevalent as related to spring wire. The general attitude of several of these organizations seems to be that the spring industry is just too small to warrant the

Keep it simple (KISS principle).

This rule can do more to keep you out of trouble than any other. The more complex you make a specification, the more difficult it will be to obtain what you really need. Complexity often leads to misunderstandings and mistakes.

time and effort required to prepare a specification, get it to the proper committee and follow it for the 18 to 24 months required to bring it to fruition. This is the reason there are so many private industry spring wire or strip specifications.

They far outnumber those that have been prepared by the international organizations.

When preparing your own specification, what should you do to make certain that you include those specific requirements to ensure that you receive the material you need to produce your product? This can be summed up in one word: knowledge. You must have knowledge of the function of the product that you are fabricating, its expected performance and operating environment. You must also have knowledge of the material to be used and what it can and cannot be expected to do. Many times, the material type will be stipulated by your customer, so this decision is removed from your responsibility. However, when the material type is not stipulated or your customer expects your help, knowledge of materials can become very important in your overall success in satisfying your customer. Stating the above is easy; applying it can be difficult at times. However, there are a few simple rules that I tell people to follow when they have to create their own material specification.

SPRINGS / Winter 2020 / 55

Don’t go it alone! Use your resources and contacts to help you prepare a good specification that will provide you with the material having the appropriate properties that will allow you to fabricate the end product with the desired performance characteristics.

Rule 1: Keep it simple (KISS principle). This rule can do more to keep you out of trouble than any other. The more complex you make a specification, the more difficult it will be to obtain what you really need. Complexity often leads to misunderstandings and mistakes. However, in some cases a complex specification cannot be avoided. Just keep in mind that you should strive to minimize it. Be careful to not simplify too much; the result can be just as disastrous as over-complexity if you do not receive what you need.

Rule 2: Build upon other specifications. If you have the luxury of needing only slight or moderate changes or additions to one of the international specifications, use it.

Keeping Rule 1 in mind, make your specification as simple as possible by referencing the already established specification, and create your document in such a manner that it includes only those items requiring modification. Why recreate an entire document that already exists? Keep this rule in mind even if you require a high degree of complexity. If you are only adding to and not highly modifying the existing specification, use it and just do your additions.

Rule 3: Work with others. This rule really goes hand-inhand with the next and final rule. Don’t go it alone! Use your resources and contacts to help you prepare a good specification that will provide you with the material having the appropriate properties that will allow you to fabricate the end product with the desired performance characteristics.

One of your best resources will be your material suppliers.

56 / SPRINGS / Winter 2020

Most have the expertise to help you formulate your needs into definable properties. If they don’t, most of them have developed their own resources over the years whom they can call upon to get the job done. Again, keep the KISS principle in mind, and do not try to create a specification “by committee.” Having others review for completeness and clarity is good; just don’t include too many people in the creation process.

The first three rules are really quite simple. They mostly involve common sense, and all of us usually follow them every day to get our work completed. The real problem comes with the fourth rule—knowledge of what we really need in a material, and how to define these needs in a manner that can be concisely stated in our specification.

Rule 4: Technical requirements (knowledge): As previously stated, the technical requirements are the real meat of a specification. It is the items that we need to define, so that our suppliers can provide us with a material having the desired properties to allow us to produce a product with the required performance characteristics. Sometimes, we have a very difficult time in defining the exact characteristics needed. Maybe we really do not have a good grasp of material properties and what they actually mean in terms of product performance. Possibly we do not know what is even available to meet specific needs. This is where Rule 3, working with others, comes into play. Draw upon the working knowledge of those who have it. Their best interests are also served if they help you create a specification to meet your needs.

But what are these needs? In general terms, they fall into spring performance characteristics and the material properties required, yielding a product meeting these desired characteristics. The key point is that you need to define the performance requirements for the given spring (or have them defined for you by your customer). These will then define the properties needed in the material used to produce the spring. Normally, we work with only the basic mechanical strength of a material along with either the elastic or torsion moduli for this material. However, in many cases, we need more information, such as: anticipated fatigue or cycle life, operating temperature, operating environment (such as wet or dry, and any corrosive media) or possible stress relaxation concerns, to mention only a few requirements. The more information you know and can provide to your suppliers, the better able they will be to meet your needs. Remember, you need to concisely define as many performance details as you can. Very rarely will you provide too much information.

Following are some of the properties that may have to be considered for your application (don’t forget to determine if you need these properties before or after any aging or specialized heat treatments): • Chemical composition • Corrosion resistance • Tensile strength • 0.2 percent offset yield strength • Elongation • Reduction of area

16 14

Elongation (%)

12 10 8 6 4 2 0 1

2

3

4

5

6

7

8

9

10

Gage Length (inches)

Figure 1 Relationship between percent elongation and testing gage length.

0.054” Elgiloy – as-drawn, spring temper condition.

• • • • •

Hardness Grain size Microstructural requirements Surface defect requirements Surface finish (typically for strip applications)

The following properties should be considered for inclusion in a specification only when absolutely necessary (they play more of a role in the spring design requirements): • Fatigue performance • Stress relaxation characteristics • Stress-rupture • Creep life Notice that all of these items are mechanical properties, not physical properties. They do not include such physical properties as density, electrical conductivity (plated material for conductive springs aside), coefficient of thermal expansion or magnetic permeability. Physical properties are inherent in the material and its condition and cannot be controlled by the raw material manufacturer with very few exceptions. Do not include physical properties in your specification unless they are there for reference only, and even then do not include them unless you have an unbelievably good reason for doing so; they will only add complexity and confusion to the specification.

Work with your team to determine which parameters you feel must be included in your specification, then define them as concisely as possible and begin putting your specification together.

This is when your knowledge sources, such as suppliers, can help you not only include the appropriate properties and values, but also make certain that they are compatible. For example, high tensile or yields strengths do not go along with high elongation or other ductility values. These people can also help you determine any specialized testing techniques that may be required. Do not forget to reference these special techniques within your specification. You

need to make certain that everyone performs any testing in basically the same manner to ensure reproducibility in data values. You also need to be aware of any special testing parameter definitions or reporting specifics and include this information accordingly.

An example that I always like to use to demonstrate this last point is the reported elongation values that always appear on material certifications. So many times, you find a percentage number reported for the elongation but without the testing gage length indicated anywhere on the document. See Figure 1, which is a plot of actual data for a spring material in the as-drawn condition. This figure plainly demonstrates that the reported elongation percentage increases dramatically as the testing gage length decreases. If you do not indicate testing parameters, you may find yourself at odds with your supplier should you decide to perform any verification testing (not always a bad idea).

Not all material properties are affected as dramatically by testing conditions as elongation is. However, virtually all material properties are affected in some manner by testing techniques or parameters. You should be aware of these possibilities and act accordingly.

Many times, you can invoke standard practices, such as defined by the widely accepted ASTM standards. However even with the ASTM standards, you may need to define specific testing parameters. Also be aware if your end-user has any specific testing requirements. If they exist and you must prepare your own specification, include them.

Summary Specifications govern our everyday lives whether we like it or not. We need to be knowledgeable in what they mean and what they can do for us. They can hinder us, or they can aid us in attaining success, as measured by customer satisfaction.

Whenever possible, we should utilize specifications and standards that have been prepared by internationally recognized organizations. However, when these documents do not give us what we need or they do not exist, we need to create our own specifications, incorporating those items required to make a high-quality product to meet our customer’s expectations. We can do this by following the basic four-rule concept as outlined in this article to develop our specifications. n Terry Bartel earned his Ph.D. in metallurgical engineering from Michigan Technological University. Following graduate school, he spent four years as a materials scientist for the materials laboratory in the United States Air Force and Wright Patterson Air Force Base. He previously worked at the National-Standard Co. as manager of new product development and Elgiloy Specialty Metals in Elgin, Illinois, as general manager of wire.

