Springs summer 2010 vol 49 no3 by Spring Manufacturers Institute

T H E I N T E R N AT I O N A L M A G A Z I N E O F S P R I N G M A N U FA C T U R E

Summer 2010,Volume 49 Number 3

A Publication of the Spring Manufacturers Institute The International Magazine g of Spring p g Manufacture Manuf e

The International Magazine g of Spring p g Manufacture

A Publ Publication licaation of o the Sprin Springg Manuf Manufacturers facturers In Institute stitute

Januaryy 2009,Volume Vo olume 48 Number 1

Sales and Marketing AVOIDING OIDING A LET LETHAL THAL L DISCONNECT DISCONNECT— — GETTING

Washington and Wall Street

MARKETING OF THEIR SALES ALES AND MA MARK M ETING NG OUT O THEIR EIR R SILOS MANUFACTURERS MANUFACTURERS’ S REPRESENTATIVES REPRESENT REPRESENTATIV ES — OUTSOURCING THE HE ORIGINAL O UTSOURCING SOLUTION SOL LUTION N 24 TURNING TURN URNING R G ANGRY CLIENTS INTO TO H HAPPY APPY ONES ON ONE O

Washington and Wall Street 20 Making Government Affairs Part of Your Operating Plan

Bailout Bill Provides Many Tax Breaks for Springmakers 36

Prsrt Std US Postage PAID Documation

2001 Midwest Rd., Suite 106 Oak Brook, IL 60523-1335 Change Service Requested

Prsrt Std US Postage PAID Documation

Oak Brook, IL 60523-1335 Change Service Requested 2001 Midwest Rd., Suite 106

The International Magazine g of Spring p g Manufacture

❋ T The International Magazine g of Spring p g Manufacture e

T H E I N T E R N AT I O N A L M A G A Z I N E O F S P R I N G M A N U FA C T U R E

AP Publication bli ti off the th Spring S i Manufacturers M f Institute I i

Apriil 2009,Volume 48 Number 2

2001 Midwest Rd., Suite 106 Oak Brook, IL 60523-1335 Change Service Requested

AP Publication bl off the h SSpring Manufacturers M f Institute I

Springmaking Cost Costs s and Springs Costing Sp rings

SP RI NG Fla S State Stat Sta tat ate tee ooff the t th International Int In nte ter ern er rna rn na ational ti Sp Spring Spr In Industry In

SPRINGMAKERS SPRINGM S PRING GMAKERS G GM M ERS GET T G TECHNICAL HNICAL

THE BENEFITS OF ADVANCED VANCED PRODUCTION PLANNING IS THE ANSWER IN THE HE CLOUDS? CLOUD COMPUTING

Mergers and Acquisitions: Insights from Industry Leaders 2001 Midwest Rd., Suite 106 Oak Brook, IL 60523-1335 Change Service Requested

Prsrt Std US Postage PAID Documation

Bargain Hunting for Survival Generational Gems Ownership and Accountability

34 38 48

HOLDS PROMISES FOR SPRINGMAKERS NGMAKERS

THE IMPORTANCE OF TEST CORRELATION

2001 Midwest Rd., Suite 106 Oak Brook, IL 60523-1335 Change Service Requested

Prsrt Std US Postage PAID Documation

2001 Midwest Rd., Suite 106 Oak Brook, IL 60523-1335 Change Service Requested

Presort Standard US Postage PAID Rockford, IL Permit No. 1

sh Iss bac ue k ! Lo Snapshots hots from the International Internat natio ationall Spring ng Industry 17

Oak Brook, IL 60523-1335 Change Service Requested 2001 Midwest Rd., Suite 106

Prsrt Std US Postage PAID Documation

What W hat at it Tak Takes es forr Lean Lea ean to Deliver l Bottom ttom Line Lin ine Results Resu sullts 25

Oak Brook, IL 60523-1335 Change Service Requested 2001 Midwest Rd., Suite 106

Prsrt S Std US Postage Pos stage PAID D Documation Documa ation

T H E I N T E R N AT I O N A L M A G A Z I N E O F S P R I N G M A N U FA C T U R E

A Publication of the Spring Manufacturers Institute

A Publication P bl off the h SSpring M Manufacturers annufa factureers Institute I

Springs and Energy SMI Members Combat Rising Costs 22 Springs, Energy and Hidden Potential

Energy Saving Ideas for Ovens 47

2001 Midwest Rd., Suite 106 Oak Brook, IL 60523-1335 Change Service Requested

ok In sid e

Prsrt Std US Postage PAID Documation

2001 Midwest Rd., Suite 106 Oak Brook, IL 60523-1335 Change Service Requested

State of the International Spring Industry

Prsrt Std US Postage PAID Documation

Snapshots hots from the Internat International nati atioonall ng Industry 17 Spring

Prsrt Std Prs US Pos U Postage PAID Documation

2001 Midwest Rd., Suite 106 Oak Brook, IL 60523-1335 Change Service Requested

Prsrt Std US Postage PAID Documation

The International Magazine T g of Spring p g Manufacture

Prsrt Std US Postage PAID Documation

2001 Midwest Rd., Suite 106 Oak Brook, roo IL 60523-1335 60523-1335 Change Requested ge Service S Requested

2001 Midwest Rd., Suite 106 Oak Brook, IL 60523-1335 Change Service Requested

What W hat at it Tak Takes kes forr Lea Lean ean to Deli Deliver ver Bottom ttom Line Lin ine Results Resu sults lts 25

Presort Standard US Postage PAID Rockford, IL Permit No. 1

A Publication of the Spring Manufacturers Institute

Springs and Energy SMI Members Combat Rising Costs 22 Springs, Energy and Hidden Potential

Energy Saving Ideas for Ovens 47

THE BEST SPRING WIRE AROUND.

Bezalplast Wire Bezinal Music Wire Bezinal Hard Drawn Phosphate Coated Music Wire Galvanized Music Wire Tin coated Music Wire Shaped Music Wire Square Music Wire Nickel Coated Stainless Steel Soap Coated Stainless Steel 17-7 Stainless Steel Annealed and Off Temper Stainless Steel Stainless Steel Knitting and Weaving Wire Stainless Steel Stranding Wire Stainless Steel Cable Monel Inconnel Vacuum Melt Stainless Steel Oil Tempered MB Spring Wire Oil Tempered Flat Wire Oil Tempered Square Wire Oil Tempered Regulator Wire Oil Tempered Chrome Silicon Oil Tempered Chrome Silicon Flat Wire Oil Tempered Chrome Vanadium

Brass Wire Phosphor Bronze Wire Copper Alloy Wire Nickel Silver Wire Bright Hard Drawn Galvanized Hard Drawn Bright Basic Low Carbon Wire Low Carbon Braiding Wire Low Carbon Book Binding Wire Low Carbon Shaped Wire Low Carbon Trapezoid Wire Many other Specialties in Carbon and Stainless round and flats

The Largest U.S. Wire Distributor Over $30 Million in Inventory 8 Nationwide Warehouse Centers All Locations are ISO Certified

InterWireGroup.com InterWire New York 355 Main Street Armonk, NY 10504 (914) 273-6633 (914) 273-6848 (Fax)

InterWire Products 50 Broderick Road Bristol, CT 06010 (860) 583-0491 (860) 582-7109 (Fax)

ÂŠ 2010 creativesolution.com

Wired to meet your needs. InterWire California 6780 Katella Ave. Cypress, CA 90630 (714) 379-0500 (714) 379-0505 (Fax)

InterWire Michigan 4700 Broadmoor Ave.SE, Suite 300 Kentwood, MI 49512 (616) 554-9900 (616) 554-9982 (Fax)

InterWire Texas 1025 Ave. S, Suite 300 Grand Prairie, TX 75050 (972) 623-0620 (972) 623-0314 (Fax)

InterWire Midwest 937 Lombard Road Lombard, IL 60148 (630) 620-6680 (630) 620-6926 (Fax)

InterWire N. Carolina 13935 South Pt Blvd. Charlotte, NC 28273 (703) 971-6923 (703) 971-6928 (Fax)

InterWire Mexico Av. Tepeyac 1420-D Parque Industrial OdonnellAeropuerto, El Marques Queretaro, C.P. 76250 Mexico (800) 699-6633 011-52442-253-0031(Fax)

President’s Message From Scott Rankin

Lessons from Trade Shows and Volcanoes I have attended the wire and tube show for the last 10 years. After going to the 2010 version in Düsseldorf, Germany I must admit, I love this show! I love the show for many reasons, but number one: It is the place to find anything in the spring industry. Years ago, I was in the market for a zinc casting machine, and after hours of looking and miles of walking I found the machine in Düsseldorf. Two years ago, I was looking for a new way to make a new spring design, and after doing my usual rounds of the show I found the solution. This year I was on the hunt for a non-contact measuring device as well as a new spring coiling machine that could make a part that we currently make by hand. Both of these products were hiding at the show, and in the end I found at least three varieties of each that fit my needs. The wire and tube show is my favorite because it is kind of like a Home Depot for springmakers. Everything is in one place and you can pretty much bet that you will leave with what you need, plus a whole bunch of other stuff that you didn’t know you needed (but that is a problem I have at any Home Depot!). Many of you were at the show and it was a huge success, but because of the way Mother Nature decided to end the event it will be one of my most memorable trade shows. I was to leave on Friday and I heard the news that a volcano, Eyjafjallajökull, had erupted on Wednesday or Thursday. This one closed the airspace over much of Europe as well as Great Britain and actually, it seemed to me, everything north of Italy. So the buzz went around the show that airports were closed and we would not be able to leave town. I decided that this would only be a small inconvenience and I would go home as scheduled. Worst case – I would spend another night in Düsseldorf and fly out on Saturday, giving me time to relax in Germany and enjoy some beer and excellent food. Well, relaxing was not going to be the case for the next four days as I once again went in search of something I needed. This time it was a way to get back home. Countless miles and many dead ends finally got me to Spain where I found a flight to the U.S. Just like the trade show I knew there was going to be a solution; I just needed to keep looking and moving until it showed itself to me. I have left out four days of adventure, frustration and victory as that is for another time. So all in all it was a great show and one that will always stay in my mind as another part of my journey in life. If you were there I hope you made it home without too much trouble, and if you stayed home it was probably a good choice this time. As we celebrate the past in this nostalgic issue of Springs, it reminds me that SMI and its members have always succeeded by finding solutions to their challenges. Though the solution may not always be easy to find, it is usually within reach by looking in the right places. SMI continues its commitment to help you discover the “solutions” and “right places” that will enable your future success. Succeed with Passion,

SMI Executive Committee President, Scott Rankin, Vulcan Spring & Manufacturing • Vice President, Steve Moreland, Automatic Spring Products • Secretary/Treasurer, Russ Bryer, Spring Team • Immediate Past President, Reb Banas, Stanley Spring & Stamping • At Large, Mike Betts, Betts Spring SMI Board of Directors Tom Armstrong, Duer/Carolina Coil • Dennis Backhaus, Spiros Industries • Jim Callaghan, MW Industries • Ron Curry, Gifford Spring • Ann Davey, John Evans’ Sons • Chris Fazio, Diamond Wire • Kurt Gillespie, Century Spring • Richard Guimont, Liberty Spring • Greg Heitz, Exacto Spring • Gene Huber Jr, Winamac Coil • Miko Kabeshita, Ark Technologies • Steve Kempf, Lee Spring • Brett Nudelman, International Spring • Hap Porter, SEI Metaltek • Byron Ress, Zapp Precision Strip • Richard Rubenstein, Plymouth Spring • Ted White, Hardware Products • Chris Witham, Motion Dynamics Springs Magazine Staff

Lynne Carr, Advertising Sales, lynne@smihq.org Dina Sanchez, Assistant Editor, dina@smihq.org Gary McCoy, Managing Editor, gmccoy@fairwaycommunications.com Springs Magazine Committee Chair, Richard Rubenstein, Plymouth Spring • Carol Caldwell, Century Spring/MW Industries • Lynne Carr, SMI • Randy Deford, Mid-West Spring & Stamping • Ritchy Froehlich, Ace Wire Spring & Form • Tressie Froehlich, Ace Wire Spring & Form • LuAnn Lanke, Wisconsin Coil Spring • Tim Weber, Forming Systems • Europe Liaison: Richard Schuitema, Dutch Spring Association • Technical advisors: Loren Godfrey, Colonial Spring Advertising sales - Japan Ken Myohdai, Sakura International Inc. 22-11 Harimacho 1-Chome, Abeno-ku Osaka 545-0022 Japan Phone: +81-6-6624-3601 • Fax: +81-6-6624-3602 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) 4958588; 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.

Scott Rankin President,Vulcan Spring & Mfg. Co. scott@vulcanspring.com

2 SPRINGS Summer 2010

Cover by Sue Zubek, Zubek Design, Inc. Cover art created using images from Istock: ©Istock/zbruch

DOES IT ALL

SPEED / PRECISION / QUICK CHANGEOVER

HAS IT ALL

SERVICE / PARTS / TECHNICAL SUPPORT

premium quality combined with outstanding knowledge & service Purchase a Bobbio Coiler and you will not only get the versatility, precision, and advanced technology that is unique to Bobbio, you’ll also receive the unmatched local service, parts and support that many satisfied customers have come to enjoy from RK Trading. RK is proud to offer the Bobbio Excel line of coilers. World renown for their European craftsmanship, this elite line of coilers offers options up to 11 axis, wire ranges from 2mm-20mm and integrated camera gauging for OD and FL control. An advanced monitoring system along with newly enhanced software makes for easier and faster setup times. And now you get all of that along with the superior service you expect from RK Trading.

Make sure you “have it all” and call RK Trading today to see how Bobbio and RK can help.

www.rktradingusa.com

847-640-9771

Table of Contents FEATURES 20

Looking Forward, Looking Back: Reminiscing with SMI By Gary McCoy 24 Beating Our Swords into Slinkys By Carl Zebrowski 27 Auntie Siphon By Don Fazio 28 Springs at War By Gary McCoy 34 Unusual Users of Springs and Spring Technology By Allison Kerns Lindley 36 Heat Treatment For Pretempered Hard Drawn Spring Materials By Harold Carlson 39 The Important Skills of a Manager By Ralph Young

What It Takes for Lean to Deliver Bottom Line Results Part Two: Tactical Issues By David Kwinn

Healthcare Reform Impacts Small Employers Immediately: What You Need to Know Now by Roger Schultz

COLUMNS

Spotlight on the Shop Floor Shop Floor Specifications — The Filtered Details By Randy DeFord

Be Aware Safety Tips Looking Back By Jim Wood

IST Spring Technology Cautionary Tale: Are Your Customers' Load Tests Identical with Yours? By Mark Hayes

Technically Speaking Precipitation-Hardened Stainless Steel for Springs By Luke Zubek, PE

DEPARTMENTS

59 4 SPRINGS Summer 2010

President’s Message Lessons from Trade Shows and Volcanoes

Global Highlights

Regional Spring Association Report

Flashback At What Stage of Design Should The Spring Manufacturer Be Consulted and Why?

Springmaker Spotlight Ted White, Hardware Products

Inside SMI SMI Annual Meeting in St. Thomas Was Smooth Sailing; SMI Board Meets in St. Thomas; SMI Will Host Industry-Wide Reception at Spring World 2010; Spiro Industries Involved In Charitable Cause; SMI Mourns Passing of Members; SMI Welcomes New Members

New Products

Advertisers’ Index

Snapshot Daniel Pierre III, JN Machinery Corporation

6 SPRINGS Summer 2010

Global Highlights North America Emhart Teknologies, a Black & Decker Company and a global leader in fastening and assembly technologies, has acquired Fastener Innovation Technology, Inc. (FIT), a designer and manufacturer of critical, highly-specialized aerospace fasteners based in Gardena, Calif. The transaction closed March 1, 2010. “Combined with our Heli-Coil® initiatives and the 2008 purchase of Spiralock Corporation, bringing FIT under the Emhart brand enables us to integrate the finest aerospace fastener platforms into a single-source organization,” said Emhart Teknologies’ president Michael A. Tyll. “This acquisition allows us to better serve the aerospace, military and commercial aircraft industries where FIT enjoys a strong reputation among the world’s leading aerospace companies.” FIT has long-term customer relationships with Boeing, Honeywell, Bell, GE, Pratt & Whitney, Embraer and Gulfstream Aerospace Corp., based on its premium-quality products and appropriate certifications. The company consistently delivers innovative products through the application of new high-strength materials such as steel alloys, titanium and super alloys. “Production forecasted for both new and replacement aircraft through 2020 reflects the projected growth in global air traffic. The purchase of FIT positions Emhart Teknologies to further support this industry growth,” Tyll said. Randy Aardema will lead FIT as general manager. Aardema recently joined Emhart from Acument Aerospace, and prior to that was with Textron Fastening Systems. For more information, visit www.fitfastener.com and www.emhart.com.

and 1,000 exhibiting companies covering more than 350,000 net square feet of floor space. Buyers and sellers from around the world will come together at this exhibition to exchange products and services, network with peers, problem-solve and discover new products and vendors. Visitors will see nearly 2,000 pieces of equipment in action on the show floor and more than 500 new product debuts. In addition to viewing the latest products, attendees will benefit from a comprehensive array of educational programs, featuring more than 100 expert-led presentations. In addition, the 2010 FABTECH will include special features attendees have come to expect from the show, including keynote presentations and free sessions in the Solutions Showcase. New for 2010, the Chemical Coaters Association International (CCAI) will join the event and host a new Finishing Technologies Pavilion on the show floor. The pavilion will feature exhibitors displaying a wide-variety of finishing technologies, including liquid finishing, powder coating, curing, and plating. CCAI will also produce conference programming focusing on these same technologies. The addition of the Finishing Pavilion allows manufacturers to visit one show that covers all metal manufacturing processes from beginning to end. FABTECH 2010 is cosponsored by the American Welding Society (AWS), Fabricators & Manufacturers Association International (FMA), Society of Manufacturing Engineers (SME), Precision Metalforming Association (PMA), and Chemical Coaters Association International (CCAI). Registration for FABTECH 2010 is now open. For further information on the event, visit www. fabtechexpo.com.

The countdown to FABTECH 2010 is underway as the event returns to the Georgia World Congress Center in Atlanta, Ga., November 2-4, 2010. This represents the first time in four years that the show will take place in the Southeastern corridor, a region that continues to see growth and expansion in metal fabricating, manufacturing and infrastructure. FABTECH is the largest trade show in North America dedicated to showcasing a full spectrum of metal forming, fabricating, stamping, tube and pipe, finishing and welding equipment and technology. The 2010 event is expected to draw 22,000 attendees

Jack Champaigne received an Outstanding Contribution Award by SAE International at the 2010 SAE World Congress in Detroit, Mich., this April. Established in 1953, the annual award recognizes outstanding service and leadership in the technical standard boards of this organization for engineering professionals in automotive, aerospace and commercial vehicle fields. Champaigne has been a member of the SAE International Materials, Processes and Parts Council since 1986 and currently serves as committee chairman of the SAE Surface Enhancement

SPRINGS Summer 2010 7

Committee. The Surface Enhancement Committee is responsible for developing and revising surface treatment standards used in the manufacture of metal components. Under Champaigne’s leadership, the committee has updated and created metal surface treatment standards that Jack Champaigne address rapid advances in technology and special applications for the automotive industry. Champaigne is the president of Electronics Inc. (EI). EI manufactures and distributes products that improve the quality and control of shot peening, and provides shot peening training programs and workshops. EI’s products and services enable manufacturers to meet SAE shot peening standards. For more information, please visit http://www. electronics-inc.com. The National Association of Manufacturers (NAM) has officially launched their new logo, branding and website.