Terry currently works for Charter Steel Incorporated. Bartel has written numerous technical articles on phase transformations and materials applications and is active in several metallurgical societies.

SPRINGS / Winter 2020 / 57

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©iStockphoto.com/00Mate00

G. Donald Jacobson Celebrates 50 Years of Service with Newcomb Spring Corp

By Donald Jacobson III

N

ewcomb Spring Corp is pleased to announce that G. Donald Jacobson, our current chairman of the board, was recognized in 2019 for 50 years of service with Newcomb Spring.

In addition to his past leadership roles within the company, Don was president of the New England Spring Manufacturers Association, also serving as director for six years, ending in 1989. He also was a three-term director for the Spring Manufacturers Institute (SMI). He served on several SMI committees that included four years as the chairman of the Springs magazine committee. He became SMI president in 1995. During his tenure, he emphasized education that included SMI developing a curriculum for coiler set up, spring design and an updated version of the Spring Design Handbook, a go-to resource for the industry.

Don has worked to develop new technology that was integrated into the manufacturing processes. As Don himself says, “We have come a long way from when I had to write the computer programs on punch cards for order processing and scheduling because the only programs available were for accounting. Now I work with my teams, encouraging them to keep Newcomb Spring at the forefront of innovation. Technology has to combine with improving efficiency at all levels without sacrificing precision, quality or standards. I am proud of the accomplishments of Newcomb Spring over the past 50 years and wish to thank

the entire Newcomb family for their support and dedication.”

Don has been instrumental in guiding the growth of Newcomb Spring as well as helping to advance the

metalforming industry. He has been a true thought leader in the industry and has worked diligently to continue to make Newcomb Spring the “First in Forming.” n

SPRINGS / Winter 2020 / 59

FORECAST 2020 Happy Consumers, Slowing Growth

By Phillip M. Perry

Slowing Growth “We look for the economy to grow below its potential in 2020,” says Sophia Koropeckyj, managing director of industry cconomics at Moody’s Analytics, a research firm based in West Chester, Pennsylvania. “Corporate profit margins have been compressing noticeably as growth in labor costs has outpaced revenue growth. Shrinking margins are often associated with late-cycle expansions and often cause businesses to be more cautious in hiring and investment.”

Moody’s expects the nation’s Gross National Product (GNP) to slow to 1.7 percent in 2020, down from a more normal 2.3 percent anticipated when 2019 numbers are finally tallied. The 2019 performance is a decline from the 2.9 percent growth clocked the previous year. (The GNP, the total of the goods and services produced by a nation, is the most commonly accepted measure of economic growth.)

©iStockphoto.com/krblokhin

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A

slowing economy. Costly tariffs. Brexit angst. A presidential election. A shaky stock market. Rising labor costs. A looming recession.

And happy consumers.

Those are the ingredients of a mind-bending cocktail of economic uncertainty now eroding business confidence and capital investment. Despite a state of full employment, robust consumer spending, low interest rates and a strong housing market, forecasters are predicting a challenging operating environment in the year ahead.

Strong Hiring Reports from the field reinforce Moody’s calculations. “In the last part of 2019 concern about tariffs resulted in a slowdown in the automotive and agricultural sectors, and a lower level of orders caused some companies to reduce their size,” says Tom Palisin, executive director of The Manufacturers’ Association, a York, Pennsylvania,-based regional employers’ group with more than 370 member companies. With its diverse membership in food processing, defense, fabrication and machinery building, Palisin’s group can be seen as something of a proxy for American industry.

Despite the slowdown, says Palisin, most of his members continue to enjoy good profits and to hire when they can find the right workers. That success, though, is tempered by a yearlong gradual decline in the lead time required to fulfill orders—a common indication of decelerating revenues throughout the supply chain.

“Manufacturers experienced significant lead time in the first quarter of 2019 as a result of high demand and capital spending,” says Palisin. “Lead time shortened as the year progressed,

to what is now an average level. We expect lead times to remain average in 2020, due to headwinds that may moderate economic growth.”

Happy Consumers The current economic picture is not lacking bright spots. The most pronounced is a consumer who seems largely contented with the way things are working out, thanks to healthy employment levels that are filling pockets with spending money. That’s important, because consumer spending is a powerful driver of business activity, representing some 70 percent of the nation’s economy.

The unemployment rate was running at an enviable 3.7 percent toward the end of 2019, well below what many economists label as “full employment.” Employers have been consistent in their hunt for workers to fill a growing number of positions. “Monthly job growth has been more than enough to keep up with the growth in the working age population,” says Koropeckyj.

Looking ahead to 2020, economists expect recession fears to have a dampening effect on the labor market.

“Unemployment is expected to edge slightly higher, to 3.9 percent by the end of 2020, due largely to a deceleration of job growth,” says Koropeckyj.

“We expect job growth to steadily decelerate and cease altogether in the second half of the year.”

For the time being at least, happy shoppers are good news for retailing, an important driver of the national economy. Moody’s expects core retail sales to increase by 4.0 percent when 2019 numbers are finally tallied, up from 3.4 percent of the previous year.

(Core retail sales exclude the volatile auto and gasoline segments.)

The unemployment rate was running at an enviable 3.7 percent toward the end of 2019, well below what many economists label as “full employment.” Employers have been consistent in their hunt for workers to fill a growing number of positions. “Monthly job growth has been more than enough to keep up with the growth in the working age population.”

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As for 2020, Moody’s expects retail sales to increase by only 2.3 percent. “A deceleration of job growth means fewer new people will enter the ranks of active shoppers,” says Scott Hoyt, senior director of consumer economics for Moody’s Analytics.

“And that will exert some downward pressure on retail sales growth that may more than offset the positive effect of the higher wages (and thus the greater disposable income) characteristic of a tightening labor market.”

Housing Rebound Confident consumers are maintaining a steady drumbeat of interest in housing, another critical driver of the economy.

Moody’s expects 2020 to be the first year of a strong residential construction recovery, led by single-family homes.

Housing starts are projected to grow 7.0 percent in 2020. This comes off a rocky 2019, in which starts were expected to drop by 0.7 percent when the year’s numbers are finally tallied.

Why the dismal 2019 experience? “There have been a number of obstacles to stronger residential construction,” says Koropeckyj. “The first is a shortage of specialized workers. The second is the prevalence of strict residential zoning regulations, especially in dense urban areas. The third is a shortage of residentially-zoned land within commuting distance of business areas in some metro areas in the Mountain West and Inland South.”

Older millennials now reaching prime home-buying age are expected to drive the 2020 housing recovery. They will be entering the market at a time when the housing inventory-tosales ratio is at record lows. The fact that zoning is generally less restrictive for single-family, as opposed to multifamily construction, translates into a much stronger single-family construction forecast. Relatively low mortgage rates will also help, though these are expected to start rising in 2021.

The housing rebound will be tempered to some degree by declining affordability, according to Moody’s. The median price for existing single-family homes is expected to rise 4.1 percent in 2019 and 2.9 percent in 2020, compared with 4.7 percent growth in 2018. The deceleration of price growth in 2020 is due largely to the increase in housing starts bringing more units to the marketplace, as well as to price resistance from buyers. “Even though home prices will decelerate they will still increase, and ownership will become even more out of reach for many households than it is today,” says Koropeckyj.

Banks, for their part, seem to be filling their critical role in a robust housing market. “Mortgage lending has been continuing unabated and largely concentrated among borrowers with high credit scores,” says Koropeckyj. “We expect this pattern to hold in the future.”

Interest rates are expected to continue to play their vital role in supporting mortgages. “In 2019, interest rates turned lower rather than higher, which was a surprise,” says Hoyt.

“The reason was the unanticipated trade war, which was clearly a negative and reduced economic prospects significantly relative to expectations.”

62 / SPRINGS / Winter 2020

Tight Labor If robust employment is keeping the consumer happy and the housing market bustling, employers are tearing their hair out.

“Because of the tight labor situation, our companies have not been able to add as many workers as they would like,” says Palisin. “As a result, it can be difficult for many of them to take on new business. We expect that to remain a problem in 2020.”

Industry is also seeing more job shifting, in which people leave their current positions for opportunities elsewhere.

“Employers are now looking at whether they need to adjust their compensation policies to retain the talent they have developed,” says Palisin. “So far we have seen only a gradual increase in the cost of labor, but we expect more accelerated wage growth in 2020.”

A tight labor market is expected to be with us awhile.

“The workforce will be put under continuing pressure in the future,” says Palisin. “Over the next 15 years, for the first time in the U.S. there will be more people of retirement age than under the age of 18. And a contraction in immigration is also putting pressure on the workforce. Companies will have to look for other ways to grow without hiring workers who might not be available.”

If you can’t get enough people, let robots do the work. That’s the mantra for the employer of the future. “Rather than invest in recruiting and training people for labor intensive jobs, our members have been investing in automation and capital equipment,” says Palisin. “We expect this trend to continue in 2020.”

Not all employers, though, can foot the bill. “While larger companies can automate internally, small and midsized ones need to call in external consulting resources,” says Palisin. “That can be challenging, because many smaller businesses do not have the financial resources to do so.”

Indeed, manufacturers around the nation seem to be shy of investing too much in capital improvements of any kind.

“Manufacturers are nervous, despite their success in reaching their earnings estimates,” says Bill Conerly, principal of his own consulting firm in Lake Oswego, Oregon. “This is showing up in capital spending numbers, which were big in 2018 coming out of tax reform but which are not so big now.”

Even forays into automation are on hold. “Labor costs are going up and good workers are hard to find,” says Conerly.

“Interest rates are low, and companies are flush with cash.

You would think that investment in labor-saving technology would be going great guns, but it’s not. Why? Uncertainty.

Businesses wonder if economic conditions in the next few years will justify more capacity or even more efficiency.”

The numbers from Moody’s support Conerly’s observations. “We expect real nonresidential fixed investment to grow by 3.2 percent annualized in 2019 and 2.8 percent in 2020,” says Koropeckyj. “That’s well below the 5.4 percent average over the last two years.”

Disrupted Supply Chains A scarcity of skilled workers is just one of the many headwinds restraining American businesses. Another is supply chain confusion—a direct result of the China trade wars.

“Uncertainty about international trade rules can throw havoc into the production system,” says Conerly. And that havoc is only intensified by the complexity of modern supply chains. “Parts for finished goods are coming from multiple countries. The more complex the chain, the less resilient it is, and the more opportunity for things to turn bad.”

Adjusting to supply chain disruption is easier said than done. “Some of our companies are trying to move their supply chains out of China, but that means abandoning long held relationships,” says Palisin. “Validating new suppliers is costly and time consuming. Smaller and midsized companies in particular do not have the resources to quickly find new sources of materials.”

Lending urgency to the supply chain disruption is the knowledge that long-established relationships, once lost, can be difficult to restore once trade tensions ease. And on the flip side of the trade coin, domestic makers fear losing their overseas markets permanently to rivals from other countries.

In a reflection of these supply chain disruptions and of the slowing global and domestic economy, Moody’s expects corporate profit to increase by only 1.9 percent when figures for 2019 are finally tallied. This less than stellar increase only adds to the uncertainty that is keeping companies from investing in the very capital projects that can help drive economic growth.

Moody’s expects better results in 2020, when corporate profit growth should increase by some 4.9 percent. “Contributing to the rebound is a weaker U.S. dollar, which will improve the competitive positions of U.S. goods, so that profits from abroad will increase,” says Koropeckyj. She adds that while

the 2020 figure looks comparatively robust, it remains weaker than the average 5.2 percent growth between 2009 and 2018.”

The Road Ahead Despite the uncertainty that characterizes many areas of the economy, a healthy labor market and high consumer confidence have done a good job propping up a decelerating business environment. Will they continue to do so? And when will the inevitable recession arrive?

That last question is particularly important, as two-thirds of the nation’s chief financial officers expect the United States to tip into an economic downturn by the third quarter of 2020, according to a Duke University/CFO Global Business Outlook survey. In the early months of the new year, economists suggest monitoring financial news for indicators of a recession, often defined as two consecutive quarters of negative economic growth. Increasing stock volatility is one such indicator, as is an inversion in the Treasury yield curve when short-term rates are higher than long term ones.

But perhaps the most important indicator of pending trouble is a downturn in the employment picture. “The job market is key,” says Koropeckyj. “If businesses begin to lay off workers, that will be fodder for recession. Watch for changes in monthly employment growth and in weekly claims for unemployment insurance benefits.”

Rising unemployment, says Koropeckyj, will result in a decline in the very consumer spending that has been the driving gear of a healthy economic machine. “Once unemployment starts rising, we are either already in a recession or will be in one very soon.” n

“Interest rates are low, and companies are flush with cash. You would think that investment in labor-saving technology would be going great guns, but it’s not. Why? Uncertainty. Businesses wonder if economic conditions in the next few years will justify more capacity or even more efficiency.”

SPRINGS / Winter 2020 / 63

©iStockphoto.com/tostphoto

Five Questions

Industrial Steel & Wire

F

ive Questions provides an opportunity for SMI associate members to tell the spring industry about the products and services they offer. In this edition, we talk with Dan Foster, vice president, sales and marketing for Industrial Steel & Wire Co. (ISW). Foster has been with the Chicago-based company since 2011.

1|

Can you tell us about Industrial Steel & Wire and the products it offers to spring manufacturers?

We’ve been providing carbon, stainless and non-ferrous spring wire to spring manufacturers and wireformers for over 84 years. We have over 400,000 sq. ft. of warehousing throughout North America, so chances are we’ll have what a springmaker needs in stock and ready to ship.

2|

What are the latest trends impacting wire distributors and what effect is it having on spring manufacturers?

Volatility and uncertainty in the global steel market have been defining characteristics in the spring wire market since last year; sweeping tariffs and quotas have impacted day-to-day business for many in the industry.

Lean manufacturing, the need for just the right amount of material at just the right time has required the entire supply chain to become more nimble. We recognize that springmakers need material quotes right away, and reliable logistics solutions to make sure every order is perfectly executed from desk to dock. That’s the reason we introduced our 5-Star Pledge of Service.

3|

What type of services do you offer?

We offer straighten and cut and torsion straightening services, custom packaging for specialty items, and localized fulfillment and logistics support. But our customers have told me they keep coming back for a different reason: our people. We have customers that have been dealing with the same ISW associate for 30 years, because we treat every caller with respect and every order with urgency.

4|

What role does logistics play in serving spring manufacturers?

Logistics is an absolutely critical component of any springmaker’s supply chain, and we’re proud to be a reliable link in that chain. We work with a number of logistics companies

to make sure our delivery promises are upheld and to offer our customers more competitive pricing.

We know that one of the worst things that can happen as a manufacturer is running out of material, or not having the material in-house when you need it.

Our reliable logistics process Dan Foster means orders placed in the a.m. can ship the same day and orders placed in the p.m. go out the next morning. We also offer customizable logistics solutions, like local warehousing of raw material inventory, hold-for-release orders for just-in-time delivery, and improved raw material velocity.

5|

Can you tell us about a recent challenge that you were able to solve for a customer?

Candidly, this is a tough question to answer because every day brings a new set of challenges. We try to be proactive in anticipating the needs of customers, so we can best equip ourselves to handle sudden changes. When changes do occur, we can lean on a staff of dedicated experts with hundreds of years combined industry experience. Problemsolving is part of our DNA, and our company’s core values implore us to embrace and drive innovative solutions.