As the voice of all manufacturing in the United States, the National Association of Manufacturers’ mission is to achieve an economic environment that promotes jobs creation and encourages the expansion of manufacturing in the United States. “We believe the new branding – communicated across all our media platforms – better reflects modern manufacturing, from the issues to the products to the people we represent,” stated John Engler, NAM president. “We are especially pleased by the new website, www.nam.org. Developed with extensive input from NAM members, the website more effectively portrays the face of modern manufacturing in the United States. The website also significantly upgrades our web-based communications, making it easier to locate information about manufacturing-related issues and resources. I encourage you to take a look, using it as a jumping-off point to explore the many new features at www.nam.org.” The 50th Anniversary Spring World 2010 Trade Show will be held October 13-15, 2010, at the Donald E. Stephens Convention Center in Rosemont, Ill., located next door to O’Hare International Airport. “Exhibitor floor space sales are tracking ahead of the 2008 Spring World show, with all the major industry spring manufacturers and suppliers eager to participate in the manufacturing resurgence,” announced Thomas Renk, Spring World executive director and show manager. “We have already sold 85 percent of the Spring World 2010 floor plan and are receiving new inquiries and exhibit space applications on a regular basis. An additional twelve booths were sold in April and we are seeing increased interest as the economy continues to improve. We are also seeing returning manufacturing companies that missed out on participating in the 2008 Show,” stated Renk. This year, CASMI is inaugurating education sessions for attendees. The sessions will be held in a dedicated location on the show floor and exhibitors are being encouraged to hold seminars all three days during Spring World. The seminars are expected to provide additional educational and networking opportunities for show attendees. A floor plan showing the companies exhibiting at Spring World is available on the show web page at http://www. casmi-springworld.org. For additional information contact Tom Renk, (630) 369-3466 or visit www.casmi-springworld.org. The Wire Association International (WAI), Inc., held Wire Expo 2010 and WAI’s 80th Annual Convention in May at the Midwest Airlines Center, Milwaukee, Wis. The exhibits, which were co-located

8 SPRINGS Summer 2010

with National Electrical Wire Processing Technology Expo, had a total of 2,931 participants who had crossover access between shows. Wire Expo registration showed 1,457 participants from 38 states and 21 countries. Early reports point to positive changes to the event initiated by a concentrated agenda that condensed exhibit days from three to two; and the coordinated scheduling with the American Wire Producers Association’s new Long Product Supply Chain Symposium, held May 9-10, which drew 220 people including presidents, CEOs, sales professionals, and senior managers from its member companies. WA I P r e s i d e n t D a n e G . Armendariz noted “scheduling three industry events within the same week helped a lot of visitors justify their trip to Milwaukee. The two-day exhibit format worked very well and with the convenience of the co-location we saw a steady flow of traffic between the shows on both days.” Highlights to Wire Expo’s 20th anniversary event included: • Participation by 157 exhibiting companies and crossover access to 100 additional exhibits • Guided facility tours of the Rockwell Automation and Charter Steel plants; • 30 technical paper presentations and a “Phosphating 101” class; • The Annual Awards Breakfast honoring the Donnellan Memorial Award winner Brian Bouvier and the Mordica Memorial Award winner Professor Javier Gil Sevillano, as well as technical paper authors; • The Fundamentals of Wire Manufacturing course; • Live production solutions demonstrations; and • WAI’s 5th Annual 5K Road Race, sponsored by Leoni Wire Inc. “The 2010 Electrical Wire Processing Technology Expo exceeded expectations,” said Jay Partington, president of Expo Productions. “Show attendance was up 16 percent from last year, with exhibitors reporting a 40 percent increase in leads and sales. Due to co-location with the Wire Expo, companies were able to go deeper into OEMs, resulting in higher attendance.” Contact WAI for more information at (203) 4532777 or visit www.wirenet.org.

International The fact that the economy is improving was reflected at the recent staging of wire 2010 – International Wire and Cable Trade Fair and Tube 2010 – International Tube and Pipe Trade Fair in Düsseldorf, Germany. The positive mood among the 2,400 exhibitors (compared to 2,200 exhibitors in 2008) and 69,200 visitors from more than 100 countries was the result of constructive talks, avid purchasing interest and actual deals as well as optimistic post-show expectations which characterized the atmosphere at both trade fairs. The exhibitors showcased the latest machinery, equipment and products from the wire, cable and tube processing industries on 1.07 million square feet of net exhibit space. “Every two years, Düsseldorf becomes the international platform for two key industry sectors. Global contacts are formed and orders placed here for the years ahead. The trade fairs are therefore taking place at precisely the right time. Companies are now investing again in order to get ready for future competition or to re-position themselves. In Düsseldorf the international key players of the wire, cable and tube industries meet with competent decision-makers from all over the world. It is a global industry forum where large enterprises, mediumsized companies and even small firms show what they have in store,” stated Joachim Schäfer, managing director of Messe Düsseldorf. At wire 2010, 1,219 companies from 52 countries presented their innovations on 559,700 square feet of net exhibit space. This is an increase of 7.3 percent in exhibitor participation compared to the show’s last staging in 2008. From the U.S., 78 companies exhibited SPRINGS Summer 2010 9

at wire 2010, including 30 companies within the North American Pavilion, organized by Messe Düsseldorf North America (MDNA) and sponsored by the Wire and Cable Industry Suppliers Association (WCISA). wire 2010 was attended by 35,000 trade visitors from 70 countries, 63 percent of which travelled to Düsseldorf from countries other than Germany. The majority of the visitors came from Great Britain, France, the U.S., Italy, India, the Netherlands and Spain as well as from Brazil, Turkey, Austria, Switzerland, Belgium and Poland. Visitors primarily represented the industry (81 percent) followed by trade (8 percent) and skilled crafts (3 percent). The visitors were mainly interested in machinery and equipment for wire production and processing (44 percent), materials, special wires and cable (41 percent), test technology (22 percent), measurement, control and regulation technologies (19 percent) as well as in tools for process engineering (20 percent). A slight increase in the number of executives was recorded. Visitors again confirmed the trade fair’s No. 1 status by giving it good to very good marks. Egon Reich, board member in charge of sales and marketing at WAFIOS AG Reutlingen, commented, “The trade fair went remarkably well. Already on the first day we had a huge amount of visitors. Visitors at our stand came well prepared and were very international. We also attribute this to our targeted information mailing before the start of wire 2010. We are expecting interesting post-show business.” A total of 1,181 exhibitors from 52 countries showcased their products on 484,300 square feet of net exhibit space at Tube 2010. Compared to 2008, exhibitor participation rose by 13.1 percent. Tube 2010 featured 40 U.S. companies, including 14 exhibitors within the North American Pavilion which was also organized by MDNA and co-sponsored by the Fabricators & Manufacturers Association, International and the Society of Manufacturing Engineers. The two trade fairs recently closed to very positive results: 69,200 trade visitors from over 100 countries came to Düsseldorf to gather information and place orders for the latest products and technologies displayed by 2,400 exhibitors. For further information on visiting or exhibiting at wire 2012 or Tube 2012, contact Messe Düsseldorf North America, (312) 781-5180 or visit www.mdna.com. Martin Doering, president of J.N. Eberle of Augsburg, Germany, is pleased to announce an alliance with Regal Steel Co. of Warren, Mich. Regal Steel Co. has been appointed sole distributor of their hardened and tempered precision spring steels in North America.

10 SPRINGS Summer 2010

J.N. Eberle has been in business for more than 174 years, producing high quality products, i.e. specialty steels such as C1095 Doctor Blade Steel, C1095 Flapper Valve Steel, C1095 Shock Valve Steel. Some typical applications are valves for shock absorbers and compressors, scraping blades for graphic printers, paper manufacturing, and saw tools. Steve Mager, president of Regal Steel Co. is also pleased to announce the purchase of an additional 27,000 sq. ft. of warehouse space adjacent to their current facilities and has installed two additional precision slitting lines to process the Eberle precision strip steel products. For information regarding J.N. Eberle material phone (800) 346-9201 or (586) 756-8300 or info@ regalsteel.com. Diran Apelian, Howmet Professor of Mechanical Engineering at Worcester Polytechnic Institute (WPI) and director of the Institute’s Metal Processing Institute (MPI), has been selected to chair a national blue ribbon panel charged with identifying ways that breakthroughs in materials and materials processes could lead to energy efficiency, energy security, and reductions in carbon emissions. Commissioned by the U.S. Department of Energy (DOE) Industrial Technologies Program and led by the Minerals, Metals & Materials Society (TMS), the panel consists of 21 thought leaders in materials science and engineering who represent academia, industry, and government. The Energy Materials Blue Ribbon Panel will explore the role that materials science and engineering can play in helping the nation meet its energy and climate challenges, Apelian said. “We need to clearly identify the opportunities and solutions for materials science and engineering in the energy sector to transform the ‘way we do it now,’” Apelian told JOM, the TMS journal. The work of the blue ribbon panel and working groups will assist DOE in launching two new university-led Manufacturing Energy Systems Centers, which are intended to accelerate the development and dissemination of knowledge related to critical technical needs in manufacturing. The centers are designed “to dramatically accelerate our progress toward a low-carbon economy by compressing the time it takes for innovation to go from pure science through engineering and finally to production, where it can have a real impact on our daily lives,” Douglas Kaempf, program manager for the DOE Industrial Technologies Program, told JOM. For the full list of members of the Energy Materials Blue Ribbon Panel, see http://www.tms.org/ newsletter/PressReleases/132.htm

Starting this year, the Confederation of Indian Industry (CII) and Messe Düsseldorf will jointly organize Wire & Cable India, the most important trade fair on the Indian sub-continent for this sector. The agreement was recently signed by Chandrajit Banerjee, director general of CII, and Hans-Werner Reinhard, vice president of Messe Düsseldorf. Wire & Cable India will be held from November 18–20, 2010 at the Bombay Exhibition Center in Mumbai. The organizers are confident that this cooperation will provide stimulus for the wire and cable companies in India and worldwide. “With the two leading trade fair organizers combining their excellence and expertise, this platform will be even more attractive for international export-oriented companies interested in entering the Indian growth market”, stated Chandrajit Banerjee. Hans-Werner Reinhard welcomed the union as an excellent addition to Messe Düsseldorf’s international trade fair portfolio: “The Indian market is becoming increasingly important for the wire and cable industry, primarily due to growth in the sectors of building and construction, automotive, aviation, energy, engineering and telecommunications. Our experience as an organizer of high-technology trade fairs will benefit Wire & Cable India.”

Event Dates wire China 2010 Shanghai, China www.wirechina.net September 21–24, 2010 Spring World 2010 Rosemont, IL www.springworld.org October 13–15, 2010 Wire & Cable India Mumbai, India www.mdna.com November 18–20, 2010 Interwire 2011 Atlanta, Georgia, USA www.wirenet.org May 2-5, 2011 Eleventh International Conference on Shot Peening South Bend, IN www.shotpeening.org September 12–15, 2011 ◆

SPRINGS Summer 2010 11

Regional Spring Association Report Chicago Fed Economist Provides CASMI with Economic Outlook

"Surprisingly, going forward, I think people are going to look at homes as less of an investment and more as a place to live. That means a very different way of thinking about housing." William A. Strauss

“I’m generally upbeat on manufacturing,” said William A. Strauss, a senior economist and economic advisor in the economic research department at the Federal Reserve Bank of Chicago. Strauss, the guest speaker for the May meeting of the Chicago Association of Spring Manufacturers (CASMI) in Rosemont, Ill., said you should be concerned if you’re a manufacturer and business isn’t improving. Strauss said the “Great Recession” came to an end around the middle of last year. However, he said that while the economy is currently expanding, it is happening at a very slow rate and most of the growth is due to inventories. “The inventory cycle is well underway,” explained Strauss. “In fact, I would even suggest that it is still in its nascent stage of recovery. So we still even have a ways to go that will be quite supportive of growth in manufacturing.”

12 SPRINGS Summer 2010

Strauss said that last year of all the groups he spoke to, manufacturers were among the most pessimistic. As a result, he said manufacturers made deeper cuts in production and personnel than “what a 3.8 percent drop in the economy would suggest.” He remains optimistic on manufacturing, both currently as well as going forward. He says the manufacturing sector has recovered better than other sectors, such as housing. Strauss said manufacturers who survived the downturn should be in good shape, because many weak companies did not make it. “What tends to be left are companies that are more efficient,” explained Strauss. “So another reason for optimism.” Strauss predicts a manufacturing growth outlook of about 5½ percent this year and over 4 percent next year. “Well above the 3.1 percent growth that we see for the economy as a whole,” he said. Strauss is also optimistic that inventory accumulation will increase through 2011. On other subjects, Strauss said the housing market could be going through a long term fundamental change. “Surprisingly, going forward, I think people are going to look at homes as less of an investment and more as a place to live,” said Strauss. “That means a very different way of thinking about housing.” He says overall GDP is forecast to grow above trend in 2010 and 2011 at around three percent. “Solid growth, but disappointing,” Strauss lamented. “We should be looking at growth rates that are twice this.” Strauss said the forecast path of the current recovery is relatively

muted compared with past deep recession recovery cycles. “One sad part was the huge loss in employment,” said Strauss of the over eight million people who lost their job during this downturn. “Because the economy is only growing slightly better than trend, the unemployment rate only edges down as we move forward,” he said. “So even by the end of next year, we’re still looking at unemployment rates of 8.5 percent. That’s pretty sad and that’s one of the bad consequences of a growth rate that is just above trend.” He believes inflation will only rise to about 2 percent next year from a rate of about 1.6 percent in 2010.

In other areas, he said corporate profits have been increasing, resulting in the rise of the stock market, and that real disposable income is anticipated to rise at a solid pace through 2011. He says consumer spending has come back quite nicely as well, and is expected to continue to be solid for the next two years. In summary, Strauss suggested that the outlook for the economy is for solid growth at a moderate pace this year. “However, I would say it is disappointing growth, all in all, for how far we have fallen,” said Strauss. “The employment side is only growing moderately, leading to

unemployment rates that are only edging lower and not coming down as quickly as we would like,” he explained. “But because of that we still have tremendous slack in labor markets and tremendous slack even in a sector like yours (springs) which is showing some better growth,” said Strauss. The “good news” take away from Strauss’ presentation was his belief that the manufacturing sector will experience outstanding performance both this year, as well as next year.

A WORLD OF SPRINGS Available in low volume quantities. Avoid no-bids or timely set up on short runs. Century Spring is a great source for filling low volume or prototype demands. Our stock parts ship same day at a very low minimum. To learn more or to request a free stock spring catalog, inquire at info@centuryspring.com or by calling us at (800) 237-5225 Mon-Fri 6:00am - 4:30pm PST. Compression • Extension • Die • Disc • Drawbar H-Clips • Tapered • Torsion • Urethane

222 East 16th Street, Los Angeles, CA 90015 ph 800-237-5225 • fx 800-474-4479 info@centuryspring.com • www.centuryspring.com/smi

SPRINGS Summer 2010 13

Donley Is New WCSMA Chairman; Two Fall Events Scheduled Debra Donley of FTR Associates in Santa Fe Springs, Calif. is the new chairman of the West Coast Spring Manufacturers Association (WCSMA). In addition, Sean Alves, C.M. Gordon Ind., Santa Fe Springs and Jim Grueser, Kato Spring, Cypress, Calif., are the newest members of the WCSMA board. WCSMA has two events planned for later this year. WCSMA members will attend a Los Angeles Angels of Anaheim game on September 11, preceded by a tailgating party hosted by the association. On November 11, 2010, the WCSMA Fall Golf Outing will be held at Los Coyotes Country Club in Fullerton, Calif. It will begin with a shotgun start at 11:30 am. If you register before November 1, the golf fee is $150 while the dinner only fee is $45. If you register after

NESMA Dinner on Social Media by Ted White, Hardware Products “Social Media for Industrial Marketing” was the topic for the May 2010 New England Spring & Metalstamping Association (NESMA) meeting. It turned out to be as much an introduction to the topic, as it was to marketing using social media. It was presented by Kristin Ahearn of Ahearn Ink, who founded the company in 1996 to provide professional writing and communications services to a wide variety of agencies and businesses. She described social media as simply “an electronic way to keep in touch with people (customers) and let them know what you are doing.” The players are primarily Facebook, LinkedIn, and Twitter, with the

14 SPRINGS Summer 2010

One of several groups of golfers that participated in the WCSMA “Spring Fling” from May 14-16, 2010 at Rancho Las Palmas Resort and Spa in Rancho Mirage, Calif.

November 1, the golf fee is $160 and the dinner only fee is $50. For more information on these events, contact Donley at (562) 945-7504, or e-mail Debra@

ftrmetalproducts.com. You can also visit www.wcsma.us.

overall goal of using social media to drive people to your website. Because so many were unfamiliar with this topic, Ahearn was very accommodating to the many questions that arose. She showed us how to do some basic research on social media, what websites to visit, and what books to read. For now, social media is largely free, and the numbers are staggering. Facebook has 300 million plus users. LinkedIn has 65 million plus users and Twitter has untold numbers of users and followers. Social media presents an inter esting challenge to the industrial world. The question becomes: “Can the industrial user take advantage of this medium?” Certainly the clever people can. A business Facebook

page, a LinkedIn presence, along with a blog can all be linked to your website and upgrade your standings on the search engines. This coupled with a Search Engine Optimization (SEO) program, can have a profound effect on Google, Bing and the like. The very large numbers represent not only a huge opportunity, but a great challenge as well. Differentiation is the key. In order to be effective, you must present unique information that will drive people to your website. This forum should be more informational and less salesoriented in order to peak interest. LinkedIn is a work and career -related network. While it is true that a fair number of LinkedIn users who are job seekers, the clever marketer can develop followers (engineers

and spring developers) so that regular professional contact may be maintained. While many of us may dismiss something like Twitter as a possible means of gaining further business, Ahearn showed us a “tweet” posted the very day of the lecture which read: “Can anyone recommend a good spring manufacturer?” Is that relevant? Ahearn illustrated many specific social media benefits, such as making press releases and announcements easier to post while driving them to a larger number of recipients. When professionals are searching for relevant topics, your presence can drive them directly to your website. In addition, you can Pictured (l-to-r): Kirstin Ahearn, president, Ahearn Ink, Ted White, president, Hardware Products and receive information on all relevant Bill Lathrop, NESMA president and president of Colonial Han-Dee Spring. topics and stay in touch with those who create information on those topics. Become a sales-oriented. Try new things. Engage a young intern member of a group or sub-group such as the SME who understands social media as second nature. Metal Stamping Group on LinkedIn. You can make The presentation ended with an informed group announcements, such as the availability of a new and a presenter who was open to more questions. You machine along with pictures on Facebook. may contact Kirstin Ahearn at ka@ahearnink.com. ◆ She also illustrated several things of which to be careful. For example, if an employee is using his or her business e-mail as a contact point, the company may want to monitor this to make sure the employee’s Facebook activity is not contrary to company standards. One gentleman also indicated that he had heard of a story where a distributor had linked both customers and vendors together and his customer saw his vendor and bypassed the distributor altogether. Your source for the Unwanted traffic is also a possibility. Once your best in close tolerance presence is posted in social media, financial planners strip and edging. and investors and the like may contact you. You must 䡲 strip: cold rolled high carbon/spring, make a commitment to this form of marketing. All coated, low carbon, stainless, questions must be answered in a timely manner. You copper based alloys and aluminum 䡲 ultra-narrow width, close-tolerance slitting must not let things get stale. As a result, constant 䡲 edging: round, square, semi-round, vigilance by an intern or staff member may be deburred, custom, etc. required. 䡲 oscillate (traverse) and ribbon wound coils How to get started? Ahearn told us to first take 䡲 ISO 9001:2000 certified time to learn some rudimentary details of social 䡲 32 years experience for product and service excellence media. Check out your competitors to see if they use it. Survey your customers to see if they use it. Go to the websites themselves and read the frequently tel. 847.537.2881 toolkinginc.com asked questions. Read a book on the subject such as Wheeling (Chicago), Illinois 60090 USA “The Zen Book of Social Media,” or “I’m on Facebook — What Now?” When formulating concepts in your head, remember to be more informational and less 䡲

SPRINGS Summer 2010 15

16 SPRINGS Summer 2010

Spotlight

Shop Floor Specifications — The Filtered Details By Randy DeFord

have worked at many spring plants and they all have had a culture and ways of doing things. Trends, managers, owners and factory software may vary, but one rock-solid practice was present at each factory–shop floor specifications. Many times called a “spec card” or “spec sheet,” this document was the road map for any given product. While the shop routing or shop traveler describes the steps needed to produce the spring, the specifications describe how the finished product is to look and act. I have had many debates over the years about the need for this document, but as an engineer and former coiler, I can and would testify that the specifications and their role to the quality of any manufactured part are critical. When I was a springmaker, I was handed a package of instructions that asked me to do something, and to make sure the result looked like the customer’s expectations. I never gave a thought to who prepared the paperwork or what it took to make those judgments. As an engineer, I do that for a living and have some firm beliefs in the necessity for this piece of paper. When a blueprint is received, its purpose is to describe the product required, including dimensions and any load expectations. It also may include most processing needs such as shot peening, grinding, pressing and special coatings or identification. This data can run the gamut from a handwritten sheet with no drawing, to a meticulously drawn instruction complete with quality information and processing specifics. However, some blueprints have been around for decades and may include blatant errors that were, for whatever reason, never corrected.

on the Shop Floor

Randy DeFord is the engineering manager at Mid-West Spring & Stamping in Mentone, Ind. He has 35-plus years in the spring industry, and believes that educating both customers and associates is the key to great customer service. Readers may contact him at rdeford@ mwspring.com or phone (574) 353-7611.