Whether it is a sales representative rushing over 100 lbs. to a customer over the weekend to avoid an automotive line shutdown, or the warehouse workers staying after hours to load a truck for an emergency delivery, our associates at ISW handle everything like taking care of their own family. Our core values of service, dedication, respect and integrity are what define us as company; it’s how we make a difference to our family of customers every day. n Contact an ISW associate to learn more about their 5-Star Pledge.

Industrial Steel & Wire 1901 N Narragansett Ave. Chicago, Il 60639 www.industeel.com 773-804-0404

SPRINGS / Winter 2020 / 65

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Springmaker Spotlight

Pictured (l-to-r): Plymouth Spring president, David DeVoe and chairman Richard Rubenstein.

Plymouth Spring at 60: Serving Customer Needs One at a Time

By Gary McCoy Managing Editor

P

lymouth Spring Company, Inc., started in 1959 in Bristol, Connecticut. The company continues to operate from a 60,000 sq. ft. building that houses its entire operations. Plymouth’s growth can be traced back 30 years ago to 1989. That’s when Richard Rubenstein took over the active management of Plymouth Spring and grew the company’s sales through acquisitions (you can read more about this strategy in an article written by Rubenstein, “A 40-Year Record of Success in Acquisitions,” in the April 2009 issue of Springs).

Plymouth’s last acquisition was in 2006, when it acquired the Bristol Spring Manufacturing Company. Plymouth Spring continues to grow through attention to customer detail and investments in new equipment and processes. The company manufactures compression springs, torsion springs, extension springs, wireforms and assemblies, and has one of the largest fourslide departments in Connecticut. The company specializes in products for the electrical market, but they also do a significant amount of medical, hardware and automotive work.

SPRINGS / Winter 2020 / 67

Rubenstein said Plymouth Spring has been fortunate to have had only three general managers over the past 30 years, including Fred Mestuzzii and Jack Haber, who are both deceased. Rubenstein said that before Haber died, he strongly recommended that David DeVoe head up the company’s manufacturing operations.

An employee of Plymouth Spring since 1994, DeVoe initially started out as a foreman in the coiling department, later becoming the plant manager and vice president of manufacturing.

In 2017, Rubenstein promoted DeVoe to become president of the company, turning over the day-to-day operations to him for all areas of the company including manufacturing, personnel and finance. Rubenstein continues to be involved as the company’s chairman, overseeing the overall management of the company.

“David started off running the manufacturing operations, and over the past five years we have worked very closely together,” explained Rubenstein. “David has done an excellent job managing the day to day operations of the company and promoting him to president was the right move for both David and the company. David and I have forged an excellent partnership over the past 20 years.”

DeVoe describes himself as a very “hands-on person.” He started in the industry right out of high school with designs to become a toolmaker. Instead DeVoe went to work at Dayon Manufacturing to learn coiling and later became a coiler at Dayon before joining Plymouth Spring.

Customer Centric DeVoe says customer needs have changed since he first started in the business. “You have to create a team with the customer to understand your needs and their needs,” he explained of today’s business landscape.

“Here at Plymouth, we understand that we have to treat every customer a little differently,” said DeVoe. DeVoe gave the example of a customer who has a sixweek lead time to produce parts. “You need to make sure the customer understands the lead time involved and work with them to make sure they have a new order in hand to meet the deadline.”

DeVoe explained that the needs of an electrical customer are going to be different from those of an automotive customer. “Which means you need to get everyone in your business to understand that,” DeVoe added.

Building a Better Business If you come into the plant at Plymouth Spring in the late morning, you’ll encounter a crew of workers from the Arc of the Farmington Valley, Inc., more commonly known as Favarh.

According to the organization’s website, Favarh, was founded in 1958 by eight local families who all wanted a better life for their children with intellectual disabilities. A small school was created in the basement of a local church, because children with intellectual disabilities were not accepted into public schools at that time.

Today, Favarh (pronounced “FAY-var”) is a local chapter of the Arc, the world’s largest community-based organization for people with intellectual, physical and developmental disabilities. Favarh supports more than 350 children, young adults, adults, seniors and families throughout the Greater Farmington Valley area and beyond.

The crew from Favarh, located in Canton, Connecticut, performs

68 / SPRINGS / Winter 2020

David Bilodeau, a staff member at Favarh (far left), with the crew from the organization that helps assemble clips at Plymouth Spring. Company president David DeVoe is pictured in the back row.

assembly of three differentsized clips at Plymouth Spring.

David Bilodeau, who serves as a job coach in the employment services department at Favarh, accompanies the crew to Plymouth Spring. He helps manage their activities and performs quality control to make sure all the clips they assemble are correct.

Bilodeau is profiled on the Favarh website, where he received high praise from Joe DeVoe, the Plymouth Spring manager who oversees the crew. Joe DeVoe recently called Bilodeau “a great coach” due to his sensitive and caring management of the crew members as well as his attention to detail related to quality control.

“Quality is very important,” said Bilodeau. “Even if you just do three pieces, they need to be done right.”

David DeVoe said Plymouth Spring is proud to support the crew from Favarh.

“To see their faces light up for doing a great job for us makes us a better business, with more of a purpose than just the bottom line.”

“We treat our employees great, but we also ask a lot of our employees, so it’s not a one-way situation,” explained DeVoe. “We feel like we have the best group of people working at Plymouth Spring that we’ve ever had, and our performance reflects that.”

Plymouth Spring employee Roy Riggings (left) with president David DeVoe. Riggings served with the U.S. Navy and is among many veterans employed by the company.

DeVoe said customer service has been a major factor in the growth of Plymouth Spring, and Rubenstein agrees.

“We represent a quality manufacturer with excellent service,” Rubenstein said. “We spend a lot of time in sales and service trying to anticipate our customer’s needs.”

Rubenstein emphasized that, in today’s world where many companies have complicated supply chains, “a customer needs as much help as they can get from their vendors to keep those chains stocked with a full volume of products.”

Both Rubenstein and DeVoe acknowledge that helping customers is not possible without a dedicated group of employees, which currently numbers 53.

Rubenstein says the employees at Plymouth Spring are treated as family members. “We take good care of them in many ways in terms of compensation, benefits and working conditions,” he explained. “We want them to feel safe in this environment. And in return, they work really hard for us. I think it’s a fair exchange.”

DeVoe says the employees at Plymouth Spring are similar to its customers. “Every employee has different needs,” he said. Acknowledging this, DeVoe says the company works hard to create an atmosphere where they can quickly get product out the door and every employee feels valued.

“We treat our employees great, but we also ask a lot of our employees, so it’s not a one-way situation,” explained DeVoe. “We feel like we have the best group of people working at Plymouth Spring that we’ve ever had, and our performance reflects that.”

Transferring Knowledge Like everyone in the spring industry, Plymouth Spring is facing a transfer of knowledge, with more people retiring from the industry than coming into it.

DeVoe says that just two years ago Plymouth’s average employee age was around 56, whereas now it is closer to 48. Even with the drop in the average age, the company’s workforce still averages around 25 years of service.

“I don’t want to make it sound like we’re trying to get rid of people, that’s not what we’re trying to do,” explained DeVoe. “We’re trying to sustain a business into the future where we transfer knowledge from older individuals that have been great employees, to younger employees. We need to transfer some of this knowledge to younger people in order to sustain growth for the future.”

One of the ways Plymouth Spring has been doing this is through a Connecticut state program that subsidizes some of the expenses to help bring apprentices to their workforce.

The company currently has two apprentices working at their facility that are part of the program.

“Getting skilled help is always a challenge and becoming harder every year,” acknowledges Rubenstein. “For some reason, people either do not want to go into or remain in the spring industry.”

Future Outlook Even with the challenges, Rubenstein sees a bright future ahead for the spring industry.

“As an industry, I think the 2020s will be a terrific time,” said Rubenstein. “We may have a short-term recession, but I think overall, as the industry consolidates, the stronger players will be able to look at the business out there and take advantage of it.”

Rubenstein says Plymouth Spring sees the company’s fourslide operations as “an expanding business with many opportunities, and that is certainly good for us.”

SPRINGS / Winter 2020 / 69

He also anticipates more growth from reshoring. “We feel that some of the business that went abroad in the ‘90s and early 2000s, especially to China, will eventually make its way back one way or another.”

Overall Rubenstein says the outlook is good, but added, “Will it be challenging? Yes, Will it be terrible? No.” One change that DeVoe notes is the amount of machinery that each company must now have on hand in order to do business.

“When I first started in the industry, every person had two machines to run; now they have six or seven,” explained DeVoe. He also points out that the technology of the machines has changed, “and it has changed so much that we now do short runs on machines that we had never used before.”

Along that same line, Rubenstein said the high cost of equipment has been a more recent challenge. “We all have to reinvest, but the cost to reinvest has grown geometrically over the last 10 years. It is much more expensive today to keep up with technology than it was 10 years ago.”

Rubenstein said the industry has consolidated, especially after the Great Recession of 2008.

“There’s no question that peripheral players have decided to join with larger companies which has made the industry stronger with companies who have a lot more capabilities,” explained Rubenstein, “because they are the ones who can invest in new equipment and new techniques.”

Fulfilling Industry Commitments Both Rubenstein and DeVoe have enjoyed being a part of the spring industry. “While the industry is competitive, it is also cooperative,” explained Rubenstein. “The members of SMI do compete with each other, but they also cooperate, and I think SMI is a perfect example of that. The association tries to make the industry better, and certainly to help improve the way all of us do business.”

“The people I deal with, my competitors, are probably the best people I’ve ever worked with in my life,” said DeVoe. “We don’t talk about our own work; we just talk about our problems and help each other understand how we can solve them together. I don’t know any other industry that does that.”

Both Rubenstein and DeVoe have volunteered as SMI leaders. Rubenstein served several terms on the SMI board of directors and was chairman of the magazine for more than six years. He served during a critical time of leadership change within SMI and the editorial staff of the magazine.

DeVoe is a current member of the SMI board, having served many years on the technical committee. In 2019, DeVoe became the new magazine chairman. He also serves on the NESMA board.

“One of the things I’m most proud of is that David has followed in the footsteps of our company and is actively involved with the SMI and NESMA boards,” said Rubenstein. “We consider community and industry involvement

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very important for our employees. I’m so glad he’s spending time and effort to make our organizations better.”

DeVoe says there are benefits to SMI that many people don’t understand. “For the industry, they have software programs that show us design capabilities,” explained DeVoe. “Plus, they have programs that can help moderate our workers’ comp rates.”

DeVoe sees SMI as an organization that brings together all the leading people in the industry to network and learn from each other and their unique experiences.

Workforce development has been an area of focus for DeVoe, especially with his service to NESMA. He said he’s proud of NESMA’s efforts to work with three local colleges to help promote alternatives to the traditional route of every student attending a four-year college.

“We want young people to understand that our careers are just as good as the traditional college career,” explained DeVoe. “We go into middle schools and high schools to create an atmosphere of knowing that a skilled machinist or a skilled tool maker is not a bad job. We try to promote these types of careers and that people can make a lot of money in these careers.”

DeVoe says recent efforts have been good but recognizes there was a 20-year gap in getting young people to join the industry. “The knowledge of losing an employee to the competition stopped everybody from trying to train people,”

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“The people I deal with, my competitors, are probably the best people I’ve ever worked with in my life,” said DeVoe. “We don’t talk about our own work; we just talk about our problems and help each other understand how we can solve them together. I don’t know any other industry that does that.”

explained DeVoe of the 20-year gap. “The understanding now is that if we get enough young people to join us then we don’t have to worry about the competition. We recognize that the pool of workers needs to get bigger.”

Out of the Spotlight When asked about the biggest challenges he’s faced in the last five years, Rubenstein laughed and said, “getting up every morning.”

All joking aside, Rubenstein said business has been excellent for Plymouth Spring. “We’ve been lucky to have wonderful customers and wonderful employees. It makes it a pleasure to come to work and to make our company grow.”

Rubenstein is known for his travel adventures. He and his wife, Lea, have visited 135 countries (and counting).

They also enjoy spending time in the outdoors hiking. The Rubenstein’s celebrated 50 years of marriage in 2018. They have two children, Anne and Peter, and four grandchildren.

Rubenstein served as chairman of a bank for 13 years and continues to volunteer and serve on the board of many nonprofits.

When not working at Plymouth Spring, DeVoe enjoys golfing and spending time with his five grandchildren. He has a daughter, Michelle, and a son, Joe, who also works at Plymouth Spring as the company’s plant manager.

“I enjoy dinners and movies, and of course, I love to play golf,” said DeVoe. “But family time is the best.”

Growing the Plymouth Spring family will always be a long-term focus for both Rubenstein and DeVoe. Described by DeVoe as a midsize company, he said Plymouth Spring continues to expand its fourslide operations and may add more stamping capabilities in the future. He quickly adds, “If we can help our customers grow.” n

SPRINGS / Winter 2020 / 71

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Turning the Flywheel: A Monograph to Accompany Good to Great

By Gary McCoy

T

he “flywheel effect” is a concept developed in the book “Good to Great” by Jim Collins. Even though it was published in 2001, “Good to Great” is still a popular business book and one that many have read and often quoted. In a new 46-page manual published in 2019, “Turning the Flywheel: A Monograph to Accompany Good to Great,” Collins takes a deeper dive into execution principles for his flywheel concept.

Summarized, the flywheel effect comes down to, “No matter how dramatic the end result, good-to-great transformations never happen in one fell swoop. In building a great company or social sector

enterprise, there is no single defining action, no grand program, no one killer innovation, no solitary lucky break, no miracle moment. Rather, the process resembles relentlessly pushing a giant, heavy flywheel, turn upon turn, building momentum until a point of breakthrough, and beyond.”

Collins says, “I wrote my latest monograph, ‘Turning the Flywheel,’ to share new and practical insights about the flywheel principle, inspired by its wide-ranging impact in recent years. At one end of the spectrum there are fastgrowing companies like Amazon, which has consciously harnessed the flywheel effect to feed its momentum machine.

At the other end of the spectrum, there is the delightful discovery of a rural Kansas public elementary school using the flywheel to elevate the learning of children.”

Collins says he’s observed leaders making use of the flywheel in nearly every sector, from startups and nonprofits to health care and professional sports teams.

“The more I challenged leaders to crystalize their specific flywheel — capturing the drivers of momentum, and how they link together — the more passionate I became about sharing what I’ve learned,” Collins explained.

This monograph serves as a guide to help you construct your own flywheel.

Collins describes seven steps in some detail (this alone is worth buying the book!) to help you along the way.

Collins says good to great work is never done. “No matter how far we have gone or how much we have achieved, we are merely good relative to what we can do next. Greatness is an inherently dynamic process, not an end point. The moment you think of yourself as great, your slide toward mediocrity will have already begun.”

If you are looking to revisit your business model, this book would be a great place to help you get started. n

Have a favorite business book you would like to tell us about or review? Send your suggestions to Springs managing editor Gary McCoy at gmccoy@fairwaycommunications.com.

SPRINGS / Winter 2020 / 73

wongwean/Shutterstock.com

Global CTE News Highlights

Showcasing Modern Springmaking: Manufacturing Day 2019

S

pring companies continue to be robust participants in Manufacturing Day. Held annually on the first Friday in October, Manufacturing Day helps show the reality of modern manufacturing careers by encouraging thousands of companies and educational institutions around the nation to open their doors to students, parents, teachers and community leaders.

Here are some of the exciting things that took place in 2019 at SMI member companies.

Betts Company On Oct. 1, 2019, Betts Company hosted students from two local Fresno, California area high schools, Pioneer High School and Central High School. Two groups of 14 students and teachers were given a presentation on Betts Company and its three divisions, which include Betts Spring Manufacturing, BettsHD and Betts Truck Parts & Service.