One of the functions of a design engineer is to screen the blueprint and describe what the customer expects and what exceptions to the blueprint are allowed. This makes the engineer the needed filter for giving the operator nothing but the pertinent data needed to make the part.

Also, wire types have changed considerably over the years with improved materials being available. There are also sizes that are not readily available and, depending on the application, may dictate a re-design of the part with current stock sizes to keep the price reasonable. This means that any errors that require correction must be approached in a way that will deliver the critical needs for part function and, at the same time, be sure the shop floor can produce the part, order after order. One of the functions of a design engineer is to screen the blueprint and describe what the customer expects and what exceptions to the blueprint are allowed. This makes the engineer the needed filter for giving the operator nothing but the pertinent data needed to make the part. This means both removing any redundant information as well as correcting errors that don’t make sense. For example, a blueprint may call out 44 coils for a given extension spring. When the engineer calculates the design, the result may show that with all other dimensions and spring rate entered, there must be 41 coils, not 44. The engineer must then make a judgment if the 41 coils will be acceptable to the customer, or if another dimension can be adjusted to make everything fall into place.

SPRINGS Summer 2010 17

Although customers may not know the science behind the spring, they do understand the science of their product and expect clear and honest communication on any issue that affects the function of that product.

The whole purpose of the design calculation is to verify that what shows on the blueprint can, indeed, be made. If anything does not match the blueprint, an exception should be noted to the customer before the order is placed to warn them if a dimension needs to be altered (wire size, wire type, body diameter, free length, etc.) to meet the most critical need for the function of the part. This also includes tolerances, which can sometimes be a highly critical need for part function, especially in “fits in” or “fits over” situations.

sizes range: 0.827”- 0.001” quantities: from 10ft profile: available in round, flat & shaped wire

After the engineer has received approval for any changes, those changes are then used to create the final document that gives the shop floor the filtered, improved and negotiated dimensions and loads that are standardized and shows any differences from the original blueprint. In most factories, both the blueprint and spec sheet are given to the shop floor operators as their instructions on what to make, and how to make it. These two documents are two halves of a whole — the blueprint which shows what the customer expects, and the specifications generated by engineering in a standardized format that is familiar to the shop floor and has the filtered details. At this point I must mention that any changes to an engineered product, such as a spring, needs to be approved by the customer. Although customers may not know the science behind the spring, they do understand the science of their product and expect clear and honest communication on any issue that affects the function of that product. Clear communication can only improve the process as it relates to the shop floor and that helps eliminate errors and rejections. ◆

Alloy Wire International 205 Hallene Road, Unit 317C, Warwick, Rhode Island, RI 02886 USA

Call Toll Free: 1-866-48-ALLOY 1-866-482-5569 fax: 401-384-6757 email: sales@alloywire.com

See us at

Spring World 2010 Chicago - Oct 13th to 15th

18 SPRINGS Summer 2010

Inconel X750 Inconel 600 Inconel 601 Inconel 625 Inconel 718 Incoloy 800 Incoloy 800HT Incoloy 825 Incoloy A286 Monel 400 Monel K500 Nimonic 90 Nimonic 80A Nimonic 75 Nickel 200 Nickel 201 Nickel 205 Nickel 212 Nickel 270 Nispan / C902 Nilo 36 Nilo 48 Nilo 52 Nilo ‘K’ Hastelloy B-3 Hastelloy C-4 Hastelloy C-22 Hastelloy C-276 Hastelloy C-2000 Hastelloy G-30 Hastelloy ‘X’ Haynes 25 Haynes 214 Phynox MP35N RENE 41 Nitronic 60 Alloy 20 Cb3 Beryllium Copper Waspaloy

Be Aware

Looking Back By Jim Wood Safety Tips

Since this issue of Springs magazine is all about nostalgia, I thought it would be interesting to go back to the very first article I wrote for Springs on May 7, 1993. That was 17 years ago and surprisingly the article below is just as relevant today as it was then. Bloodborne Pathogens Rule On December 6, 1991, OSHA published its final rule on employee exposure to bloodborne pathogens (disease causing agents). The rule will affect all workplaces where employees may be reasonably anticipated to come in contact with human blood or other potentially infectious materials as a result of performing their job duties. Because OSHA inspectors were often unfamiliar with the measures taken by healthcare employees to protect themselves from exposure to bloodborne pathogens, enforcement of the standard under the general duty clause tended to be haphazard. OSHA now plans to provide special training to its inspectors regarding compliance with the provisions of the new rule. General Requirements • Establish a written exposure control plan. • Identify workers with occupational exposure to blood and other potentially infectious human body fluids or tissues.

Jim Wood is an independent regulations compliance consultant to the Spring Manufacturers Institute (SMI). A certified instructor of the OSHA Out-Reach Program, Wood conducts seminars, plant Safety Audits and In-House Safety Trainings. These programs help companies create safer work environments, limit OSHA/Canadian Ministry of Labor violations and insurance costs, and prepare for VPP or SHARP certification. He is also available for safety advice and information by phone at (630) 495-8597 or via e-mail at regs@smihq.org.

• Implement engineering controls such as special marked biohazard containers for contaminated materials, gloves, bandages, etc. • Implement work practices such as hand washing to reduce contamination. • Require personal protective equipment such as gowns, face masks and gloves. • Provide for housekeeping procedures such as decontamination of surfaces. • Offer voluntary hepatitis B vaccinations to employees with occupational exposure. • Provider appropriate medical follow-up and counseling after an exposure incident. • Provide training and labels to alert workers to risks posed by bloodborne pathogens. • Keep accurate records of exposure incidents, post exposure follow-up, hepatitis B vaccinations and employee training. Each one of the aforementioned general requirements must be studied to determine the content of that requirement. In other words, what is contained in a written exposure control plan? What are some of the other potentially infectious materials? What is involved in engineering controls, housekeeping and personal protective equipment? Employee training and recordkeeping are very involved and must be looked at in detail. Jim’s Regulatory Tip: Conduct a mini safety inspection of your offices and plant. Look for ungrounded appliances, tools, fans, etc. Make sure you have three-pronged plugs, and cords that are not frayed or spliced. Get rid of extension cords unless they are strictly temporary. This “quicky” inspection could save you thousands if OSHA comes knocking. ◆

SPRINGS Summer 2010 19

Looking Back, Looking Forward Reminiscing R i i i g with ith S SMI Photographer's Choice RF/Punchstock

by Gary McCoy

“The past is behind, learn from it. The future is ahead, prepare for it. The present is here, live it.” Thomas S. Monson

20 SPRINGS Summer 2010

he spring industry has a storied history of providing vital parts to make a lot of things work properly. As Robin Brooksbank of Lion Precision opined in an article, “A Glimpse into the Past” in the Spring 1999 issue of Springs: “Newcomers to the spring industry are always amazed at the number of and kinds of springs produced and used in all aspects of modern life. They’d also be surprised at how long springs have been used. It is thought that early mankind used primitive spring-activated traps to capture food, and the energy-storing ability of a bow for shooting arrows is a simple spring. As outlined in the ‘History of the Spring Industry,’ the development of metallurgy more than 10,000 years ago and the use of the elasticity of metal led to the use of springs in pincers, clothing fasteners and, later, crossbows and catapults.”

Over the years, Springs magazine has looked at the history of the spring industry. The latest article was edited and compiled by Cheryl Chonajcki in the July 2008 issue (which is available online in the Springs magazine section at www.smihq.org). Although we will touch on the history of the spring industry in this “Flashback” issue, we have purposed that this look back will provide the opportunity to observe patterns and lessons. We believe the past provides instructive lessons that are still applicable to today’s spring industry. We also look back at the many different uses of springs with several contributions about the history of the Slinky, a device called Auntie Siphon and one member company that has developed a variety of springs including ones for the so-called “deelie-bobbers.” In the very first issue of Springs in May, 1962, this sage advice was excerpted from an unidentified SMI member’s newsletter. “Recently a famous watchmaker announced a new electrically powered watch whose innards derive from a timing mechanism used in space missiles. Unlike the few previously announced electrical timepieces, this one doesn’t use even a balance wheel and hair spring. After we recovered from the initial shock, we realized that inventions and new products have been putting old, accepted products out of business – ever since matches supplanted flint and steel, ever since gunpowder put bows and arrows out of business. It seems to us that one of the most exciting facets of industry is change. It would be a dull world for us indeed if we were making today just the same old springs in the same old way. Our industry gave up the anvil, hammer and forge

It seems to us that one of the most exciting facets of industry is change. It would be a dull world for us indeed if we were making today just the same old springs in the same old way. — Springs, May 1962 a long time ago and the skilled manual fashioner of springs, who could produce one in ten minutes, is, if still alive, making on a machine hundreds of springs a minute — all accurate, all alike.” Change and progress have always been signposts along the spring industry’s road to success. Here are five important lessons from the past that will continue to lead the industry forward into the future.

Lesson #1

spring industry grow in their skills and knowledge. Numerous articles have been published on a variety of topics from the induction heat treatment of wire for spring applications (Spring 1997) to quality control considerations for the design and testing of springs (May 1973). In this issue we reprint Luke Zubek’s most popular “Technically Speaking” column on the precipitation hardening of metals. Springmakers have always kept up with the latest certifications for quality assurance, such as ISO 9002. These achievements by SMI members demonstrate their commitment to maintain globally recognized standards in their operations. SMI has also published articles on new materials, design, finishes and equipment. In addition, numerous articles have been published on how springmakers can improve their manufacturing processes. The articles have included updates on shot peening, selecting the right heat treatment and new methods for producing springs. The goal has always been to instruct with ample numbers of charts and data. Be sure to read an article on page 36 by Harold Carlson from the May 1962 issue. The article, “Heat Treatment for Pretempered Hard Drawn Materials,” provided useful techniques for working with these materials.

Lesson #2

Technical information and process improvements have always led to advances in spring design and manufacturing.

SMI has published vital information to improve member knowledge of springmaking.

For many years Springs was identified as “The Magazine of Spring Technology.” The statement recognized the vital role that technical information has played in helping the members of the

Design handbooks for various types of springs have been published by SMI over the years and are still available from the association. For many years SMI’s “Standards Manual” was the

SPRINGS Summer 2010 21

Looking Back, Looking Forward

SMI was Born in 1933; What Events Were Shaping the World at That Time? • Roosevelt inaugurated; launches a new deal. “The only thing we have to fear is fear itself.” • Unemployment reaches 25 percent in U.S. and Great Britain. • The original King Kong movie is shown. • Germany and Japan withdraw from league of nations. • Ernst Ruska of Germany invents electron microscope. • Work starts on the Golden Gate bridge. • Prohibition in the U.S. repealed. • Adolf Hitler becomes German chancellor. • The chocolate chip cookie is invented. • Japanese scientist demonstrates machine gun, firing 1,000 shots per minute. • First-class U.S. stamp costs three cents. • First drive-in movie theater opens in New Jersey, invented by Richard Hollingshead. • Strong winds strip topsoil from parched Midwest farms, creating the Dust Bowls. • Roosevelt announces creation of 4 million public works jobs. • First Loch Ness Monster sighting in modern times. • Board game Monopoly is invented.

authoritative source of information for technical data on making springs. In the November 1969 issue of Springs a preview of SMI’s new “Spring Design Handbook” was provided. As SMI president Hugh A. Parnell pointed out at the time: “The Handbook is not an exhaustive, all-inclusive text but it is a basic working tool for the spring designer.” Here’s an excerpt from the introduction to the book. “This design handbook has been written for both student and practicing engineers who are not spring specialists but must occasionally design and specify springs. They are most likely to be concerned with designing a device in which the spring is only a small element. Therefore, this manual will be limited to the major types of springs. Among these types the design methods presented will consider only the most common operating conditions and performance requirements. Helical compression, extension and torsion springs will be assumed to be made of round metal wire since the method is basically the same for rectangular and other special cross sections.” Today, SMI has manuals for complying with the Americans with Disabilities Act, regulatory compliance programs for springmakers, the classic book “Mechanical Springs” by A.M. Wahl, along with updated versions of the “Handbook of Spring Design,” and many other spring-related design publications.

Lesson #3 Education and networking opportunities are still an important function of association membership. “The Sonesta Beach Hotel in Nassau was the site of SMI’s 1972

22 SPRINGS Summer 2010

Annual Meeting, November 12-14 and the attendance broke all previous records.” While not every year has been a record setter for attendance, SMI educational and networking events have been a constant and important function of membership in SMI. Some of the speakers have been of the famous variety, such as Richard Nixon, and others drawn from the ranks of the SMI membership. Many times the debates and deliberations of SMI members about important industry topics have landed in the pages of Springs as an expanded article. Please enjoy the reprint of an article from one of the first issues of the magazine in our “Flashback” section on page 42 that examines the question: “At What Stage of Design Should The Spring Manufacturer Be Consulted and Why?”

Lesson #4 Good management plays a vital role in making springs. Springmakers over the years have realized that people play a vital role in the making of springs. Without a team of professionals selling, designing, testing, manufacturing and shipping products, the spring manufacturing operations would grind to a halt. Recognizing the role of leadership and management, Springs has published numerous articles on managerial styles and motivational patterns, finances and operations, customer requirements, compensation, pr oduct liability, and pr ofit strategies. Be sure to read the May 1973 article on “The Important Skills of a Manager,” written by Ralph Young (found on page 39). Do these skills still apply today?

Lesson #5 SMI has led the industry in promoting safety in the workplace. In his Summer 1997 “President’s Message,” Donald Jacobson pointed out that the spring industry is a safe place to work but that “…even one accident is too many.” He went on to report that new data, sent to SMI, suggested that accidents do happen. “Nevertheless, simple in-plant training and education can almost surely eliminate accidents that accompany the operation of any springmaking or other industrial machine.” SMI has always had an established committee that looks at regulatory compliance and safety in the workplace. Jim Wood, SMI’s regulatory compliance manager, started working with SMI in 1993. During the past 17 years he has toured the country helping springmakers eliminate hazards on the plant floor, provide a greater level of employee safety and help springmakers comply with various national and local standards. Be sure to read Wood’s very first article from 1993, which we have reprinted on page 19. As Wood said about the article he wrote nearly two decades ago, “surprisingly it is just as relevant today as it was then.” Something for Everyone Though we’ve taken a moment to look back at the history of the industry and SMI, Springs normally doesn’t dwell on the past. The magazine will continue to move forward into the future with the most up-to-date coverage of the technical areas of spring design, materials, equipment and processes. But you will also see timely reports on the subjects of management, regulations,

training, quality control, supply chains and other issues of interest to spring industry professionals. While we recognize Springs cannot be “all things to all people,” we endeavor to provide “something for everyone”—owners, presidents, plant managers, engineers, human resources, IT managers, finance and

accounting personnel, and shopfloor workers—the vital people who make up the spring industry. ◆ Gary McCoy is the managing editor of Springs magazine and the president of Fairway Communications. Readers may contact him by phone at (847) 622-7228 or e-mail gmccoy@fairwaycommunications.com.

The advantage of steel is its strength and endurance. Precision Steel Warehouse has those very same qualities. Since 1940, we’ve built a company that can weather the most corrosive environments. Need weekly deliveries? No problem. We back-up your yearly contract with inventory to see it through. Upfront acquisitions give us inventory depth that’s the envy of our rivals.

Stainless Steel, Spring Steels, Low Carbon Sheet And Strip, Coated Metals With hundreds of gauge and temper variations in stock. Custom Slit Premium Precision Steels. Meets all ASTM, AMS, AISI speciﬁcations.

PRECISION STEEL WAREHOUSE, INC, www.precisionsteel.com Charlotte, NC Franklin Park, IL 1-800-438-5646 1-800-323-0740 Fax 704-393-3312 Fax 847-455-1341

A Berkshire Hathaway Company

Celebrating 70 Years Of Service

SPRINGS Summer 2010 23

Looking Back, Looking Forward

Beating Our Swords into Slinkys by Carl Zebrowski ©October 2009 AMERICA IN WWII magazine, www.americainwwii.com. Used with permission. ©Istock.com/Craig Veltri

ick James was doing serious wartime work in his office at the William Cramp and Sons shipyard on the Philadelphia docks in 1943. He and other mechanical engineers had been trying to figure out how to keep delicate ship instruments functioning properly. Rough waters, churning propellers, and recoil from giant guns tended to make them go haywire. James was experimenting with hanging the instruments from springs to lessen the shock on them. He’d tried hundreds of varieties—long and short, thick and thin, high-tension and lowtension. Assorted coils lay about his office. One day one of them fell off his desk and twisted intriguingly on the floor. He began to fiddle with it, and at the end of the business day, he took it to his home in the suburbs for his young son Tommy to play with. T ommy couldn’t keep his hands off the thing. Eventually, he pushed it down the stairs to see what would happen. This was no helplessly tumbling toy fire

24 SPRINGS Summer 2010

truck. The spring quivered a bit and then appeared to walk almost deliberately down a step or two. W h e n n e i g h b o rh o o d k i d s came over and showed a similar fascination with the toy, James realized he was onto something. He began to put in his workdays at the shipyard and then return home to spend the night tweaking the design of his toy. “Our house was a mess while I experimented,” he recalled. Two years later, James was finished. He had a two-inch tall, low-tension spring made of a 75-foot-long flat ribbon of steel wound into 98 coils. His wife, Betty, scoured the dictionary to find a name for the amazingly simple toy. She found a Swedish word meaning “sleek and sinuous” and it stuck: Slinky. By the summer of 1945, James bet everything on the Slinky. Cobbling together his savings, he paid a piston ring manufacturer in the city to make 450 Slinkys. Then he quit his job to devote his time to the new venture.