Betts engineers then led groups on tours of the company’s springs and heavy duty truck parts manufacturing floors. Students saw vehicle springs being made and learned about the springmaking process. They were also able to see truck parts being made by robots and learn how manufacturing often relies on both human and automated processes.

Betts Spring/HD marketing manager Randy George said, “Students and teachers were engaged during the tours, taking photos, videos, and asking questions about robotics and manufacturing.”

Wolverine Coil Spring Co.

Wolverine Coil Spring Co. Jay Dunwell, president of Wolverine Coil Spring Co. in Grand Rapids, Michigan, reported that the company had a great “Discover Manufacturing Week” with three separate school visits.

Dunwell said the West Michigan area led the country, with more than 9,600 students visiting manufacturing plants (and still counting, as employers report). “This wouldn’t happen without a full-time project manager assigned to coordinating nearly 200 employers and nearly 200 schools,” explained Dunwell.

The Yost Superior Co. Scott Spohler and 17 students from his physics class from Global Impact STEM Academy in Springfield, Ohio toured The Yost Superior Co. as part of Manufacturing Day 2019. “This was our third group we have had tour, and we are encouraged by the enthusiasm

of the young people as they learn about manufacturing today,” said Sharon Deerwester, co-owner, The Yost Superior Co. “One young lady seemed very engaged. I asked her as she was walking out what she thought of the morning.

She said that she had never even been in a factory before and thought it was really interesting,” explained Deerwester.

The idea behind Manufacturing Day is to open the minds of students to see the possibilities of a career in the manufacturing field, and Deerwester said The Yost Superior Co. thinks it was a success.

“Frequently in smaller towns like Springfield, youth feel they will need to move away for higher earning career opportunities,” said Deerwester. “Hopefully, tours of factories around the nation shed a new light on potential job openings in a field they had never even considered.”

SPRINGS / Winter 2020 / 75

Deerwester said the Yost Superior Co. is glad to partner with SMI and Manufacturing Day, and that she looks forward to the next group of students that will come to tour.

The L.S. Starrett Company The L.S. Starrett Company welcomed more than 100 attendees, including students, state representatives and the community, to its third annual Manufacturing Day Friday, Oct. 4, 2019, at Starrett corporate headquarters in Athol, Massachusetts. Students attended from Massachusetts schools, including Quabbin Regional High School (Barre), Athol High School, Franklin County Technical School (Turners Falls) and Montachusett Regional Vocational Technical School (Fitchburg).

Starrett gave guided tours at its headquarters, where attendees learned how a Starrett micrometer is manufactured. Visitors were welcomed with a general introduction and visited the new Starrett Manufacturing Training Center where an overview of making

Frequently in smaller towns like Springfield, youth feel they will need to move away for higher earning career opportunities,” said Deerwester. “Hopefully, tours of factories around the nation shed a new light on potential job openings in a field they had never even considered.” a Starrett No. 230 Outside Micrometer was given, followed by visits to the various departments where the micrometer is made. Also, several attendees enjoyed visiting the on-site Starrett history museum, which showcases Starrett founder Laroy S. Starrett’s original desk, as well as his first invention — a meat chopping machine called The Hasher. Laroy’s first Starrett invention, the combination square, is

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also on display, along with many more historical items.

Ace Wire Spring & Form Co. Ace Wire Spring & Form Co., Inc. celebrated Manufacturing Day 2019 throughout the month of October, hosting five different groups of students ranging from local high schools to trade schools to colleges for a presentation and tour of the company’s facility.

“Ace believes in supporting the local community and the education of young people in the field of manufacturing,” said John Higgins, the company’s marketing manager.

Higgins said the goal of the tours is to show students springmaking and manufacturing up close and help expand their minds to the many opportunities for a career in the manufacturing industry.

Manufacturing Day 2020 It’s not too early to start planning your Manufacturing Day 2020 events. Visit www.mfgday.com for ideas and to register your event. n

Inside SMI ©iStockphoto.com/seraficus

SMI Annual Meeting Heads to the Bahamas Start making your plans for the 2020 SMI Annual Meeting. This year’s event will be held from March 7 - 10 at the Atlantis, Bahamas.

The 2020 meeting promises to provide many opportunities to network with fellow springmakers and suppliers, along with numerous educational and optional events.

Speakers include Kenneth W. Gronbach, president of KGC Direct, LLC, and author and speaker David Rendall.

Gronbach’s presentation, “Demographics is Human Analytics, Planning for What’s Next,” will be take place on Monday, March 9.

“Come explore the common sense, but very counterintuitive and fascinating realm of demography,” explained Gronbach. During his presentation, Gronbach promises to bring SMI members into his world of counting people.

Gronbach is a marketer who has immersed himself in 19 years of proprietary demographic research.

His understanding of worldwide demographics, fertility, migration, aging,

immigration and dying have enabled him to forecast societal, political, economic, cultural and commercial phenomena with uncanny accuracy.

Here are some the questions he will answer during his presentation: What nations are demographically doomed?

How will the workforces change?

What is the future of communications?

How will our children’s children get their education? Will big data change marketing and branding forever?

What is the fate of mass media? What countries and continents are demographically positioned to excel?

On Tuesday, March 10, Rendall will address “The Freak Factor.”

“Our parents, teachers, and managers have told us that, if we want to succeed, we should find and fix our weaknesses,” explained Rendall. “However, this is the wrong approach, because each weakness is also a strength.” Rendall says SMI members will find out “how to create outrageous personal and professional success by amplifying flaws, instead of denying them.”

David Rendall

Kenneth W. Gronbach

During the last 15 years, Rendall has spoken to audiences on every inhabited continent. His clients include the U.S. Air Force, Australian government, and Fortune 500 companies such as Microsoft, AT&T, United Health Group, Fannie Mae and State Farm.

Before becoming a speaker, Rendall was a leadership professor and standup comedian. He also managed nonprofit enterprises that provided employment for people with disabilities. In between presentations, Rendall competes in ultramarathons and Ironman triathlons.

Rendall earned a doctor of management deg ree in orga nizat ional leadership, as well as a graduate degree in psychology. He is the author of four books, “The Freak Factor,” “The Freak Factor for Kids,” “Pink Goldfish” and “The Four Factors of Effective Leadership.”

Reminder: Each guest attending the meeting in the Bahamas will need a valid passport, including children.

To learn more about the resort, visit https://www.atlantisbahamas.com.

SPRINGS / Winter 2020 / 77

Inside SMI

Mike Betts (right) receives the Automotive Aftermarket Management Award from Northwood University president, Dr. Kent MacDonald.

Calendar of Key Events for the Global Spring Industry 2020 February 20 WCSMA Regional Meeting Buena Park, California March 6–10 SMI Annual Meeting Atlantis, Bahamas

Former SMI President Receives Prestigious Education Award Mike Betts, immediate past president of SMI and chairman and CEO of Betts Company, was a 2019 recipient of the Northwood University Automotive Aftermarket Management award.

Betts received the award during a lunch ceremony Nov. 5, 2019, during the Automotive Aftermarket Products Expo (AAPEX) show in Las Vegas.

Betts received the award for his noteworthy accomplishments in education both within and outside the automotive aftermarket industry.

Betts helped develop and start the Heavy Truck Program at Duncan Polytec High School in Fresno. The program is noted as a “one of a kind, best in class Career Technical Education (CTE) program.” The school currently has 83 students enrolled in the program.

In addition, Betts has led initiatives in CTE manufacturing programs

at area high schools and community colleges.

Betts served as president of Betts Company from 1995 to 2015, having previously held numerous positions in sales, marketing, innovation and leadership with the company for a combined total of more than 38 years.

In his role as chairman and CEO, he continues to provide guidance and support to Betts Company’s leadership team. Betts graduated from the University of the Pacific in 1978 with a degree in business administration.