Retail stores were less optimistic about the toy than James was. A local toy store finally agreed to take a dozen, but James would get paid only if they sold. Then something changed: the war ended. Victory was in the air, morale was at an all-time high, and Christmas promised to be a big celebration. The Gimbels department store in downtown Philly offered James counter space and a cashier to sell his Slinkys during the holiday season. James would have to demonstrate the toy to shoppers himself. James debuted the Slinky at the busy store on November 27, just a few days after Thanksgiving and the unofficial start of the Christmas shopping season. It didn’t take much to sell the Slinkys. James simply placed a sample at the top of a ramp he’d set up and started it walking down. Slinky was an instant hit. Customers crowded up to James’s counter six deep. The 100 Slinkys James had brought with him were disappearing fast at $1 each,

The Slinky’s 1946 patent diagram dissects the physics of fun (above). The pictures on Slinky’s original box (top right) were about as much fun as a diagram, but they did show the amazing Slinky walking down steps!

and he called his wife to bring in the rest of the stock. An hour and a half after the first Slinky walked down the ramp, the entire

remaining stock of 400 Slinkys was sold. “We didn’t sleep that night,” James said. The Jameses didn’t get much sleep in the nights that followed, either. Buoyed by their quick success, they ran out and borrowed money to have more Slinkys made. By Christmas they’d sold 22,000. Business took off from there. Even after James left for Bolivia to join a cult in 1960, Slinky continued to move forward with barely a stutter in its step under Betty’s guidance. Every televisionwatching kid in America in the 1960s and ’70s could sing along with the infectious “Everyone knows it’s Slinky” commercial jingle. And every kid was amazed the first time he or she watched a Slinky walk down the stairs. Today, Slinky is still made in Pennsylvania with the machinery Dick James designed six decades ago, machinery that has made more than 300 million Slinkys over the years. From the time James

inkys

left the company until 1998, Betty was president. She died in November 2008, and as this issue was going to press, her estate was up for auction. Among the family treasures headed for the block were original Slinkys. “Strictly speaking, I didn’t invent Slinky,” Dick James once said. “He practically walked into my life.” His, and most everyone else’s ever since. ◆

SPRINGS Summer 2010 25

If You’re in the Spring Industry, You Should be at Spring World 2010 ®

October 13-15, 2010 • Donald E. Stephens Convention Center • Rosemont, IL We all recognize the fiercely competitive environment facing the spring manufacturing and wire forming industries. Attending Spring World 2010 offers the opportunity to see the newest technology available in machinery, materials, quality control, grinding, heating and other processes and services upon which you depend. Attending Spring World provides a unique opportunity to network with other spring manufacturers and wire formers in an informal setting where you can share your problems, concerns and solutions. You also have the chance and to reconnect directly with existing suppliers and establish relationships with new vendors exhibiting at the show. This year, for the first time since CASMI founded Spring World in 1959, many of our exhibitors will be presenting free seminars to help you learn new ways to improve your productivity, quality and service. CASMI makes it easy for you to attend and get “leg-up” on the competition. Spring World takes place at the conveniently located Donald E. Stephens Convention Center in Rosemont, IL. Registrations received before September 20, 2010 are FREE!!! It is easy to register online, by fax or by mail. Register today! You won’t want to miss any of this year’s opportunities to help you make your business grow.

BY MAIL:

ATTN: Spring World 630-369-3773

Spring World 1601 North Bond Street, Suite 303 Naperville, IL 60563

ONLINE: Click the Spring World link at www.casmi-springworld.org

Contact Name: (First) ______________________________________ (Last) ____________________________________________

(M.I.) ______________

Nickname (for badge): _______________________________________________ Title: ________________________________________________________ Business Name:__________________________________________________ Email: __________________________________________________________ Purchasing Authority: I can ... Recommend Purchases

Authorize Purchases

Both

Address: __________________________________________________________________________ City:__________________________________________ State/Province __________________________________ Zip/Postal Code ______________________ Country _______________________________________ Please circle one category: Spring Manufacturer (A-1)

Exhibitor (A-2)

Please answer the following questions: Is the Company a “job shop” Spring Manufacturer Yes No

CASMI Member (A-3)

Other (Explain) ________________________

If the answer is No, what does the company do? _________________________________

Please check all the product categories that apply: (B1) Extension Springs (B-6) Stampings

(B-2) Four Slide

(B-7) Torsion Springs

(B-3) Power Springs (B-8) Wire Forms

(B-4) Compression Springs

(B-9) Spring Washers

(B-5) Flat Springs

(B-10) Hot Wound Springs

(B11) Other Products (please describe) __________________________________________________________________________________________________ Please indicate if you are a member of any of the following spring/metalforming organizations (check all the apply): (C-1) CASMI

(C-2) NESMA

(C-3) PMA

(C-4) SMI

(C-5) TMA

(C-6) WAI

(C-7) WCSMA

(C-8) WFA

Advance registration (received prior to September 20, 2010) is Free! Registration received after September20, 2010 will be assessed the onsite registration fee and must be picked up and paid for at the show registration desk. Onsite registration fees are: CASMI members & exhibitors $15, non-members $25.

Looking Back, Looking Forward

Auntie Siphon by Don Fazio, President, Diamond Wire Spring I am sure many spring companies have a story or two to tell about springs they have made for unique and fun applications. Here at Diamond Wire Spring, we have made springs for the “Johnny Bench Batter Up” hitting device and for a window display of the latest “spring” fashions for the Kenneth Cole shoe company. However, it is the spring we made during the 1975 oil embargo that really stands out as one of the craziest and most fun. For those who remember the embargo, the OPEC countries in the Middle East withheld oil causing a shortage of gasoline here in the states. Depending on your license number, one could only get gas on odd or even days. There were long lines at the gas stations, and people would argue over their place in line. This led some people to begin stealing gas. Locking gas caps became a hot item and were usually sold out. When all this started, we had heard of a spring that was used in WWII to insert in the neck filler of your car to prevent the gas from being siphoned out. My boss at the time said “let’s make some” even though we had no idea how to go about pricing, packaging or selling them. I was in my mid 20s and put in charge of sales. In the long run, I think the inexperience of my youth served me well, as I had no idea what we were about to get into. We decided to come up with our own name and packaging scheme, then go about selling them ourselves. At the time, my mother was our president and she thought of the name, “Auntie Siphon.” We created the springs,

the packaging and then packaged them ourselves. I started calling on the local department and auto parts stores—anyone that I thought would buy these. They took off like hot cakes! Trucks would line up at our dock on Friday afternoon in order to get them on their shelves for the weekend. To keep up with demand, we bought wire wherever we could and hired friends and relatives of employees to help package them. The account that took us over the top was NAPA Auto Parts. At the time, they were headquartered in Indianapolis. Getting in to see a buyer there was like trying to see the Pope. Being young and not very familiar with sales rejections, I called and got through to the buyer. He asked if I could be there

in the morning, so I got the first plane out of Pittsburgh headed to Indianapolis. The buyer was in his mid 60s and even though I was much younger, we hit it off. He said for me to return home, and that I would hear from him in the morning. We ended up being NAPA's sole source for the U.S.! We had to run 24/7. It was crazy! The whole thing lasted about five months. We were actually getting ready to ship overseas, when OPEC lifted the ban. Boy, did everything stop quickly after that. We had cancellations and springs galore left in stock. In the end, I do not know if we made any money, but it sure makes for a great story and experience. ◆

SPRINGS Summer 2010 27

28 SPRINGS Summer 2010

Looking Back, Looking Forward

springs at war specially during times of war, Americans have pulled together and sacrificed to help in the nation’s effort to defeat foreign enemies. It was during World War II that Associated Spring Corporation (now owned by the Barnes Group, Inc.) published a booklet titled “Springs at War.” This 48-page document outlined the many uses of springs for air power, fire power, sea vessels, tracks and trucks, and instruments. “It is very difficult, as we fashion a piece of wire or strip of steel into a spring, to realize the contribution to the war effort which we are making in our daily work,” remarked Fuller F. Barnes, president, Associated Spring Corporation, in the foreword to the publication. “We call this a ‘Mechanical War,’ which means that industry is putting into the hands of its armed forces, machinery which, though destructive in purpose, is a marvel in operation and efficiency,” Barnes continued. “Practically all of this equipment depends for its performance on springs, particularly where the action is automatic or repetitive as in the case of engine valves, machine guns and fuses, for examples.” In conclusion, Barnes said: “To all of these employees, as well as those in the service of the United States, this booklet is dedicated, with the hope that it will help them to visualize some of the thousands of ways the results of their efforts are serving to bring VICTORY.” If you don’t know who Barnes is, in 1933 he played a leading role in establishing SMI. He also served as the association’s president from 1933-41 and again from 1944-46.

Springs for Air Power “From its earliest days, aviation has called upon springs in the development of speed, maneuverability, flying range--and most important today--fighting power.” The company noted that among its contributions to aircraft springs were a piston pin retainer ring, clutch oil seal rings, aviation clutch springs and an airplane engine valve spring. Rugged compression springs of rectangular wire were used in the starting mechanism of engines, while cowling springs help to hold the sleek “skin” on bombers and fighters.

In regards to the Lockheed Lightning P-38 airplane, it was explained that “our enemy airmen know the striking power” of this aircraft. “Generators, superchargers, magnetos--you can’t name a mechanism that doesn’t rely on some spring action.” In addition to airplanes, the “development of helicopters has called upon the ingenuity and skill of our designers and toolmakers to supply many special spring applications.” Even soldiers who drop from the sky are mentioned in the section on air power. “When a paratrooper ‘hits the silk,’ there’s many a spring there to get him down safely.” Springs for Fire Power In the opening to the section “Springs for Fire Power,” the company explained: “Our enemies know all too well the power of Allied arms. Overwhelming

Legendary Accuracy.

Larson Systems Inc. 1-877-780-2131 larsonsystems.com

SPRINGS Summer 2010 29

A B-17 bombing Marienburg, Germany in 1943.

superiority in fire-power and in amount of weapons is an accomplishment in which we springmakers in every plant of the Associated Spring family can share. Each of us may know of some individual achievement in design or outstanding record in mass production, but it is the combined effort of this group as a whole that has contributed so much to the variety and effectiveness of weapons.” It was noted that submachine guns, along with small arms, are “vitally dependent on accurate, unfailing springs wherever repetitive, automatic action is demanded.” In addition, the company explained that a soldier’s automatic rifle may contain up to 40 springs. T h e Bofors gun was one of the most popular mediumweight anti-aircraft systems used during World War II by most of the western Allies as well as various other forces. The Bofors gun had recoil springs that were visible in plain sight.

30 SPRINGS Summer 2010

Recoil springs were also used for 57 mm guns and 20 mm machine guns. United States Ship PT-109 was a Patrol Torpedo (PT) boat last commanded by then-Lieutenant, junior grade (LTJG) John F. Kennedy (later President of the United States) in the Pacific Theater during World War II. Kennedy’s actions to save his surviving crew after the sinking of the PT-109 made him a war hero, which proved helpful in his political career. PT boats carried twin-mounted .50 caliber machine guns with flash protected muzzles. “These guns, dependent on their intricate spring mechanisms, are widely used in planes and on mobile units as well.” Other weapons containing springs included the Bazooka, hand grenades and “even land mines require the services of springmakers for hair-trigger operation.” Land mines contained Belleville springs and spacer rings.

Looking Back, Looking Forward

a former associated springs worker wrote: “i am in the armed forces. i have found hundreds of springs in peeps, half tracks, and weapons of all kinds. little did i realize when i was making these springs i would see them in operation now.” Springs Afloat “Ours are seagoing springs too—taking part in shore bombardments, transporting supplies to our fighters and those of our Allies, stalking out enemy shipping from deep in the sea. Here are still different conditions of service for springs, requiring special finishes and plating to combat corrosive conditions, and to resist great forces of vibration and hard service.” A picture of the battleship Idaho, “a floating maze of mechanical devices,” was displayed on page 22 of the booklet. “No one can guess how many thousands of springs are in constant use here, but from control bridge to ship’s refrigeration machinery, springs are ready to leap into action.” Submarines also contained a number of springs, including the flat coil spring of phosphor bronze that helps close hatch covers on subs. “Subs use both diesel and electric motors for propulsion, requiring many types of springs—valves, brush holder, switch, generator, etc.” It was also explained that “catapult launchers send observation planes skimming from the decks of destroyers and cargo vessels. In the release valve mechanism of the launcher are found heavy-duty extension springs.” Page 26 of the booklet contained a quote from a springmaker on duty aboard an aircraft carrier: “I have run across springs I had something to do with in their making. If some of them had not operated correctly, I probably would not be here today, so keep up the good work!” Springs on Tracks and Trucks “Mobile land warfare calls for great speed and rugged endurance. As in other branches of warfare, many strange but effective vehicles have emerged from our great production lines under the guiding genius of mechanical experts. In every case, the toughest kind of test proves the worth of this equipment before it is released for combat. The fact that our springs have proved more than equal to such hard service is evidence that skill and constant attention to quality standards are worthwhile always.” It was observed that springs in tanks made it easy for the crew to maneuver—in clutch, gauges, pumps,

turrets and guns. “Engine valve springs are ground at both ends in arms which swing down between the abrasive wheels.” A former Associated Springs worker wrote: “I am in the armed forces. I have found hundreds of springs in peeps, half tracks, and weapons of all kinds. Little did I realize when I was making these springs I would see them in operation now.” The company stated that compression springs are the “workhorse of war, perhaps the most used type of spring we make. Their load carrying capacities can be accurately determined by choice of material, space requirements and degree of heat treatment.” In addition to jeeps and trucks, the company stated that tractors are the workhorses of wars that are ready for any job, at any time. “Rough work of this kind calls for every ounce of performance from every moving part. That’s why we take such care in ™

ISO 9001 REGISTERED

On Track with your Steel Solution!

The Admiral Nippers engineer another on-time delivery of specialty low carbon strip and high carbon spring steels! Maintaining the tightest schedule on the tracks is easy when it all happens under one roof. Our well equipped plant, located in Chicago, keeps chugging out world class products and service. No order too small – we do ‘em all!

Don’t Miss The Train – Call Today! 4152 West 123rd Street • Alsip, Illinois 60803-1869 800-323-7055 • Fax: 708-388-9317

SPRINGS Summer 2010 31

Looking Back, Looking Forward

A World War II Jeep and soldier under a maintenance sign.

selection of materials for springs—to make sure they measure up to the work expected of them.” Springs in Instruments Radar, electronics, searchlights, and radio panels were among the instruments cited for use in warfare that needed springs to make them work. “Instrument springs, because of their low stresses and sensitive operation, require a special degree of care in manufacture.” Other instruments utilizing springs were sound locators, the so-called “Handie-Talkie,” and antennas for field radio transmission. In addition, it was noted the springs are “everywhere in gauges and operating mechanisms of a submarine.” Here’s a quote from another springmaker in military service: “Our springs will meet me face to face every day and I can’t help but brag about the kind of work being done by our soldiers on the home front.” In the concluding section of the booklet, Associated Spring summarizes its commitment to the war effort.

32 SPRINGS Summer 2010

“With a first-hand knowledge of the huge quantities of supplies needed for victory, we springmakers have willingly met every appeal for war bond purchases. The value of our products and the production records of our men and women have earned highest awards by our armed services.” And the company did brag that the war had carried their products to every land by plane, tank ship, truck and tractor. “We can be proud of our combined contribution of history-making mechanical developments. For this is not the record of any one plant—or any one department—it represents teamwork for one result: Victory and a future filled with new opportunities for the practice of our craft of fine springmaking.” Certainly there were many SMI members who manufactured springs for the war effort. This is the example of how one company participated and documented their contribution. ◆

SPRINGS Summer 2010 33

©Istock.com/Joe Belanger

Unusual Users of Springs and Spring Technology By Allison Kerns Lindley, Sound Spring, Inc.

eople are fascinating. The ideas that become part of our culture, economy, and life are limitless. Spring manufacturers have been making the dreams and ideas of entrepreneurs a reality for years.

Reminiscing I think what makes most great ideas work is hidden in little seeds of ideas. People from all walks of life, particularly farmers, have been “making do” for years with metal scrap and bale wire. That’s how I imagine my dad, Al Kerns, as he grew up in the Idaho panhandle. Like many people, he headed toward the Seattle area in the late 1960’s lured by the potential of finding work in the shadow of the big aerospace and other manufacturing and technology companies. In 1978, Dad started a spring manufacturing business with a few customers and a few machines in our family’s two-car garage. I remember stress relieving springs in our kitchen oven. (Yes, a home appliance can do the job, but pizza will never taste the same!) Needless to say, we invested in equipment that would be designated for that purpose, and mom got a new range for our house. In the years since then, we have met many inventors and folks with great plans including toymakers, racing bicycle designers, aerospace engineers, medical equipment suppliers, and artists. These unusual users of springs and spring technology have all been amazing, creative, and fascinating people. Toys We Have Loved and Made In the early 1980’s we made what seemed like millions of springs for something called “deelie-bobbers.” It was basically a plastic

34 SPRINGS Summer 2010

Looking Back, Looking Forward

headband with two six-inch long tightly wound coils with Styrofoam glittery shapes attached on the ends. These were all the rage at county fairs and New Year’s Eve parties. We also made springs for model train enthusiasts, sports equipment and outdoor gear applications. We cannot even begin to imagine how many kids of all ages enjoyed the toys and gear that were made with these springs. Prototypes and Short Runs R & D (Research and Development) is a big part of the past and present of spring manufacturers. There is always someone out there with a sketch pad and a great idea. People would bring in a spring they had modified from something else. They were trying to use it for a new purpose altogether, but the spring they made failed early (broke) and they were looking for expertise to help design something that would last in their new application. Together we made that happen.

In the late 1980’s we bought another spring company, Advanced Spring, in Milwaukie, Ore., just outside of Portland. Operating in two locations almost two hundred miles apart was challenging. A few years later we decided to consolidate the two locations into one. As a result, we moved the inventory, machines and some of the key personnel to our facility in Washington state which resulted in added diversity. Some of the larger machines helped expand the capabilities of the company, and several relationships with new customers began. All manufacturers, especially spring manufacturers, are continually looking to upgrade equipment, develop great relationships with vendors and customers, increase quality, and invest in personnel and continued education. Thank you for this opportunity to reminisce and take a retrospective look at the “unusual users of springs and spring technology” over our past 32 years in the industry. It continues to be a great adventure! ◆

Artists and Dreamers as Partners After the big blast in May of 1980 at Mount St. Helens, Wash., there were many artists making the ash into sculptures, glass ornaments, jewelry and artwork. We helped design and make the wire stands and decorative coils to showcase and display much of that artwork. Of course, there is not a huge amount of profit in many of those small ideas, and the bulk of the market was in the more established industrial companies. But looking back, even those big companies change product lines with the times. Plastics We used to make lots of clips for the plastic ash trays in cars and trucks, but in a sign of the times, many cars and trucks don’t even have ash trays anymore. It’s not as culturally acceptable to smoke, especially on the job, and the big trucking companies don’t order ash trays or spare ash trays for their fleet trucks. Aerospace and Diversification As an aerospace certified manufacturer, we have had the opportunity to manufacture aircraft parts and continue to do so. It has been a good part of our business over the years. We often have been very glad that our customer base included other industries as well, when big companies would cut back on orders. Some small businesses that had the bulk of their business from aerospace companies were not able to weather the ups and downs of that industry, which leads to the subject of diversification.

SPRINGS Summer 2010 35

Looking Back, Looking Forward

Heat Treatment For Pretempered Hard Drawn Spring Materials by Harold Carlson, president, The Carlson Company (Originally published in May, 1962)

Springs is pleased to present the first of a series of articles dealing with the heat treating of springs. Other heat treating articles are scheduled for subsequent issues. As the Spring Manufacturers Institute has not yet developed its own heat treating standards, the articles presented will reflect acceptable engineering practices according to the various authors. Baking Temperatures: Springs made from tempered wire, music wire, etc., do not require a hardening heat treatment, but they always should have a stress equalizing heat treatment after coiling wherever possible. Extension springs having initial tension and torsion springs do not always require stress relieving, but it is advisable to give them some heat provided the correct load and deflection can be maintained. In coiling, forming, or shaping springs, the wire is stressed beyond the elastic limit, thereby causing a slight plastic flow of the material to take place. Such springs are not stable; they have a strong tendency to grow in length if dropped, and should, where possible, be heated after coiling, (preferably before setting). This treatment is called tempering, bluing, baking, stress relieving, seasoning, annealing, stress equalizing, etc. Baking Time: The length of time that springs are allowed to remain at a stress equalizing heat (after they reach the temperature recommended) is very important. Readjustment of the structure takes time, and attempts to speed up the process by a higher temperature and shorter time should be avoided. 1. Compression springs are baked after coiling (before setting) to relieve residual stresses and thus permit larger deflections before taking a permanent set. A light heat is sometimes given also after pressing to stabilize the material and retard growth during transit.

36 SPRINGS Summer 2010

2. Extension springs also are baked, but heat removes some of the Initial Tension. Allowance should be made for this loss. Baking at 500 F for 30 minutes removes approximately 50 percent of the LT. The shrinkage in diameter however, will slightly increase the load and rate. 3. Torsion springs do not actually require baking because coiling causes residual stresses in a direction that is helpful, but such springs frequently are baked so that jarring or handling will not cause them to lose position of ends. 4. Outside diameters shrink when springs of Music Wire, Pre-tempered MB and other carbon or alloy steels are baked. This slight reduction should be allowed for during coiling. Baking also slightly increases the Free Length and these two changes combined causes a little stronger load and increases the rate. 5. Outside diameters expand when springs of Stainless Steel (18-8) are baked. The Free Length also reduces slightly and these changes cause a little lighter load and decreases the rate. 6. Inconel, Monel, and Nickel Alloys do not change much when baked. 7. Beryllium-Copper shrinks and deforms when heated. Such springs usually are baked in fixtures or supported on arbors or rods during heating. 8. Brass and Phosphor Bronze springs should be given a light heat only. Baking above 4500 F will soften the material. Do not heat in salt pots. (See item 15). 9. Position of loops will change with heat. Parallel hooks may change as much as 450 during baking. Torsion spring arms will alter position considerably. These changes should be allowed for during looping or forming. 10. Quick heating after coiling either in a high temperature salt pot or by passing a spring thru a gas flame is not good practice. Samples heated in this way will not conform with production runs that are properly baked. A small controlled temperature oven should be used for samples and for small lot orders.

Baking Temperature Heat Treat No.

Spring Material

Baking Temperature, Degrees F. General Service

Severe Service

High Temp. Service

HD-T

Hard Drawn Wire

420 to 450

450 to 500

Not used

MB-T

Tempered MB

420 to 450

450 to 500

600 to 650

HB-T

Tempered HD or HXB

420 to 450

500 to 550

600 to 650

CV-T

Chrome-Vanadium

450 to 500

550 to 600

650 to 700

SM-T

Silicon-Manganese

450 to 500

550 to 600

650 to 700

CS-T

Chrome-Silicon

450 to 500

550 to 600

650 to 700

MW-T

Music Wire*

400 to 420

450 to 500

Not used

MD-T

Monel

450 to 500

550 to 600

650 to 700

PB-T

Phosphor Bronze

212 to 250

325 to 375

Not used

SB-T

Spring Brass

212 to 250

325 to 375

Not used

IN-T

Inconel

700 to 750

800 to 850

850 to 900

IX-T

Inconel X

1200 to 1250

1300 to 1350

450 to 500

550 to 600

650 to 700

SS-T

Stainless

*For Light Sections of Music Wire under .025” dia., use 350 to 400 F.

Baking Time Spring Material

Wire Diameter, Inches

Baking Time, Minutes* General Service

Severe Service

High Temp. Service

Music Wire, Stainless & all types of Spring Steels

Up to .015 .016 to .050 .051 to .120 .121 to .375 .375 to .500

10 to 15 15 to 20 20 to 25 25 to 30 30 to 45

15 to 20 20 to 30 30 to 40 40 to 50 50 to 60

20 to 30 30 to 45 45 to 60 60 to 80 60 to 90

Phosphor Bronze & Spring Brass

Up to .025 .026 to .375

20 to 30 30 to 40

30 to 45 45 to 60

Not used Not used

Monel & Inconel

Up to .025 .026 to .375

30 to 45 45 to 60

50 to 60 60 to 80

1 to 2 hours 2 to 3 hours

Inconel X

All Sizes

6 hours

8 hours

10 hours

*The time in minutes is for recirculating air ovens — it may be reduced 25 to 33 percent for liquid baths.

11. Plated springs should always be baked before plating to relieve coiling stresses and again after plating to relieve hydrogen embrittlement. 12. Japanned springs baked at about 4000 F for 30 minutes, automatically provide a baking treatment and frequently this is the only heat necessary for some springs. 13. Hardness values lower with high heat - but Music Wire, Hard Drawn and Stainless will increase 2 to 4 points Rockwell C.

14. Sharp bends on loops or arms cause high stress concentrations; such springs should be baked as soon as possible after forming. 15. Spring Brass and Phosphor Bronze springs which are not too highly stressed and are not subject to severe operating use may receive adequate stress relieving after coiling by immersing them in boiling water for a period of one hour. ◆

SPRINGS Summer 2010 37

38 SPRINGS Summer 2010

Looking Back, Looking Forward

The Important Skills of a Manager

By Ralph Young, Vice President, AMANSCO, Incorporated (Originally published in May 1973)

Imagezoo/Punchstock

. C. Penney described a managerâ€™s job as getting things done through people. He went on to say that a manager has to know how to handle people, how to motivate them, and how to make them want to do the things that he needs to have done. How does a manager accomplish the things Mr. Penney referred to? What skills does he need to get people to work? I have broken down what I consider to be important managerial skills into these elements: 1) Leadership Personality 2) Intelligence 3) Vitality 4) Integrity and Honesty 5) Communications 6) Human Relations 7) Organization and Direction 8) Decisiveness 9) Goal Orientation

You notice that the first of these to surface is leadership personality. Thatâ€™s because personality generates an immediate response. In assessing

leadership personality I have found that people generally react to a manager in one of two ways: 1) Either because he is an individual with in-depth personality, or 2) Because he holds a commanding position within the organization; consequently people must obey him. Obviously, we know that the first skill is the better. Being a good leader requires not only a knowledge of people, but also the ability to handle and deal with people. Certain traits denote leadership personality. They are: personal philosophy, a concept of fair play, and an insight into human behavior. A manager having leadership personality does the following: 1) Delegates rather than orders. 2) Uses suggestion rather than force. 3) Explains new ideas so they can be understood. 4) Keeps employees working without displaying authority. 5) Bases his sternness upon fairness, and 6) Speaks in a manner that generates respect. SPRINGS Summer 2010 39

Looking Back, Looking Forward

Another basic requirement of a good manager is intelligence. A manager can have many fine attributes, but if he does not use good intelligent reasoning, he will not make an effective manager. A manager’s intellectual resources include more than just level of intelligence. They encompass other mental traits, such as creativity, logical reasoning, a sense of being practical, quickness of mind, flexibility, and the ability to do global thinking. With these traits he is able to: 1) Think abstractly 2) Think comprehensively 3) Solve difficult problems 4) Make sound judgments 5) Do long-range planning 6) Create 7) Put past experiences into new patterns 8) Follow ideas to logical conclusions, and 9) Learn quickly One thing that is difficult to measure, but is very important, is vitality. Does the manager have the physical stamina to bear up under the rigors of the job? Being a manager requires good health. He must be on the job constantly. The strain is tremendous. He must put in an enormous amount of extra hours

40 SPRINGS Summer 2010

and extra days. Today, travel may be a major function of any manager’s responsibilities. Even international travel is becoming more of a requirement. If a man does not have the health and the energy, he cannot possibly make a good manager. Regardless of how we arrive at ratings, people will give different grades to various qualities. I think that one of the most important assets of any manager is integrity. Integrity is the one quality that employees sense. It’s the one thing that helps keep morale high. The manager’s integrity must be above reproach. Integrity is the quality which causes people to trust a manager. Who wants to work for or with a man whom no one can trust? Who wants to work for a man who has absolutely no integrity? Although drive, imagination and creativity are requirements for managerial leadership, all of these combined cannot suffice to get the job done if a manager has no ethics or morals. The manager must not have hollow ambitions. He must have the basic ability to want to produce good results. A manager must be a good communicator. Communicating is the one thing people do the most of in this world. It is also the one thing at which we are probably least effective. Why is communicating so important? 1) Because lots of effort is wasted when workers do not clearly understand what the manager wishes them to do. 2) The manager himself must be a clear thinker. A good communicator is generally a clear thinker. 3) A manager must be able to direct his ideas. Failing to communicate is a serious manager weakness. Don’t blame subordinates for the communications gap. It’s up to the manager to open and keep open the doors of communication. The subordinate doesn’t know what his station with the manager is unless the manager makes himself available for communicating. A manager who wants to encourage healthy relationships among his employees communicates. There is a definite relationship between communication and productivity. One part of the manager’s key to effective communications is learning to listen. A manager can fail to listen for two reasons. He can be so intelligent and sharp that he can’t tolerate slower-minded people. Or, he can think that he knows all the answers and finds himself talking when he should be listening. Learning to listen is a basic art in human relations that every manager must learn and master if he is to be successful. In the area of human relations, a good manager possesses additional qualities. He is loyal to his people. He sticks up for them. He has the courage

Although drive, imagination and creativity are requirements for managerial leadership, all of these combined cannot suffice to get the job done if a manager has no ethics or morals. The manager must not have hollow ambitions. He must have the basic ability to want to produce good results. to praise them and to defend them in the face of criticism. It’s the job of a manager to let subordinates know that he is loyal to them and will support them. A manager who practices good human relations smiles easily and displays a friendly manner. He also: 1) Likes to be with people 2) Attracts others to himself 3) Is adaptable to many kinds of people 4) Adjusts quickly to the social level of the group 5) Leads others to accept his ideas 6) Insists upon fairness 7) Puts others at ease when they are in his presence A manager generally gets the best out of his people when they want to work for him. After all, employees like to work for a man they can look up to. Since the chief goal of a manager is to get things done, he must be able to give organization and direction. He must establish goals. However, once the goals have been established, the manager doesn’t neglect the subordinates and wait for end results. He is judged on whether he can organize his people and direct them in order that they might accomplish goals. Then after the job is completed, he must have the ability to measure the results to determine how well his original goals were achieved. Sometimes this measurement or evaluation step results in establishing new objectives. But this means that he must be decisive. I have found that one of the things that irritates employees most is to have a manager who is indecisive, who procrastinates, or who can’t make decisions. And the decisions must be valid ones. If he makes them too fast, he may be using snap judgment. Soon people begin to doubt this kind of reasoning. If he ponders the question too long, then he may not be able to make the decision. In essence, a manager must be able to make studied and believable decisions based upon a thorough evaluation of all the facts or information. When a manager makes a decision, he: 1) Determines the objectives and decides which are important. 2) Collects and analyzes all the in formation available on these factors and attaches values to each.

3) Determines and selects the alternatives. 4) Communicates his decision to the people concerned and sees that the decision is implemented. 5) Collects information that may be used as the basis of a further decision. A manager must be goal-oriented. If he expects results, then he must lead his people toward this end. I feel that a manager analyzes his people and knows what he has to work with. Knowing people’s strengths, weaknesses, skills and abilities is a definite managerial attribute. In the final analysis, a good manager is able to do the things Mr. Penney defined because he has amassed a good bank of skills. They have been cultured through experience, education, intelligence, personality, desire, energy, and all of the hundreds of human traits that man possesses. He knows how to use all the management tools. He knows how to establish goals and work toward them. He is a planner and is goal-oriented. He has a realistic idea of his own capabilities and limitations, He knows his skills, physical condition, when he can work best, what irritates him, why he likes and dislikes certain things, and why he reacts the way he does to accomplish the goals he has projected. ◆

When Material Performance is Critical...

TRUST Instron

825 University Avenue, Norwood, MA 02062 | 1.800.564.8378 | go.instron.com/Trust

SPRINGS Summer 2010 41

Flashback At What Stage of Design Should the Spring Manufacturer be Consulted and Why? A Panel Discussion (Originally published in December, 1962)

e asked four representative spring manufacturers to present concisely their thinking on this question, “At What Stage of Design Should the Spring Manufacturer be Consulted and Why?” One of the most widely discussed subjects whenever representatives of our industry get together is design participation by the spring manufacturer. In far too many instances we are consulted too late and our only hope is that of a compromised design. We are pleased to present the four replies.

F.R. Downs, Jr., Stanley Industrial Components Div. Stanley Industries, Bristol, Conn.

Digital Vision/Punchstock

42 SPRINGS Summer 2010

This is one question on which spring manufacturers are in agreement. The answer: At the earliest possible opportunity. Springs are frequently the last component to be considered in a new project with the result that space limitations are established which compromise the design. Often the spring is the most critical of all components and should have first consideration. Our engineering department has found that early contact with the spring manufacturer can result in cost savings to the customer as well as sound functional design. Many elements of cost such as unnecessary grinding, extremely close tolerances, and expensive materials can be discussed and possibly removed from specifications if the opportunity is available while the design is still fluid. Many of these cost factors are not thoroughly understood and are often repeated on new designs simply because they appear on previous designs. There is reluctance on the part of many companies to make changes after a new part is “frozen” or released. If a new design can be studied prior to release, problems due to troublesome or expensive specifications often can be resolved without requiring engineering changes after release. John A. Kennedy, Quality Spring Products, Inc., Coldwater, Mich.

In reference to your question, we feel that the machine designer or the equipment designer should consult a spring supplier as soon as possible when they are ready to put thoughts on paper. A spring designer is not necessarily a machine designer, but he could help materially inasmuch as he realizes the stresses and all the other factors of required energy, more so than the machine designer. He could simplify, improve or eliminate other items of overall mechanisms by the use of the most efficient spring design possible. A typical example is a spring clutch where little printed data is available. Here the spring manufacturer can be of real value to the designer. These attributes should be utilized in the drawing board and prototype stages, not after other parts are finalized and ordered. A spring manufacturer learns to use his suppliers for timely help and information and hopes to be allowed to supply his customers with the same type of assistance. G. T. Zahnke, Wallace Barnes Division Associated Spring Corp., Bristol, Conn. Living in an age of specialization, where education has progressed to the point where no one person can retain all knowledge on a specific subject, the spring industry has been experiencing increased difficulty where new designs are involved. To explain, assemblies, parts or products are designed without regard for space needed to install a proper spring. Due to this factor, many times it is necessary to furnish an over-stressed part of special alloy materials that we, as manufacturers, actually would rather not furnish. Moreover, if the springmaker is consulted before extensive tooling has been purchased, it would be possible to furnish a trouble free, long life spring at a saving. Springs are normally the most highly stressed unit in any product. If a spring fails, the product is criticized not the spring manufacturer. As mentioned before, if the spring manufacturer is called during the design stage perhaps tolerances could be opened, stresses kept down, material analysis determined, and (to make your purchasing agent happy) a reasonable price on an item his inspector will pass. Harry C. Faust, Paragon Spring Co., Chicago, Ill.

We invest many dollars a year on free “Engineering Service” and quite frankly we are pleased to do it. In fact, we urge our customers to call us at the earliest design stages involving springs and before any prototypes are made. As springmakers, we are much more aware of modern spring making techniques and can direct their thinking towards spring or wire forms which are simple and well designed. Without this preliminary counsel at the early design stage, the customer may be faced with considerable unnecessary expense due to an inadequate spring design and experience the problem of finding a vendor capable and willing to produce his “square” springs. Thus, with a thorough knowledge of the customer’s requirements, we try to design his springs around our machines and production facilities, keeping to a minimum the tooling expense we are invariably asked to absorb thus justifying our engineering investment with the best possible product result. W.S. Doremus, Diamond Wire Spring Company, Pittsburgh, Pa. Editor’s note: We welcome your reaction to this story from nearly 50 years ago. Are these views still relevant today? How has it changed? Send your comments to Gary McCoy, managing editor at gmccoy@fairwaycommunications.com. ◆

SPRINGS Summer 2010 43

Mount Joy Wire...Your Missing Piece.

Chrome Silicon Wire… Mount Joy Wire Corporation is a manufacturer of high quality chrome silicon wire used in a variety of applications. For applications where high performance cannot suffer under extreme temperatures, chrome silicon is the answer. Mount Joy Wire is a leading supplier to the North American automotive industry of tempered chrome silicon for transmission springs. Our commercial grade Tempered Chrome Silicon performs under the most exacting conditions. Contact us with your next chrome silicon wire application.

Wire Products: • • • • • • • • • •

Chrome Silicon Oil Tempered Music Shaped Hard Drawn Patented Process Electro-galvanized Tinned Rocket Low Carbon

Capabilities: • • • • • •

Chemical Cleaning Lead Patenting Spheroidize Annealing Oil Tempering Plating Sizes from .010” - .125”

You are never far from our wire.

Mount Joy, PA 17552 • Tel. 717-653-1461 • Toll Free 800-321-2305 • Fax 717-653-6144 www.mjwire.com ISO 9001 : 2000

44 SPRINGS Summer 2010

What It Takes for Lean to Deliver Bottom Line Results

resuming you can sell the extra product Lean can enable you to build, several tactical issues need to be addressed to ensure your financial results improve. For example, a kaizen event may remove Work In Progress (WIP) from a line, but the event is really not finished until the kaizen team has found a way to make sure that the inventory impact will be properly recognized on the books.

Imagezoo

By David Kwinn

/Punchst

ock

Part Two: Tactical Issues

Lower Inventory and WIP: Is Inventory Off Your Books as Well as Off Your Lines? As a result of single piece flow, quite a bit of WIP should be eliminated from a production line. The value of this WIP should be calculated as soon as it is eliminated, and it will be a one-time reduction in baseline inventory. The number may not be large for many businesses, and it will only be reflected in the bottom line if the supply chain is synchronized with production so that inventory is only booked into plant inventory close to when it is used in production. A line will look Lean with little WIP, but there wonâ€™t be any benefit to the bottom line if the same inventory that used to be on the production line is moved to bins and shelves somewhere else in the plant. The way suppliers provide raw material to the lines is a key to seeing savings in the bottom line. With regard to finished goods, a key to seeing benefits is shipping just in time for customer requirements so that warehousing and staging are minimized.

SPRINGS Summer 2010 45

Cost avoidance may not turn up in the bottom line directly, but as a result of manufacturing improvements such as error proofing, there should be less rework, which should mean that the labor content in a product should go down. When this happens, the standard cost should be adjusted to capture the savings.

Higher First Pass Yields: Does Your Cost System Reflect the Benefits of Reduced Rework? Making something right the first time is obviously valuable, as rework is pure waste. Even worse, rework may miss defects that later result in warranty claims when defects end up in the field. To measure the value of increased first pass yields, there needs to

INDUSTRIAL SPRING STEEL ....your dependable source for flat, cold rolled, high carbon spring steel. •

TEMPERED OR ANNEALED

•

EDGING

•

LEVELING

•

CUTTING TO LENGTH

Industrial Spring Steel, Inc. Phone 215-426-7000 Fax 215-426-7003 Email sales@industrialspringsteel.com www.industrialspringsteel.com

46 SPRINGS Summer 2010

be a baseline of what the yields were before Lean deployment compared to what they are after. The yields should, over time, correlate with warranty rates. Lower warranty rates can be captured as cost avoidance. Cost avoidance may not turn up in the bottom line directly, but as a result of manufacturing improvements such as error proofing, there should be less rework, which should mean that the labor content in a product should go down. When this happens, the standard cost should be adjusted to capture the savings. If not captured in the cost system, the savings may turn up as a variance. The variance may have other offsets and not be recognized in the bottom line as a Lean savings, so it is important to make the cost system reflect reduced rework as soon as it is achieved. Less Manufacturing Floor Space: How Are You Going to Benefit From the Space You Save? One of the easiest improvements Lean can achieve is to reduce manufacturing floor space. Space is saved by removing excess raw material from the line, limiting the space for work in process, moving operators closer together, shortening conveyor lines, and optimizing layout patterns. In order to see the value of the reduced floor space in the bottom line, there must be a cost offset: • Can the space saved be sublet? Perhaps the space can be fenced off and rented to another business or used by a supplier for consignment inventory. • Can unused space be consolidated and vacated? • Can freed space be used for a new product or the addition of new lines that otherwise would require renting new space? If space is sublet or otherwise released, then the space saving must be reflected in the calculation of the overhead applied to existing product lines so that the space savings can be reported accurately in the future. In order to see Lean savings in the bottom line, the accounting community must plan to account for the Lean savings achieved. Perhaps the most important key to Lean savings is defining the targets upfront, along with what will be done with the savings. The following is an example, which can be converted to revenue and margin dollars.