Northwood University honors a select few industry leaders each year “in recognition of substantial dedication over a number of years to the educational process and the field of the motor vehicle aftermarket,” according to the university.

March 30–April 3 wire Düsseldorf International Wire and Cable Trade Fair Düsseldorf, Germany www.mdna.com/trade-shows/ details/wire June 1–4 WAI Operations Summit & Wire Expo Mohegan Sun Resort & Casino, Uncasville, Connecticut Sept. 14–16 International Committee on Spring Technologies – ICST – 2 Düsseldorf, Germany www.icst2020-germany.de/ Oct. 7–9 SpringWorld Rosemont, Illinois www.casmi-springworld.org Nov. (TBD) ISO/TC 227 – Springs Milan, Italy www.iso.org/committee/369318.html

2021

Springs Magazine App SMI has an app for Springs magazine that can be accessed via smartphones and tablets. The free app from SMI contains the current issue of the magazine and archived issues beginning with the Winter 2015 edition. The app has archives of all issues going forward, which are available for download.

Individual email addresses or websites mentioned in the magazine are all hyperlinked on the app.

To download, search: Spring Manufacturers Institute or Springs Magazine in your Android or Apple device. n

78 / SPRINGS / Winter 2020

Sept. 28–30 2021 SMI Metal Engineering eXpo South Point Resort and Casino Las Vegas www.metalengineeringexpo.org Sept. 30–Oct. 1 ISO/TC 227 – Springs South Point Resort and Casino Las Vegas www.iso.org/committee/369318.html Oct. 8 11th International Congress of Springs Spain (location TBD)

Save the date!

September 28-30, 2021 South Point Resort & Casino

Las Vegas

OFFICIAL EVENT OF

Learn more at www.metalengineeringexpo.org

©iStockphoto.com/Studio-Pro

Committee Connection SMI Board Meets in Pittsburgh

J

ust prior to the start of the 2019 SMI Metal Engineering eXpo in Pittsburgh, SMI’s board of directors met Monday, Sept. 30. SMI president Steve Kempf presided over the meeting, where he welcomed Don Jacobson III of Newcomb Spring as the newest member of the SMI executive committee, along with new board member Tim Zwit of Michigan Spring & Stamping. Zwit is heading up the technical committee.

With Jacobson being elevated to the executive committee, David DeVoe of Plymouth Spring was announced as the new chairman of the magazine committee. In addition, Dave Deerwester of The Yost Superior Company and Agustin Estalayo of RPK Mexico SA de CV were announced as co-chairs of the membership committee.

Kempf reported on his recent trip to Hamburg, Germany to attend the 10th International Congress of Spring Industry, organized by the European Spring Federation. Kempf made a presentation

80 / SPRINGS / Winter 2020

on the state of the spring industry in the U.S. The meeting included representatives from 27 other countries.

The meeting featured networking and presentations on current economic conditions around the world. Technical presentations included information on stainless steel wire, powertrain systems and 3D printing.

Kempf announced that SMI will be hosting the 2021 ISO/TC227 meeting. SMI hopes to hold the meeting in conjunction with the 2021 Metal Engineering eXpo, which will be held at the South Point Resort and Casino in Las Vegas from Sept. 28–30.

SMI executive director Lynne Carr reported that SMI has hosted three roadshows this year across the country. She said more events are planned for next year, in conjunction with spring design classes being conducted across various regions. The SMI roadshow could expand to Texas/Mexico, CASMI and to other areas where an event has not yet taken place.

Brett Goldberg of International Spring, who heads up the benchmarking committee, reported that in 2019, 51 companies participated in SMI’s benchmarking survey, which is down from 58 in 2018.

Zwit reported that technical committee has been busy working on 14 spring design courses that have been or are in the process of being completed.

This breaks down to three fundamental courses, seven basic and four advanced.

The first course, Spring Design 201, was taught just prior to the start of the eXpo (see more on page 51).“It’s the culmination of a lot of work,” Zwit said. He noted that 11 individuals who contributed to the development of the courses were in the room as members of the SMI board and staff.

With the Advanced Spring Design (ASD) software playing an important role in the spring design courses, it was noted by SMI technical advisor Gary Van Buren that it’s not just spring companies who purchase the software.

He said many other manufacturing companies and individuals buy it. “We need to market the classes to all of those people and teach them how to use it properly,” Van Buren said.

The SMI board will next meet during the 2020 annual meeting in the Bahamas. n

New Products ©iStockphoto.com/hüseyin harmandaglı, morkeman, PeskyMonkey

FR Series Payoff Reels HSI Machinery and FSI have announced the addition of the new FR Series of highspeed payoff reels with inverter technology.

The main features of the FR series are: • Inverter drive and motor for optimum high-speed control.

• Motor brake to prevent the wire from getting tangled.

• Synchronized control ensures smooth wire feed to increase spring quality.

• Optional auto speed control.

• Optional fine wire arm for optimizing the fine wire production.

For additional information, contact Forming Systems, Inc. at info@formingsystemsinc.com or 269-679-3557.

Bihler 4 Slide-NC Bihler 4 Slide-NC, Inc., the machinebuilding division of Bihler of America, Inc. that specializes in servo-controlled fourslide machines, showcased its advanced rapid prototyping capabilities to the metalforming industry at the 2019 SMI Metal Engineering eXpo in Pittsburgh.

As an innovator in fourslide manufacturing equipment, Bihler 4 Slide-NC combines the latest technology in additive manufacturing with complete motion control of servo-driven slides for enhanced manufacturing outcomes. The servos in the Bihler 4 Slide-NC® machine enables precise tooling positioning and adjustment, as well as improved set-up times. Along with advanced engineering capabilities, the Bihler 4 Slide-NC®

machine supports 3D-printed tools that boost production efficiency, and that enhance the prototyping process and tool precision.

Improvements to the machine, which were developed based on studies and customer feedback, include enhanced ergonomic features, advanced design support, a video training library and setup times of as little as 5 to 30 minutes.

The company says that for many decades, tooling development in the slide forming industry has been based on 2D/3D design, and on CNC machining of tool components. Precisely designing and building the perfect tool using these dated methods could easily take several months. Now with the implementation of

3D-printed tools using Bihler 4 Slide-NC® technology, tooling development is only a weeklong process. Depending on material strength, these tools can even be used for early-stage prototypes and for proof of concept, which reduces the development period for hard tooling.

“Imagine having the ability to try out early-stage concepts on a live machine,” says Max Linder, director of sales and marketing at Bihler of America. “That capability is changing how we train our new employees, and how we transfer our knowhow to the next generation of tool designers. Instead of feeding abstract FEMA models, we now can prove strategies on a live production machine within hours.”

SPRINGS / Winter 2020 / 81

New Products

Grieve 650°F Universal Oven No. 841 is a 650°F (343°C), universal oven from Grieve, currently used for a variety of heat treatments. Workspace dimensions of this oven measure 36" W x 36" D x 36" H. 9 KW are installed in Incoloy sheathed tubular heating elements, while a 600 CFM, 1/2 HP recirculating blower provides universal airflow to the workload.

This Grieve universal oven features 6” insulated walls, aluminized steel exterior and Type 430 stainless steel interior with double doors. Additional features include a workspace floor reinforced for 500 lbs. loading at removable subway grate and an integral leg stand.

Controls on the No. 841 include a digital programming temperature controller, manual reset excess temperature controller with separate contactors and a recirculating blower airflow safety switch.

For more information, contact Frank Calabrese at The Grieve Corporation, 500 Hart Road, Round Lake, Illinois 60073-2835; phone 847-546-8225; fax 847-546-9210; www.grievecorp.com; or email sales@ grievecorp.com.