Example of Lean Goals and Objectives • Increase productivity 30 percent to meet growing demand after the recession without adding new headcount. • Improve throughput 30 percent to expand sales to new customers with no margin erosion. • Shorten lead times by 25 percent to pick up business currently being lost when customers go to a competitor when product is not available for shipment for their requirements. • Reduce finished goods inventory by 40 percent and WIP by 70 percent, resulting in lower carrying costs. • Improve first pass yields by 50 percent as a result of reduced rework. Reduce warranty by 30 percent. • Reduce manufacturing space by 40 percent, which will permit consolidating two manufacturing facilities. Once these objectives are developed and presented to the organization, all questions can be addressed

—— From Design —— **New** Version 8 Spring Design and Validation for Compression Springs

and a foundation can be built for buy-in and continuing success. Behind each of these goals and objectives there should also be a contingency plan to cover any shortfalls. Status of Lean benefits needs to be an integral part of the monthly operations review. Plant management has to own the attainment of Lean goals. The attainment of Lean goals cannot be delegated to a Lean team that may try to build support at the grass roots level without full buy in from the top. Employees are much more likely to engage in the Lean process if they understand the strategic drivers behind the tactics they are deploying. The tracking process for potential Lean savings is crucial to success, and with diligent accounting efforts, Lean should deliver the benefits expected. ◆ Process improvement expert Dave Kwinn is a coach with the Milwaukee School of Engineering’s Business Excellence Consortium and works on Lean deployment in a wide variety of organizations with both administration and manufacturing. Contact Kwinn at (636) 328-5708 or dckwinn@yahoo.com.

—— Final Inspection ——

Features • Full design or validation. • Full graphical interface. • International standards. • Fatigue data. • Relaxation data. • Scale spring drawing. • Multiple design features. • Customised reports. • Extended Material database with user input. • User configurable layout. • Export in pdf, dxf etc. • Demonstration program available.

LTM Manually powered Compression / Extension spring testers. 22 & 110lbf capacities.

**New** LT2 Computer controlled Compression / Extension spring tester. 45 & 110lbf capacities.

TT computer controlled Torsion testers. 8.8, 88, 880lbf.in capacities

Institute of Spring Technology

Nichols International Machinery Systems Co.

Henry Street, Sheffield, S3 7EQ, United Kingdom. Tel: +44 (0)114 276 0771 Fax: +44 (0)114 252 7997 E-mail: mailto:ist@ist.org.uk Internet: www.ist.org.uk

5115 B Tremont, Davenport, IA 52807, USA. Tel +1 563/391 0400 FAX +1 563/391 0403 E-mail: info@nimsco.com Internet: www.nimsco.com

SPRINGS Summer 2010 47

©Istock.com/YinYang

Healthcare Reform Impacts Small Employers Immediately: What You Need to Know Now by Roger Schultz

n March 23, healthcare in America changed forever. The President signed into law the Patient Protection and Affordable Care Act, followed one week later by the Health Care and Education Reconciliation Act of 2010. Together, these two pieces of legislation have commonly been referred to as Healthcare Reform. These two new laws change the healthcare landscape significantly, including how consumers access health insurance coverage. Additionally, they facilitate the creation of exchanges, which alter shopping and health plan enrollment, change plan benefits and administration of those benefits, establish new reporting requirements and create new taxes. Most of these changes require government regulations before they can be implemented, and that implementation will take place over the course of the next several years. But a few key provisions take effect immediately, or begin with plan renewals or purchases occurring on or after September 23 of this year. So, what do these new laws mean for you, the small business owner? How do these laws affect your health plan, the coverage you provide to your employees, your administrative and reporting requirements, and how your employees interact with their healthcare providers? Let’s focus on three important categories to better understand the implications: 1) the near-term changes to health insurance plans from both a benefits and administrative perspective, 2) the immediate changes affecting small businesses and 3) future implications for health plans and small businesses.

Near-Term Changes to Health Insurance Plans From a benefits perspective, there are a few changes that take effect for new group health plans sold or renewing on or after September 23, including: • 100% Coverage of Preventive Services: The cost of preventive care services, as defined by the law, are not subject to cost-sharing, such as deductibles, coinsurances and copayments.

48 SPRINGS Summer 2010

• Lifetime and Restricted Annual Limits: Group health plans can no longer contain lifetime limits on essential benefits, which are to be defined by the Secretary of Health and Human Services. Health plans, however, may place limits on benefits that are not essential health benefits. Annual dollar limits will be restricted, and the Secretary of Health and Human Services will define these restrictions. From an administrative perspective, the following changes will occur: • Coverage for Dependents up to Age 26: Group health plans that provide dependent coverage of children must extend coverage to dependent children up to age 26. • Pre-existing Conditions: Group health plans cannot exclude coverage of pre-existing conditions for members under age 19. • Any Willing Provider and Prior Authorization: Members may now select their own participating primary care provider or pediatrician. Prior authorization or increased cost-sharing for emergency services, whether those services are received in- or out-of-network, are prohibited, as is prior authorization or referral for member access to OB-GYN services from a participating provider. • Nondiscrimination Rules for Eligibility: Group fully insured plans must now follow the same nondiscrimination rules from Section 105(h)(2) of the Internal Revenue Code that apply to self-funded health plans. As a result, special plans for a subset of employees will no longer be permitted. • Appeals Process: Group health insurers must implement and inform members about their internal and external claims appeals process. The internal appeals process is to be modeled after existing Department of Labor regulations and the external appeals process is to meet, at a minimum, the standards set forth in the NAIC’s Uniform External Review Model Act or applicable state law, if more stringent. Some of these changes may cause health insurance companies to increase premiums to reflect the expansion of benefits. Do I have to move to a new health plan at my renewal or can I be grandfathered? If you choose to keep the coverage you had as of March 23, 2010, this coverage is considered a grandfathered plan. Regulations regarding grandfathered plans have not yet been issued, so there are many aspects of the grandfathering provisions that remain unclear. It appears that grandfathered plans, however, are exempt from some of the new requirements including those regarding: • Preventive services • Appeals • Emergency services • Any willing provider/prior authorization • Nondiscrimination

Timeline Overview 1/1/10 • Small business health insurance tax credit 3/23/10 • Federal rate review 5/23/10 • Standardized presentation of coverage options format developed for internet portal. 7/1/10 • Internal portal up and running • National high-risk pool created • Early retiree reinsurance 9/23/10 • Coverage mandates: • Lifetime limits • Annual limits • Rescissions • Preventive services • Coverage for young adults • Pre-existing condition exclusions • Emergency services • OB-GYN • Other provisions: • Nondiscrimination rules • Appeals • Reporting 2011 • Medical loss ratios • Employer reporting • HSAs, HRAs, FSAs • CLASS Act (long-term care) • Small-group wellness grants • Tax/fee changes • Self-funded and large group market study • Uniform explanation of benefits 2012 • Health plan reporting requirements • Comparative effectiveness fee

SPRINGS Summer 2010 49

Immediate Changes Relevant to Small Businesses

Future Implications for Health Plans and Small Businesses

Now that you have a better understanding of the various changes to health plan benefits and administration occurring in late September, let’s talk about other changes that may directly affect you.

There are several changes that go into effect between 2011 and 2018. The following is not a comprehensive list, but does highlight some of the changes that might have a more direct impact on the small employer.

• Small Business Tax Credit: As a small business, you may be able to claim a new credit on your 2010 tax returns if you pay at least 50 percent of employee insurance premiums in 2010. You may be eligible if you employ no more than 25 employees (more if you employ parttime employees), and pay less than $50,000 in average annual wages. • Reporting on W-2s for 2011: As an employer, you will be required to disclose the value of the healthcare benefits you offer on your employees’ annual W-2s.

2011 • HSA and FSA Spending Accounts: Health savings accounts (HSAs) and flexible spending accounts (FSAs) cannot be used to purchase over-the-counter drugs unless prescribed by a physician. Additionally, taxes for nonqualified HSA withdrawals will be increased to 20 percent from 10 percent. • Medical Loss Ratio: Small group insurers will be required to meet minimum medical loss ratios or provide rebates for premiums in excess of these ratios. Regulations regarding this requirement are still under development. • Benefit Summaries and Coverage Explanations: Uniform standards and definitions for benefit summaries and coverage explanations will be developed by Health and Human Services, in conjunction with the National Association of Insurance Commissioners. No later than March 23, 2012, group health plans will begin to provide members with these documents and notify members 60 days in advance of any material changes not included in the previous summary.

2013 • FSA Contribution Limits: Flexible spending account (FSA) contributions will be limited to $2,500 per year.

50 McDermott Rd., North Haven, CT 06473

50 SPRINGS Summer 2010

• Employer Reporting: Employers must notify employees of several things, including: • Exchange availability (at time of hire, or by March 1, 2013, for existing employees) • If you, the employer, contribute less than 60 percent of the total allowed costs of the plan benefits, employees may be eligible for a subsidy under the exchange. • If an employee qualifies for the Free Choice Voucher program then the employer’s contribution can be used to purchase coverage in the exchange. If employees choose to purchase coverage through the exchange, they will lose the employer’s plan contribution.

2014 • Small Business Tax Credit: In 2014, the small business tax credit jumps from 35 percent of premiums to as much as 50 percent of premiums paid for health insurance coverage purchased through an exchange. • Wellness: Employers that offer wellness programs may provide employee discounts of as much as 30 percent of total coverage costs, and up to 50 percent with Health and Human Services approval. Eligibility may be based on the employee satisfying a health-related standard. • Guaranteed Issue, Pre-existing Conditions and Waiting Periods: Group health plans issue coverage to anyone applying for health insurance coverage during open or special enrollment periods and can no longer exclude coverage of pre-existing conditions for members of any age. Waiting periods cannot exceed 90 days. • Annual and Cost-Sharing Limits: Annual limits on essential benefits, as defined by the Secretary of Health and Human Services, are eliminated, and cost-sharing on group health plans is limited to HSA amounts. Plans being offered in the small group market will have deductibles that are limited to $2,000 for individual coverage and $4,000 in the case of any other plan. • Exchanges: Small businesses will be able to use state health insurance exchanges to search for and purchase coverage.

2018 • Excise Tax on High-Cost Insurance: Insurers and plan administrators will be subject to an excise tax of 40 percent of the value of the plan that exceeds $10,200 for self-only coverage and $27,500 for family coverage. There are many areas of the reform yet to be defined by the Secretary of Health and Human Services. Once these definitions become clear, group health insurers, plan administrators and employers will have a much better idea as to the specific ways these new laws will impact not only health plans and administration, but also how we, as consumers, interact with and use the healthcare system as a whole. IMPORTANT: This article provides a general overview of the new healthcare reform law. It does not cover all of the law’s provisions, and does not constitute legal or tax advice. For more information, visit www.trustmarkcompanies.com or e-mail roger. schultz@trustmarkcompanies.com. ◆

2013 • CO-OP program • Administrative simplification • Tax changes (2.3% tax on medical devices and FSAs limited to $2,500) • Large employer reporting requirements 2014 • Coverage mandates • Pre-existing condition exclusions • Guarantee issue/renewal • Annual limits • Small group and individual rating • Clinical trials • Deductible limits • Cost-sharing limits (exchange only) • Waiting periods • Essential benefits • Exchanges • Rate monitoring • Merged markets: premium increased monitored in and out of exchanges • Auto-enroll for large employers • Coverage responsibility: • Individual • Employer • “Free-Choice” Vouchers • Wellness • Premium tax • Administrative simplification 2017 • Exchanges can be expanded to large group 2018 • “Cadillac” Plan Tax

Roger Schultz is vice president of marketing and product development for the Medical Division of Trustmark Companies, headquartered in Lake Forest, Ill. Trustmark’s Medical Division supports the Starmark, Trustmark Affinity Markets and Trustmark Group Benefits health insurance brands. www.trustmarkcompanies.com, roger.schultz@trustmarkcompanies.com

SPRINGS Summer 2010 51

Don’t Let OSHA Play Games with Your Company! Hidden Hazards can be Dangerous and Expensive.

SMI’s Safety Audit of your facility will identify safety hazards and recommend abatements.

The program includes a preliminary interview, a review of the company’s written programs, a plant floor inspection and a detailed, written, post-audit report. Cost: $1,000 for Members, $1,250 for Nonmembers

For more information, contact: Spring Manufacturers Institute 2001 Midwest Rd, Suite 106 Oak Brook, IL 60523 Phone: 630-495-8597 Fax: 630-495-8595 E-Mail: regs@smihq.org Spring Manufacturers Institute 52 SPRINGS Summer 2010

Springmaker Spotlight

From left: Ted White today; A much younger Ted White (with a mustache) is pictured second from right, along with former SMI president George Underwood (far left) who hired White at Hardware Products. Also pictured are former Hardware Products employees Tricia Teixeira, purchasing agent, and Clark Holland, general manager.

Troubling Himself With the Facts A Profile of Ted White, Hardware Products Company by Gary McCoy

s president of Hardware Products, Ted White drives one hour each way to his office in Chelsea, Mass. While long commutes are not unusual in large metropolitan areas, what is different is White’s practice of not turning on the radio or making phone calls during the roundtrip. “I know it sounds corny, but I love to think,” explains White of his practice. White says he spends the two hours of silence in the car, “Thinking about solutions to work problems or my religious beliefs or philosophy or whatever.” But his “thinking time” doesn’t stop there. When he’s at home, White walks about four miles each day. “I find that clarity of thought that comes after the first mile is remarkable,” relates White. “It is as if the first mile clears the mind of all of the petty distractions and then the mind is clear to focus when you begin the second mile. Of course my dog Molly thinks it is all about her.” Through his 36 years at Hardware Products, White has used his “thinking” skills to help the 144 year old company succeed in the spring industry. “Lee Iacocca once said that the trouble with Harvard MBA’s is that they want all of the information before they make a decision and in business you are lucky if you have half the information you need before you must make a decision,” said White of the lessons he’s learned during his career in the spring industry.

SPRINGS 2010 53 SPRINGS Summer Spring 2010

“…in those days, a lot of people called up and had a concept and didn’t have a blueprint and wanted you to design [the spring] with them. I enjoyed that quite a bit; it was fun for me.”

“Aside from the fact that my boss is a Harvard MBA,” deadpanned White, “I find this very much to be the case (the fact that you only have half the information).” As a result, White says it is “always important to trouble ourselves with the facts.” And before making a decision to “be as thorough as possible.” But White says once a decision has been made, the time for debate is over and the time for implementation is at hand. He says you must focus all your energies on making it work. In addition, White advocates what he calls “zerobased thinking.” “If you have been doing something for a long time, it is always good to ask: What would happen if you stopped?” White says even if you have invested a lot of time and energy in doing something, “if you decide not much would happen if you stopped, then stop doing it.” The Spring Pathway Unlike other springmakers, White did not grow up in a family business. His path to Hardware Products and the spring industry was not one he had planned. Born in Manhattan, he lived there until age five before his family moved to Wayland, Mass. After high school, White enrolled at Merrimack College in North Andover, Mass., where he graduated with a degree in economics. Perhaps owing to his current fondness for silence while commuting, White drove a cab around Boston during his freshmen year of college. “I got to know Boston as only a cab driver gets to know the city.” Later he had a business driving computer documents back and forth from the Andover area to Boston in his Volkswagen Squareback. As White explained, computer programming at that time was done mostly using punch cards. “So I had a punch card courier business and that’s largely how I paid my way through college.” White met the owner of Hardware Products, George C. Underwood, at what he described as a

54 SPRINGS Summer 2010

“regular job seminar.” Underwood, active in SMI as a committee member and president, was looking for an inside sales person and liked the fact that White had some automation savvy because of his background and experience with computers. “So it was a match,” said White. During his early time at the company, White wrote several computer spring design programs. “These programs would be quite crude by the SMI standards of today, but it certainly made it quite quick for us at the time.” Because of his computer work, White said he had to “learn springs quite well and I developed a true interest in springs.” Starting at Hardware Products in 1974 at a salary of $8,500 a year, White never envisioned he would stay as long as he has. A fresh college graduate, White said he had not framed in his mind a career path and didn’t imagine staying at Hardware Products would be very long. He thought Hardware Products was a small company and a bit “rinky dink” at the time. He first looked at the company as a good place to start and “it was fun work.” White said he especially enjoyed being on the phone with customers and helping them design a spring. “It’s different from today, where everybody has a blueprint and a lot of people don’t want changes… they want it manufactured to the print,” explained

White. “But in those days, a lot of people called up and had a concept and didn’t have a blueprint and wanted you to design it with them. I enjoyed that quite a bit; it was fun for me.” Textiles and Phones Hardware Products was established in 1866 by the Goodnow family as a supplier to the New England textile industry. The company supplied pulleys, pillow blocks, shaft supports and springs for the machinery used in the textile industry. As one of the oldest spring manufacturing companies in the U.S., the company’s original purpose was to manufacture hardware specialties for the Goodnow and Wightman Hardware Store in Boston. One of those specialties was springs, which were hand wound on lathes. The company developed a line of stock springs which was sold through a catalog by T.F. Welch Co., successor to the Wightman Hardware Store. It is said that Alexander Graham Bell bought springs from that store for use in the assembly of the original telephone. “Because most of these parts had to be in stock, we have what we believe is one of, if not, the oldest stock spring line in the country,” said White. Being one of only a dozen companies in the U.S. that still has a stock spring line, White said they’ve used it as a competitive advantage. “We use that to try and get people in the door,” he explained. “Then if it’s not a stock spring they want, we can design the spring they do want. A lot of times they use it on a trial basis; so it’s a good foot in the door for us.” The plant is now in Chelsea, but up until 22 years ago Hardware Products was located in Boston’s historic North End and the plant had an unobstructed view of Paul Revere’s house. The company was in the hands of the Goodnow family until 1971, when Underwood bought the business. Hardware Products was purchased by its current owners, SEI Metaltek, in 1991. It continued to be run by Hap Porter, who was president of Hardware Products at the time. White served as Porter’s right hand man and took over running Hardware Products in 1998 when Porter became president/COO of SEI MetalTek. Now with 25 employees, Hardware Products is what White describes as “truly a short order job shop.” He says the company serves one of the broadest Standard Industrial Classification (SIC) codes in the spring industry. White says one thing Hardware Products has specialized in is helping other SMI member companies, who are accustomed to larger runs, satisfying their

customer’s R&D needs. “They will frequently come to Hardware Products to make 10 pieces for them,” said White of the practice. “It is more economical than the down time necessary on one of their larger run production machines. “We are small run specialists and to properly serve these markets we have always been a rapid response company,” said White. The company manufactures compression springs, extension springs, flat springs, torsion springs, wireforms, retaining rings and other special items. A Capitalist at Heart “I’m a true capitalist at heart,” explained White of his business philosophy. “As much as I like making springs, the reason that we are here is to make money. I don’t think you need to be shy about that or feel guilty about it. Profit is the motivator and I’m a big believer in knowing your costs.” White says costs are manifesting themselves in very different ways than they did in the past. “Know the cost of every spring. Know the cost of managing every account,” advised White. “Develop your own activity based costing system. Make sure you spend your time on the truly profitable accounts.”

SPRINGS Summer 2010 55

While White wants to ensure that his company makes money, he believes that business is no different than life. “The golden rule applies here as well: people and companies want to be treated well.” Manure Spreaders and Space Springs As someone with a long career making springs, White has formed opinions about the industry. He says frequently design engineers, who work on the most expensive portions of a project, overlook the “two-bit” spring even though it is the most operative portion of the mechanism. “What then becomes the most challenging is designing a spring that overcomes this shortsightedness,” said White. He believes the design aspect of the industry helps keep you on the forefront of new ideas. “It never ceases to amaze me how clever people are and what they dream up,” related White. “We make springs that go in manure spreaders and springs that go into space,” said White. “The constant challenge is to remember which is which, and to apportion the appropriate amount of resources to these varying applications.” In a qualified answer about what he dislikes about the spring industry, White mentions the incredible

56 SPRINGS Summer 2010

competitive nature of the business. “Not that I mind competition; it keeps you lean, and anyone who knows me knows keeping me lean is a task unto itself,” says White with a laugh. White says he’s frequently run into unusual situations where someone has quoted a price for a spring that is less than the cost of the material. “How can you possibly compete with that, yet your customer wants to know why you are more expensive,” lamented White. He also dislikes “the fact that many customers think of a spring as a machined part instead of a mechanical device and assign machined tolerances to it.” Essential Belongings As a board member and chairman of the SMI membership committee along with his service on the NESMA board, it is no surprise that White is a strong advocate for spring associations. “I really don’t know how anyone can run their business without it,” he explained. Among the things that Hardware Products utilizes are SMI’s spring design software, failure analysis service, the annual market survey and safety programs run by Jim Wood.

“The tenets we clung to in yesteryear are just not going to be there tomorrow. They’re going to be chuckled at tomorrow; they’re going to be foibles,” said White. “I think keeping an open mind and being optimistic about it and changing with it is going to be absolutely mandatory.”

In particular, White said his company has calibrated its financial performance by using the SMI market survey each year. “We find it is even more important to belong to SMI and get this survey when times are lean because that is when it is more important to make sure that your costs are in line with the industry in general.” In addition, White says he uses the annual salary survey to help control Hardware Products’ wage policy. “Even though other parts of the country have different wage scales than Boston,” he explains, “it is still easy to see if the market salary has gone up, down, or stayed the same from year to year and then extrapolate for our own wage policy.” Initially working for Underwood, an SMI president, White said he had opportunity to accompany him all over the country and tour many spring companies. “I never entered one of those companies when I did not learn something,” said White. “I never stole a customer as a result or used the new found knowledge against the company, but I also learned a heck of a lot about the variety of ways to make a spring.” White said that as the years went by he realized that “the more you put into a trade organization the more you get out of it.” As an active board member of SMI and NESMA, White says he has thoroughly enjoyed working with other springmakers on common problems. Keys to Success It is a simple mantra, but White firmly believes one of the keys to success in the spring industry is to give the customer what he wants. He quips: “Who would have thought years ago that we would be doing half of the things we are doing now. Before saying ‘no,’ ask yourself if this is a reasonable request no matter how unorthodox.” Never say “no” is the way White has trained his customer service staff. “The more you can give the customer what he wants, the more they are going to buy from you,” he says. White says with today’s computer technology it is much easier to provide customers with quotes in just a matter of minutes. Years ago customers would

ask Hardware Products to provide a quote on all the springs they use. It was a time consuming process that White said used to take weeks to complete. Regarding the future, White sees a “change in the wind.” He advises springmakers to keep an open mind. “The tenets we clung to in yesteryear are just not going to be there tomorrow. They’re going to be chuckled at tomorrow; they’re going to be foibles,” said White. “I think keeping an open mind and being optimistic about it and changing with it is going to be absolutely mandatory. I think those people who do are not only going to survive, they are actually going to prosper. This is a time of great change and it is going to be terribly exciting. Enjoy it.” ◆ Gary McCoy is the managing editor of Springs magazine and the president of Fairway Communications. Readers may contact him by phone at (847) 622-7228 or e-mail gmccoy@fairwaycommunications.com.

Carbide Spring Tooling High Quality Carbide Spring Tooling, including: Quills, Liners, Feed Rollers, Coiling Tools, Cutters, Arbors & Mandrels

Offered at very reasonable pricing for many spring & wire forming machines.

PO Box 5323 Buffalo Grove, IL 60089 Phone: 847-769-2099 Fax: 847-913-4528 mshapiro@gibraltar8.com

SPRINGS Summer 2010 57

58 SPRINGS Summer 2010

Inside SMI

Members of the SMI Executive Committee (l-to-r): Russ Bryer, secretary/ treasurer, Scott Rankin, president, Steve Moreland, vice president, and Reb Banas, immediate past president. Not pictured: Mike Betts, at-large member.

SMI Annual Meeting in St. Thomas Was Smooth Sailing

The 2010 SMI Annual Meeting in March was warm and inviting as members and their families had fun in the sun at the Marriott Frenchman’s Reef and Morning Star Resort in St. Thomas, Virgin Islands. Touring the island, snorkeling, and shopping the bargains in Charlotte Amalie were popular activities during the trip. Members were educated by the insights and experience of motivational business speaker Brian Tracy and terrorism expert General Nick Halley, who was such a hit at his appearance at SMI’s meeting two years ago that he was booked for a return engagement this year.

The Annual Meeting culminated in the induction of new SMI president Scott Rankin. One of Rankin’s goals during his time in office is to increase the attendance at SMI’s meetings, welcoming new SMI members as well as those who do not regularly attend, and including them in special events so that more members can benefit from sharing ideas and experiences with their peers in the spring industry. On that note, SMI welcomes members to join us next spring for SMI’s Annual Meeting at the Marriott Doral Golf Resort and Spa in Miami, Fla., March 25–29, 2011.

SPRINGS Summer 2010 59

SMART SOLUTIONS... ...for TANGLED SPRINGS

UNTANGLE YOUR SPRING PROBLEMS AND... Improve employee morale Save money, time, and hours of frustration Use before vibratory feeder bowl for less jams Ship springs in bulk without extra separators or trays Eliminate expensive tack (fly) paper and special handling

SMI Board Meets in St. Thomas Led by outgoing SMI president, Reb Banas, the SMI Board of Directors met in regular session on March 20 just before the start of the SMI Annual Meeting in St. Thomas. Banas welcomed new board members Chris Witham, Jim Callaghan, Kurt Gillespie and Hap Porter. He also announced that Mike Betts will join the executive committee as an at-large member. Banas noted that due to strong attendance at the annual meeting that there “possibly is some economic recovery.” He noted that SMI weathered the economic storm extremely well, “due to good decisions by current board members and staff.” Under the leadership of committee chairman, Richard Rubenstein, Springs magazine continues to be high quality and recently added a new electronic version of the magazine that is highly interactive. Banas reported that ASD 7.0 is up and running and will continue to be produced by UTS. Secretary/treasurer Steve Moreland indicated that the recent audit of SMI is complete with a positive determination. Dennis Backhaus said the “Annual Market Survey” was set to be mailed to members on April 1, 2010 and the results will be compiled by MacKay Research. Bob Iorio indicated a desire to have some sort of benchmarking tool for associate members that would be similar to the Annual Market Survey. Joe Sirovatka indicated that Spring World 2010 is 80 percent sold and thanked SMI for their alliance with CASMI.

SMI Will Host Industry-Wide Reception at Spring World 2010

If the D-Tangler can separate these treble hooks efficiently with no damage, just imagine what it can do with your springs!

DISPENSE WORKS INC 4071 Albany Street . McHenry IL 60050 815-363-3524 phone / 815-363-8089 fax info@dispenseworks.com / www.d-tangler.com

60 SPRINGS Summer 2010

SMI will host an industry-wide opening reception during the first night of Spring World 2010 at the Donald E. Stephens Convention Center in Rosemont, Ill. The reception will take place on October 13 and is open to SMI members and show attendees and suppliers. Two years ago during Spring World 2008, more than 500 people attended the first-time event. “The opening reception is a fitting way to end the first day of Spring World,” said Scott Rankin, SMI president. “We are pleased once again to sponsor this event and provide a venue for fellowship and networking among members of the spring industry. If you are coming to Spring World you’ll definitely want to make this event part of your schedule.” Information about the reception location will be available at the SMI booth (#621) at Spring World.

Spiro Industries Involved In Charitable Cause

“Hope Springs Eter nal” is the title of the art project that raised $5,500 for breast health

SMI Mourns Passing of Members It is with deep regret that Springs announces the passing of Robert E. Geen, 87, on June 1, 2010 after a short illness in Rockford, Ill. Geen served with the United States Coast Guard in World War II. He was the owner of All Saints Monument Company in Des Plaines, Ill. and later was the vice president of sales and marketing at Mohawk Spring Company for 33 years, retiring in 1995. Geen was president of CASMI in 1983. Geen was an avid golfer, card player and loved to go fishing and boating. Recently his most enjoyable times were spent at Jordan Lake in Wisconsin. Survivors include his sons, Tom (Colette) Geen of Rockford, Ill., Bill (Pam) Geen of Wisconsin Dells, Wisc. and David (Jane) Geen of Highland, Mich.; several grandchildren and great-grandchildren; and sister-in-law, Romayne Geen. He was preceded in death by his wife June of 67 years; brother, Bud Geen and sister, Wilva Snyder. Contributions in memory of Geen may be made to Heartland Hospice of Rockford, Ill.

research when it was put up for bid at the recently held John C. Lincoln Hospital Gold Ball in Phoenix, Ariz. The artist, Joy Matthies, of Sun City, Ariz. is a mammographer at the hospital’s breast health research center. The art piece is dedicated to the artist’s friend, Cindy Backhaus, who is a ten-year breast c a n c e r s u r v i v o r. “What inspired me to create this piece,” stated Matthies, “is Cindy’s story and how her husband, Dennis, supported her through her health challenges.

It is with deep regret that Springs announces the passing of Barbara J. Magiera, 59, on April 28, 2010 at her home in Richland, Mich. Magiera was born June 7, 1950 in Jarkowice, Poland. In the mid 1970s she earned her masters degree in chemical engineering from Western Michigan University. On July 16, 1983 in Allegan County, Michigan, she married Andrew Magiera of Krakow, Poland. In 1984, she and Andrew opened their own business, Hytech Spring and Machine, in Plainwell, Mich., which they still own and operate. With the heart of a giant, Barbara loved animals, was an avid reader, enjoyed traveling, entertaining, and cooking. Above all, she loved her family. In addition to Andrew, she is survived by her mother, Zofia Maruniak-Slotwinski; her sister, Teresa Ramos; her father-inlaw, Stanislaw Magiera; nephews, Alex and Brian; extended family in the United States and Poland; and many friends. Contributions in memory of Magiera may be made to the S.P.C.A. of Southwest Michigan or the Michigan State University College of Veterinary Medicine.

Cindy wrote about her many surgeries and therapies and how she came to think of her cancer as a gift that changed her life and helped her recognize the people and life-values that are most important to her. Her story touched me, so I felt it important that it be included as part of the art work. I feel that it is the story behind the creation of the art that motivated the large donation.” Matthies attached Cindy’s handwritten pink booklet of inspiration to the connector springs on the bra. Dennis Backhaus is one of the owners of Spiros Industries, Inc., an SMI member company located in West Bend, Wis. Are you an SMI member involved in a charitable cause? Please send your news to Springs for consideration in a future issue.

SMI Welcomes New Members SMI is pleased to welcome its newest members. Regular Members Dayco Products - Roseville div. of Mark IV Automotive 16000 Common Road Roseville, MI 48066 (586) 779-5850 www.markivauto.com Felix Buccellatto, Q.A. Manager Dayco Products - Springdale 1351 Stewart Place Springdale, AR 72764 (479) 756-7500 www.markivauto.com Charles Cook, Q.A. Manager Associate Member ThyssenKrupp Materials NA 22355 W 11 Mile Road Southfield, MI 48033 (800) 926-2600 www.tkmna.thyssenkrupp.com Bill Hann, Sales Manager Ronald Buzinski, Vice President SPRINGS Summer 2010 61

Spring Technology

Cautionary Tale: Are Your Customers' Load Tests Identical with Yours? by Mark Hayes

ot exactly, is the usual answer. When discrepancies are small and sell within given tolerances, it is often of no importance that your customer gets a slightly higher or lower result. When discrepancies are larger, they may be important, and IST frequently undertakes independent load and torque testing for both springmakers and spring users to resolve such differences. Assuming that both your load or torque tester and that of your customer are calibrated correctly, the reason for the discrepancy may lie with the reproducibility and repeatability (R & R) of load testing for springs. My colleague, Mike Bayliss, senior engineer at IST, has prepared the following discussion to help resolve any differences between your customerâ€™s results and yours.

The R & R Method The R & R method of quantifying the suitability of a piece of test equipment makes the assumption that the individual test pieces are completely stable compared to the test equipment. This is simply not the case with springs, and several features in springs mean that they do not make reproducible or repeatable test samples. The R & R results are examining a machineâ€™s repeatability and reproducibility, and as a rule, only machines specifically designed for spring testing should be used. If the R & R was undertaken using dead weights or gauge blocks most spring testers would give good results. When using springs to test the R & R, a

Mark Hayes is the senior metallurgist at the Institute of Spring Technology (IST): The International Independent Centre of Excellence for Spring Technology. He manages ISTâ€™s spring failure analysis service, and all metallurgical aspects of advice given by the Institute. He also designs and delivers the majority of the spring training courses that the IST offers globally. Readers are encouraged to contact him with comments about this cautionary tale, and with subjects that they would like to be addressed in future tales. Contact Hayes at (011) 44 114 252 7984, fax (011) 44 114 2527997, or e-mail m.hayes@ist.org.uk. 62 SPRINGS Summer 2010

completely uncontrolled factor is introduced, which is totally ignored by the test analysis. There is a wide variety of spring testing machines of differing quality, so it is important to understand what factors affect R & R results, including the spring. This will enable you to decide whether the machine or the spring is the problem when poor R & R results are found.

Spring Factors Influencing Results Loss of Free length If a spring is repeatedly load tested, it may shorten slightly, giving a reducing load characteristic. This feature depends on the stress level in the spring and the design and manufacturing process routes; hence, a progressive reduction in load can sometimes be seen as the operators test the spring Spring Recovery If the spring is left in the unloaded position, it may start to recover some of the lost length. This is a time-, stress- and temperature-dependent feature. Hence the time between different operators carrying out their test runs can influence the results. Spring Orientation, Positioning and Location If the spring is turned upside down the squareness and parallelism of the ends will cause the spring to sit differently, causing a difference in load characteristics. Positioning of the spring offset relative to the central axis of the tester will induce bending moments in the loadcell and frame and influence the results. If the spring is subject to buckling and has to be supported, this will produce considerable nonrepeatability/reproducibility due to the spring/ support interface friction conditions. It is recommended that the test springs be marked to enable all operators to place and orientate the springs repeatedly. Non-axial Forces Produced by the Spring When compressed, a spring produces shear forces and moments about the end plane. The magnitude

Figure 1: Typical IST load test equipment

is used below this limit the resolution becomes too coarse and this influences the R & R result. Length Measurement System Most machines use digital length encoders to measure the spring deflection. These are usually very good, and as long as it is fitted correctly, will readily give a 0.01mm resolution and accuracy. Machines that use rotary encoders on the ballscrews or motors can be subject to nonrepeatability if there is mechanical backlash. Length resolution When measuring high rate springs the length measuring system must have sufficient resolution so that the resultant uncertainty in load calculated by Spring Rate x Length Resolution is a small percentage of the tolerance band. High rate springs may require resolutions of 0.002mm.

and direction of these forces will influence the loadcell and measured results. Different types of loadcell behave differently when subject to these extraneous forces, and simply rotating the spring about its axis will also influence the results. Spring Design High rate springs require higher precision measurement systems and mechanics. This is because the test machine will stop at the correct test length, but with a possible error equal to ± 0.5 resolutions, so the recorded load will vary by the ±spring rate x 0.5 x length resolution. When measuring low load, ensure the measuring system has sufficient resolution. For class 0.5 machines (per ISO 7500-1:2004), the lowest load to be measured on the machine is 400 x load resolution. Springs that buckle must be guided by a rod of design such that it can be repeatedly fitted and that the rubbing surfaces remain undamaged. Lubrication may be used to help make the friction more consistent.

Test Machine Factors Influencing Results Loadcell System The load measurement system must be stable and the choice of loadcell has a big influence on test results. As a rule modern electronics are very stable in respect to drift in calibration and do not usually cause problems. Loadcell Calibration The top grade for spring testers is Class 0.5, which means the reading is accurate to 0.5 percent. This will be over a range between fullscale and a lower limit dictated by the resolution of the display system. If a machine

Frame Deflection Loading frame rigidity, mechanics, deflection and compensation must be extremely good with high rate springs to minimize errors and non-repeatability. The ease and precision of the length zero datum must also be good to achieve high reproducibility. The IST’s load test machine meets the above requirements and is shown in Fig. 1.

Our precision shaped wire – where your great products begin. Radcliff custom rolled wire is at the heart of the superior springs and other products our customers make. With the best service, on-time delivery and competitive pricing, we’re the industry leader. ISO 9001:2000 certified and RoHS compliant. Credit cards accepted. Call: 860-583-1305.

www.radcliffwire.com SPRINGS Summer 2010 63

Value

% Tolerance Band

% Total Variation

Repeatability (EV)

0.00031

20.6

13.4

Reproducibility (AV)

0.00002

1.4

R&R

0.00031

Part Variability (PV)

0.00229

Total Variability (TV) Tolerance band

Table 1

Value

% Tolerance Band

% Total Variation

Repeatability (EV)

0.0002

3.7

1.8

0.9

Reproducibility (AV)

0.0002

3.9

1.9

20.6

13.4

R&R

0.0003

5.3

2.7

152.6

99.1

Part Variability (PV)

0.0101

201.5

100

0.0023

Total Variability (TV)

0.0101

0.0015

Tolerance band

0.0050

Understanding the Results Repeatability is the ability of a machine to measure a spring many times and give the same result. Reproducibility is the ability of a machine to be reset and used by different operators and to achieve the same result. If a bad R & R is achieved then it is important to be able to look at the results and find where the fault lies. R & R results of less than 10 percent error are satisfactory. Results of 10 – 30 percent may be acceptable based upon the importance of the application, but results greater than 30 percent indicate that the measurement system needs improvement. Table 1 above shows an R & R of 20.6 percent, which would not usually be accepted. This test used ten springs, three operators and tested three times. Looking at the "% Tolerance Band" column it can be seen that the repeatability is the dominant problem indicating that the machine or springs are not repeatable. Looking at the part variation shows that this is 1.5 times the required tolerance band, indicating that maybe there is a spring manufacturing problem or the tolerance is unrealistically small. Alternatively the machine may have an issue with noise, electrical or mechanical, or an ability to find a test length repeatedly, because the mean values are good (reproducibility), but the results have a non-repeatable scatter about the mean. The IST’s load test machine does not have these faults and is shown in Fig 1. The reproducibility is very good indicating that different operators can readily and accurately set up the machine. Looking at Table 2 (above) it can be seen that the tolerance band is more than three times larger than in the previous example; now the R & R looks good. Part variability is still poor, indicating that the springs are out of tolerance and hence there may be a manufacturing problem.