Starrett Expands Hardness Testing Line The L.S. Starrett Company, a leading global manufacturer of precision measuring tools and gages, metrology systems and more, has significantly expanded its line of Benchtop Hardness Testers, adding seven Rockwell systems, eight Vickers

82 / SPRINGS / Winter 2020

systems and one Brinell system, for a total of 16 new testers. “From basic analog and manual control, to advanced digital and fully automated systems, our new hardness lineup offers customers a complete and comprehensive range of solutions for

any or all of their hardness testing needs,” said Emerson Leme, vice president Starrett Industrial Products – North America.

The new Starrett Rockwell Hardness Systems include two regular Rockwell Digital Testers, two Superficial Rockwell Testers, (one dial and one digital), two Twin Rockwell-Superficial Rockwell Testers (one dial and one digital), and two Twin Rockwell-Superficial testers with a dolphin nose design that are fully automated digital systems with output to PC and capable of measuring 30 different Rockwell scales.

New Starrett Vickers Hardness Testers include six Micro Vickers Testers for handling a testing range of 1HV-2967HC and 8 test forces, two with Digicam Basic Manual Software for manually selecting edges of indentation, two with Digicam Auto Software for automatically detecting edges of indentation, and two testers with Auto Turret control (one with basic software, one with auto software). In addition, there are two Macro Vickers Testers for handling up to 17 test forces; one featuring Digicam Basic Manual software and one featuring Digicam Automatic Software.

The new Starrett Digital Brinell Hardness Tester features automatic loading and can handle 10 scales.

New Products

Starrett Salutes Made in America The L.S. Starrett Company also recently released a special-edition brochure that heralds the company’s history and commitment to American made quality and innovation. The 18-page brochure includes overviews of Starrett’s five U.S. manufacturing facilities where thousands of Starrett precision tools, metrology systems, gages, shop tools and saw blades are made. An introduction from Douglas A. Starrett, an overview of the company’s key competencies, photos of skilled employees, and a complimentary, laminated pullout Starrett/U.S.A. flag poster are also included.

The printed brochure with a laminated U.S.A. pullout flag poster is available free by request online at www.starrett.com/ american-made. In addition, a digital flipbook of the brochure can be viewed at the same link. n

Advertiser's Index A & D Trading (440) 563-5227. . . . . . . . . . . . . . . . . 74 Admiral Steel (800) 323-7055 . . . . . . . . . . . . . . . . . 9 Alloy Wire International (866) 482-5569. . . . . . . . . . . . . . . . .16 CASMI www.casmi-springworld.org . . . . . .66 Diamond Wire Spring Co. (800) 424-0500 . . . . . . . . . . . . . . . . 24 Dispense Works (815) 363-3524. . . . . . . . . . . . . . . . . 70 Fenn/Torin (860) 259-6600 . . . . . . . . . . . . . . . . 52 Fives Group www.fivesgroup.com . . . . . . . . . . . 49 Forming Systems Inc. (877) 594-4300 . . . . inside front cover, back cover Gibbs Wire & Steel Co. Inc. (800) 800-4422 . . . . inside back cover Gibraltar (847) 383-5442. . . . . . . . . . . . . .33, 58

Industrial Steel & Wire (800) 767-0408. . . . . . . . . . . . . . . . . . 6 Interwire Products Inc. (914) 273-6633. . . . . . . . . . . . . . . . . . 1 JN Machinery (224) 699-9161. . . . . . . . . . . . . . . . . 23 Jowitt & Rodgers/Syntech (704) 525-8030. . . . . . . . . . . . . . . . .24 Kiswire (201) 461-8895. . . . . . . . . . . . . . . . . 64 Maguire Machinery (609) 266-0200 . . . . . . . . . . . . . . . . 20 Mapes Piano String Co. (423) 543-3195. . . . . . . . . . . . . . . . . 71 Messe Dusseldorf (312) 781-5180. . . . . . . . . . . . . . . . . 18 NIMSCO (563) 391-0400. . . . . . . . . . . . . . . . . 14 North American Spring Tool (860) 583-1693. . . . . . . . . . . . . . . . . 14 Proto Manufacturing (800) 965-8378 . . . . . . . . . . . . . . . . 11 Radcliff Wire (860) 583-1305. . . . . . . . . . . . . . . . . 54

RK Trading (847) 640-9371. . . . . . . . . . . . . . . . . .5 Shanghai SFK Precision Co. sfkppd@163.com. . . . . . . . . . . . . . . . 8 Simplex Rapid (563) 391-0400. . . . . . . . . . . . . . . . . 72 Spring Manufacturers Institute (630) 495-8588. . . . . . . . . . . . . . . . .79 Suzuki Garphyttan (574) 232-8800. . . . . . . . . . . . . . . . . 26 Tool King (847) 537-2881. . . . . . . . . . . . . . . . . 19 United Wire (800) 840-9481 . . . . . . . . . . . . . . . . 76 Vinston (847) 972-1098. . . . . . . . . . . . . . . . . 13 Vulcan Spring & Manufacturing Co. (215) 721-1721. . . . . . . . . . . . . . . . . 76 WAFIOS (203) 481-5555. . . . . . . . . . . . . . . . . . 3 Zapp Precision Strip (203) 386-0038 . . . . . . . . . . . . . . . . 58

SPRINGS / Winter 2020 / 83

Snapshot ©iStockphoto.com/Tryfonov Ievgenii, nicholas belton

David Janowski AMW Springs Name: David M. Janowski Nickname (if any): Dave Company name, city and country: AMW Springs and A&D Trading LLC in Rock Creek, Ohio.

Brief history of your company: I started AMW Springs in 2003 with the initial purchase of equipment from eBay and production in my garage. With a rapid growth in sales during our initial years, this eventually led to the purchase of a larger space. AMW Springs now employs 12 people and utilizes 27 production machines. In 2005, we started the machinery sales company A&D Trading LLC, to supply equipment and service to fellow spring companies.

Job title: President Spring industry affiliations: PittsburghOhio Spring Makers Association and SMI Birthplace: Cleveland, Ohio.

Current home: Geneva, Ohio.

Family: Wife, Amanda, daughters, Veronica and Caroline.

What I like most about being a springmaker: Solving difficult spring production situations.

Favorite food: Just about anything, not picky!

Favorite books/authors: Anything car related, I’m a huge gear head!

Favorite song/musician: Anything produced under the Sun Records label; I love that early rock, country and rockabilly sound. If you are not familiar,

84 / SPRINGS / Winter 2020

Team members at AMW Springs are pictured (l-to-r): Kevin Rose, Sharon Miller, Phil Oeffner, David Janowski, Amanda Janowski, Thurman Lahner, Tim Beck and Ed Dobay.

listen to recordings of Elvis, Carl Perkins, and Johnny Cash under the Sun Records label; that sums it up.

Hobbies: Working on my car collection, along with making many of my own custom parts for those cars.

Favorite places: Northeast Ohio.

Best times of my life: Present day, I have two healthy, beautiful daughters and an amazing wife! What more could a man ask for?

A really great evening to me is: Dinner with my wife at one our favorite restaurants.

The one thing I can’t stand is: Laziness.

I don’t want excuses, I want results.

My most outstanding qualities are: Ability to get the job done and the gift of gab.

People who knew me in school thought I was: An underachiever.

I knew I was an “adult” when: My oldest daughter, Veronica, was born.

If I weren’t working at (AMW Springs), I would be: Working as a springmaker for someone, it’s all I have ever done, and I love what I do.

The most difficult business decision I ever had to make was: Buy out my initial business partner.

I wonder what would have happened if: I wouldn’t have been hired by Sanborn Wire Products out of high school.

Dave Morrow gave me my first taste of the business!

Role models: Frank, Walter, Kevin, Jim, Dennis, Jeff, Gary, Dave, Reb, just to name a few of all the mentors in the springmaking industry that have helped me through the years.

I would like to be remembered in the spring industry for: Helping my fellow springmakers with making springs and purchasing equipment. A guy that can get it done!

But people will probably remember me for: My quick wit and humor!

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