64 SPRINGS Summer 2010

Table 2

Summary • R & R testing assumes the test pieces are stable — springs are often not stable. • High rate springs will require high-resolution length measuring systems. • High rate springs will require high rigidity loading frames and compensation systems. • Test samples should be marked to enable repeatable positioning by operators. • Poor reproducibility indicates that the machine’s set-up is variable. Often down to a length measurement problem or unstable spring lengths. • Poor repeatability indicates variable test length searching, or noise. • High part variability indicates the spread of spring results is great compared to the tolerance band and a problem in process capability is present. • If the reason for discrepancies between load tests at two sites cannot be traced, the IST can independently test the springs and resolve the problem. When the IST load or torque test springs, the result is regarded as definitive. ◆

Precipitation-Hardened Stainless Steel for Springs

Technically Speaking

by Luke Zubek, PE

(Editor’s note: To follow the “Retro” theme of this issue, we present here one of Luke Zubek’s most popular articles. It was originally published in the January 2006 issue of Springs.) he challenge with most engineering materials is finding something that is soft enough to be formed into a useful shape and then strong enough to be of practical use. This issue is reflected in the spring materials in use today. Steel wire or strip can be hardened primarily in two ways: cold working, or quenching and tempering. Stainless steels can also be hardened in a similar fashion, but an additional strengthening path exists called “age hardening” or “precipitation hardening.”

Precipitation Hardening In 1906, precipitation hardening of metals was accidentally discovered on the aluminum-copper alloy called “Duralumin” by the German metallurgist Alfred Wilm. It took about 15 years after this finding to fully understand and then exploit the mechanism of precipitation hardening. This discovery provided aluminum an extra level of strengthening that enabled its alloys to be used in high-strength applications. The growth of the modern aircraft industry would not have been possible without this development. Many high-strength alloys have been developed using this mechanism, which is not only evident in aluminum but also cobalt, nickel, copper and titanium alloys. Two common spring grades of precipitation-hardened stainless steel are 17-7PH and A-286. In general, the strengthening process is performed in the following three steps:

Luke Zubek, PE is the former technical director of the Spring Manufacturers Institute. Prior to that, he was a metallurgical engineer for a major steel producer for 10 years. He holds a masters of materials and metallurgical engineering degree from the Illinois Institute of Technology and a bachelors in metallurgical engineering from the University of Illinois at Chicago. Zubek is currently a senior lead metallurgical engineer for Exova.

1. Solution treatment. This process consists of a relatively high temperature treatment that allows any precipitates and alloying elements to dissolve, or go into a supersaturated “solution.” Typical solution heat treatment is done around 1800° to 1950°F for most stainless steels. This treatment can be done during the hot rolling process and is sometimes referred to as a “Mill Anneal” or “Condition A.” 2. Quenching or cooling. After the alloys are brought into solution, the metal is cooled to about room temperature. Cooling can be done in air, oil or water, but must be accomplished fast enough to obtain a supersaturated solid solution. The cooling rate during this operation can be critical to the final performance of the wire. A slow cooling rate from a high temperature tends to produce a coarser grain size than a faster cooling rate from a lower temperature. Material performance can be improved by a creating a finer grain size at this point. 3. Precipitation or age hardening. The supersaturated solid solution decomposes with time or temperature as the alloying elements form small precipitate clusters. The formation of these clusters act to significantly strengthen the material. In some alloy systems, these precipitates form at room temperature with the passing of time; this process is then called “natural aging.” When heat is used

Figure 1: Characteristic relationship between hardness and aging temperature for austenitic PH stainless steel.

SPRINGS Summer 2010 65

to harden the material, the process is sometimes referred to as “artificial” aging1. For stainless steel spring materials, there is an additional hardening step. This occurs between the cooling (step 2) and the precipitation hardening (step 3). This step consists of strengthening the steel with enough cold reduction to make the properties that are required by the appropriate specification. As expected, increasing the amount of cold work will cause the final hardness to increase, as seen in Figure 1, previous page. Note that for austenitic stainless steels, as the cold work increases, the optimum aging temperature decreases. Figure 2, location, shows the relationship between the aging temperature of 17-7PH steel, and the tensile, yield and elongation. As the hardening temperature is increased, the tensile and yield properties increase to a maximum, and then drop off dramatically. As these properties begin to decline with increasing temperature, the elongation starts to increase. This increase in elongation signifies a condition that is called “over-aging.” Over-aging occurs as the particles that caused the increase in strength continue to grow in size. As these particles grow, they begin to coarsen and cause a decrease in the hardness with a corresponding increase in elongation.

Figure 2: Properties of 17-7PH vs. aging temperature2.

As the hardness increases during aging, so does the susceptibility to hydrogen embrittlement. Studies of precipitation-hardened stainless steels indicate that material at the peak hardness or slightly overaged may have enhanced resistance to hydrogen embrittlement3. From a material standpoint, being at the peak hardness or to the right of the peak would be better than being under-aged, or to the left, as the ductility increases when the material becomes over-aged. One exception to this rule is with alloy PH15-7 Mo, where the best combination of strength and elongation is in the under-aged condition4. Stainless Steel Alloys Most precipitation-hardened stainless steels contain a titanium and/or aluminum addition that forms the fine precipitates responsible for the increase in strength. For example, 17-7PH has about a 1% aluminum addition, and alloy A-286 has a 2% titanium addition. The alloys 17-7PH and A-286 represent the two most popular groups of springgrade precipitation-hardened stainless steel; semiaustenitic and austenitic, respectively. Alloy 17-7PH is classified as a semi-austenitic stainless steel because the chemistry is composed so

66 SPRINGS Summer 2010

Comparison between the precipitation hardening alloys 17-7PH and A-286 17-7PH

A-286

6.5 – 7.8%

~26%

600°F

950°F

Precipitation Treatment

900° for 1 hour

1325° for 16 hours

Magnetic Permeability

>40

~1.007

C38 – 57

C35 - 42

Nickel Content Maximum operating temperature

Rockwell Hardness (in aged condition) Corrosion

General corrosion resistance

that the microstructure is primarily austenitic at room temperature. Some applications of this grade require refrigeration to -100°F before age hardening. This low-temperature operation is analogous to the cold working done on wire grades, in that both processes transform the microstructure into martensite4. The refrigerated and aged condition is identified as the “RH950 condition,” and the cold-worked and aged condition is called the “CH900 condition.” Note that, in either condition, significant strengthening is obtained from the formation of martensite before aging; therefore it can be expected that this grade is somewhat magnetic. The amount of nickel impacts the transformation to martensite as well as the workhardening rate on this grade. Unlike semi-austenitic precipitation-hardened stainless steels, the austenitic stainless steels cannot be transformed into martensite either by refrigeration or cold work, and they remain virtually non-magnetic even after cold work and aging. Most of these alloys contain a significant amount of nickel (25 to 30% vs. about 7.5% for the semi-austenitic grades) that prevents the transformation of martensite. The greater alloy content enables the austenitic precipitationhardened grades to have better corrosion resistance and operate in hotter environments. The precipitation reaction is markedly slower in these alloys, as can be seen in Figure 3, location. The thermal treatment used for precipitationhardened spring steels not only provides a significant increase in strength but also supplies the necessary stress relief. Cold forming after age hardening is generally not recommended, due to the marked increase in strength after hardening. Additional thermal treatments performed after the precipitation hardening may lead to excessive over-aging. This brief review of the processing of precipitationhardened stainless steels shows that a balance between alloys, cold work and thermal processing are

needed to make a final product that performs optimally after the prescribed age hardening. This balancing act makes these alloys a challenge to produce, but the reward is high-strength steel that can operate in high temperatures yet has a relatively low cost. ◆

References 1 Samuels, Leonard. Metals Good corrosion Engineering: A Technical Guide. resistance Editors: Car nes Publication Services Inc. ASM International, 1988, pp. 368-369. 2ASM International Handbook Committee. Heat Treating, Stainless Steels. J.R. Davis, Davis and Associates, ASM International, 1999, p.309. 3Craig, Bruce. Hydrogen Damage, ASM Handbook, Volume 13A Corrosion: Fundamentals, Testing, and Protection. Editors: S.D. Cramer and B.S. Covino Jr. ASM International, 2003, p.374. 4ASM International Handbook Committee. Heat Treating, Stainless Steels. J.R. Davis, Davis and Associates, ASM International, 1999, p.35.

Precision Quincy / 1625 West Lake Shore Dr. / Woodstock, IL Made in USA / 800.338.0079 / www.precisionquincy.com

SPRINGS Summer 2010 67

New Products StarLite® SM and Scorpion® SM Safety Eyewear for Smaller Faces To increase safety, Gateway Safety offers StarLite® SM and Scorpion® SM, smaller-size safety eyewear designed to fit individuals with small or narrow faces. Both StarLite SM and Scorpion SM provide all of the advantages of their “parent” designs, but are ten percent smaller to achieve a correct, comfortable fit. Light in weight, yet incredibly durable, both styles offer exceptional impact protection, superior optical quality, and a fashionable design. With appropriately sized safety eyewear that won’t slide down or fall off, workers are less likely to remove their eye protection and risk injury. StarLite SM and Scorpion SM meet or exceed the ANSI Z87.1+ standard. The scratchresistant polycarbonate lenses also filter out more than 99.9 percent of harmful UV-A and UV-B rays. StarLite SM features the same lightweight, popular design as the original, permitting wide, unobstructed vision. Deep, universal-fit temples provide as much side protection as large side shields. Lenses are available in Clear, Gray, Amber, Pacific Blue, Clear Anti-Fog, Clear Indoor/Outdoor Mirror, Silver Mirror, and Blue Mirror. Scorpion SM, has adjustable-length, four-position ratcheting temples for a custom fit. A soft fingertip nosepiece helps prevent slipping, even in hot work environments, while a venting system between the frame and lens helps minimize fogging. Lens options include Clear, Gray, Clear Anti-Fog, Clear Indoor/ Outdoor Mirror, and Silver Mirror. For more information call Gateway at (800) 8225347.

Accu-Lube JL-12 High Performance Tube Bending Lubricant Accu-Lube JL-12 is an opaque gel formulated specifically for tube bending applications. It can be pumped or hand-applied directly to the tube or bending mandrels, leaving a clean coating on the mandrel that will not build up over time. Accu-Lube JL-12 is designed to stay where it is applied, eliminating the mess of conventional lubricants. No cleaning is required before welding and it is easily cleaned before paint or plating. This new lubricant enables substantial cost saving over

68 SPRINGS Summer 2010

conventional products that flow down tubes, by reducing consumption and improving housekeeping as well as tool or mandrel life. Accu-Lube JL-12 is supplied ready to use and is available in 5- and 55-gallon containers. ITW ROCOL North America designs and manufactures a full line of lubricants and cutting fluids for the metalworking industry including the Accu-Lube product line of environmentally-safe lubricants and equipment for minimum quantity lubrication.

New Point-Of-Purchase Display Fixtures from SDP Feature Spring-Powered Reels A new series of point-ofpurchase (P.O.P.) display fixtures from Stock Drive Products (SDP) feature spring-powered reels. These display fixtures, identified as the A3Z55 Series are stocked in three different sizes for displaying small products such as appliances and communication devices. These P.O.P. units each contain a smoothly-operating, retractable cable which is attached to the displayed product with the use of a separately available black ABS plastic cable attachment. The three display fixtures range in size from 1.08" sq. to 1.87" sq. The two smaller sizes have a black nylon case; the largest size is stocked in white. The retractable cable is made of nylon coated stainless steel. The end of the cable contains

an eyelet for a #8 screw (.175"). The spring element of the spring powered reel is stainless steel. Quotes, online orders, available stock, and 3D CAD

The Daylight Company Introduces ESD Ultra Slim Magnifying Lamp The Daylight Company, the world’s leading maker of high quality specialty and magnifying lamps, introduces its ESD Ultra Slim Magnifying Lamp, which provides full protection against static electricity and electrostatic discharge (ESD). The Daylight ESD Ultra Slim Magnifying Lamp , which is now available, features 28-watt ef ficiency with the combined power of a seven-inch-wide glass magnifying lens and 1.5-inch diopter swing arm lens, while giving complete protection against ESD events. With 6,500 kelvin light spectrum and super magnification, it is believed to provide the strongest light and largest lens system on the market today. The entire lamp—head, lens, joint and

arm—is fully grounded and has special dissipative materials to remove static charges and prevent build up of static electricity. The lamp has been independently verified as suitable for use in Electrostatic Protected Areas (EPA - IEC 61340-5-1 and ANSI/ESD 20:20). This lamp helps solve one of the biggest problems facing manufacturers, testing agencies, repair facilities and other industrial users — how to work in environments that are prone to electrostatic discharge (ESD). This sudden momentary flow of electric current between two objects caused by direct contact can damage electronic circuits and components. ESD is a serious issue in solid state electronics and this lamp prevents it. For further information, visit http://us.daylightcompany.com/.

Model downloads are available at: www.sdp-si.com/eStore. For more information, phone Stock Drive Products at (516) 328-3300.

HSI OVENS Forming Systems Inc. and HSI announce the newest development for adherence to AIAG (Automotive Industry Action Group) standard CQI9 for heat treat assessment capability. HSI’s high performance ovens are now offered with complete data reporting systems which record the oven’s performance direct to PC or network. HSI oven systems will automatically download information direct to PC, to flash card, or wireless direct to PC or client network. Reporting functions include temperature, time at temperature, and belt speed for conveyor ovens. For additional information, contact Forming Systems, Inc. at (269) 679-3557 or info@ formingsystemsinc.com. ◆

SPRINGS Summer 2010 69

You donâ€™t have to be a legal eagle to protect prrotect your you ur employeesâ€™ rights. rights.

SMI can help your company comply with the complicated regulations of the American with Disabilities Act, which affects all employers with more than 15 employees; and with regulatory programs in accordance with OSHA published standards. To purchase either the ADA Compliance Manual or the Regulatory Compliance Safety Manual, call us at 630.495.8588 or check out our website, www.smihq.org.

Spring Manufacturers Institute 70 SPRINGS Summer 2010

Advertiser’s Index A Admiral Steel (800) 323-7055 / 31 Alloy Wire International (866) 482-5569 / 18 C Century Spring, Division of MW Industries (800) 237-5225 / 13 Chicago Association of Spring Manufacturers Inc. (630) 369-3772 / 26 D Diamond Wire Spring Co. (800) 424-0500 / 66 Dispense Works, Inc. (815) 363-3524 / 60 E Elgiloy Specialty Metals (847) 695-1900 / 25 F Forming Systems Inc. (877) 594-4300 / inside front cover, back cover G Gibbs Wire & Steel Co. Inc. (800) 800-4422 / inside back cover Gibraltar Corp. (847) 769-2099 / 5, 57

I Industrial Spring Steel (215) 426-7000 / 46 Instron (800) 564-8378 / 41 InterWire Products Inc. (914) 273-6633 /1 J JN Machinery (630) 860-2646 /8 K Kiswire (201) 461-8895 / 38 L Lapham-Hickey Steel (800) 323-8443 / 55 Larson Systems (877) 780-2131 / 29 M Mount Joy Wire Corp. (800) 321-2305 / 44 N NIMSCO (563) 391-0400 / 43, 47 P Precision Quincy (800) 338-0079 / 67 Precision Steel Warehouse (800) 323-0740 / 23 Proto Manufacturing (800) 965-8378 / 40

Pyromaître Inc. (800) 231-7976 / 10 R Radcliff Wire (860) 583-1305 / 63 R RK Trading (847) 640-9371 /3 S Simplex Rapid (563) 391-0400 / 58 Spring Manufacturers Institute (630) 495-8588 /52, 70 Suzuki Garphyttan (888) 947-3778 /16 T Tool King (800) 338-1318 / 15 U Ulbrich Stainless Steels (203) 239-4481 /6 United Wire Co. (800) 840-9481 / 50 V Vulcan Spring & Manufacturing Co. (215) 721-1721 /35 Z Zapp Precision Strip (203) 386-0038 / 33

When you enroll in the SMI | YRC shipping program, you receive a 70% discount on LTL shipments. Enroll today and we’ll give you $100 off* your next shipment, courtesy of the Spring Manufacturers Institute and YRC! Enroll online, by phone, or email. www.enrollhere.net | 800.647.3061 | Associations@yrcw.com *Freight bill must be greater than $250 and paid by the location receiving this offer in order to receive the $100 off. There is no limit on the number of shipments for this offer. This offer is non-transferable. Visit yrc.com/promotion for complete terms and conditions.

SPRINGS Summer 2010 71

Snapshot Daniel Pierre III JN Machinery Corporation

Nickname (if any): Not “Dan Jr.”… that’s my father! Company name, city and country: JN Machinery Corp., Elk Grove Village, Ill. Brief history of your company: JN Machinery got its name from Jackson Spring and North American Spring & Stamping (“J”- Jackson; “N” North American”) and became an independent company 26 years ago after outfitting those two companies with inline ovens, allowing them to achieve tremendous productivity gains and quality improvements. We have been focusing on conveyor ovens ever since. Job title: President Current home: Arlington Heights, Ill. Family: Wife, Mari, daughters, Marisa, Sarina, and our chinchilla, Phoebe. What I like most about being in the industry: Springmakers are straight shooters. You instantly know exactly how you stand with them. This constant feedback keeps you on your toes and as a result you become a better person and better company. Favorite food: Popcorn. I pop it from kernels in a saucepan about four times a week! Favorite books/author: I have two favorite authors: Wilbur Smith, who writes wonderful novels set in Africa, and Umberto Eco—and since his novels are translated from Italian, requires the use of a dictionary. Favorite song/musician: Huey Lewis and the News. However, I listen to a lot of Hannah Montana these days. Hobbies: Running, Scuba and Barbecuing.

72 SPRINGS Summer 2010

Favorite places: Kobe, Japan. At any time, one can walk north a half mile and Daniel Pierre with daughters Marisa (13), Sarina (11) and wife, Mari. be alone on a mountain trail, or I knew I was an “adult” when: I think walk a half mile south and stroll along I hit middle age before I realized I was the shoreline. an adult. Best times of my life: Running If I weren’t working at JN Machinery, with the Hash House Harriers. It’s I would like to: Be a chef in my own a bunch of crazy people who call restaurant. I already have a restaurant themselves “drinkers with a running problem.” We run 5~6 miles and then theme, name and a menu planned out. consume very large quantities of beer. The most difficult business decision Thousands of branches of this club I ever had to make was: Leaving exist all over the world, and when I a high-paying and very luxurious travel, I usually look up the local club ex-pat job in Japan to come work at and have instant friends and contacts. JN in an industry so closely affected by economic conditions. I traded A really great evening to me is: A off a stable income and stress-free barbecue dinner in our backyard with environment for the opportunity for my family and friends. We do it almost daughters to grow up in the USA. every weekend in the summer. We have a 100 year old Norwegian Maple Role model: My father. I see the that towers over the entire backyard respect he has earned in his career, with lights that light up the canopy. and this includes our suppliers, colleagues and customers alike. That The one thing I can’t stand is: respect spills over into his private life, People in front of me driving way too too. Most of my technical skills have slow and backing up traffic. come from on-the-job training or past My most outstanding quality is: I am experience, but everything else I know fiercely loyal to my suppliers and work comes directly from him. closely with them so they understand I would like to be remembered in the how important their components are spring industry for: My enthusiasm, to my products’ overall quality. I work passion and optimism for JN’s just as hard for my customers to make products, especially Aqua-TRC. This sure my ovens fit into their production has been my project since inception process. just like the inline conveyor oven was People who knew me in school my father’s. thought I was: The most ethnocentric But people will probably remember person on the planet. I refused to me for: My unreliable golf. Golfing make friends with an Australian partners never know if I will bring my exchange student because his accent A game or F game. I can shoot an 85 and word usage was different. or a 125.

Why Partner with Gibbs? Innovation.

Innovation is one of many added-value benefits you enjoy when you partner with Gibbs. Like our unique ability to slit strip to widths others simply cannot achieve, using traditional slitting procedures. The benefit? Production economies leading to lower prices for you. Since 1956 Gibbs Wire and Steel has represented a combination of excellent quality product, a high level of responsiveness, knowledgeable and reliable people, leading edge technology, the lowest total cost and a commitment to innovation well beyond traditional expectations.

That’s why so many leading companies have chosen to partner with us.

The People You Can Rely On For Wire And Strip

1.800.800.4422 www.gibbswire.com Connecticut

•

Indiana

•

Texas

•

California

•

Nor th Carolina

•

Ontario