Springs fall 2013 vol 52 no4

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

Presorted Standard US Postage PAID Michigan City, IN Permit #3

YEARS OF SMI

80 A Publication of the Spring Manufacturers Institute / Vol. 52, No. 4 FALL 2013

THE INTERNATIONAL MAGAZINE OF SPRING G MANUFACTURE

President's Message From Steve Moreland

SMI Executive Committee President: Steve Moreland, Automatic Spring Products Vice President: Hap Porter, SEI MetalTek Secretary/Treasurer: Mike Betts, Betts Company Immediate Past President: Scott Rankin, Vulcan Spring & Manufacturing At Large: Steve Kempf, Lee Spring

SMI Board of Directors

Happy 80th Anniversary, SMI On August 19, Sandy and I celebrated our 35th wedding anniversary; I distinctly remember the night I sat next to the telephone, sweaty palms and all, trying to muster up the courage to ask Sandy out on our first date…that was 37 years ago! Since that time we have been blessed with a life together that most couples could only dream about; yes, we’ve been through some very difficult, heart-wrenching times, but we have also been through some amazingly wonderful times together. Through it all, our relationship and love for each other has only grown stronger and deeper.

Back on August 11, the SMI celebrated its 80th anniversary! Although I cannot remember back to the night the SMI started (I wasn’t born yet) I do know we owe a tremendous amount of thanks and gratitude to Fuller F. Barnes of Associated Spring. He had the amazing foresight, courage and vision to start the Spring Manufacturers Association (as it was called back then) along with 40 charter members, 16 of whom remain SMI members today. Like our marriage, the North American spring industry has grown stronger over the past 80 years, thanks in large part to the SMI and the important role it plays in our industry.

The SMI provides such a wide range of products and services that I cannot imagine trying to compete in a global marketplace without their assistance. Benchmarking reports help SMI members understand how they “stack up” against their competitors in various categories of financial performance, quality performance and safety performance. The benchmark reports help participating members understand where they need to focus to improve the competitiveness of their businesses. The SMI convention and business meetings provide additional competitive advantage to SMI members who attend. They provide educational offerings that strengthen those companies and plenty of networking opportunities to allow sharing of best practices, helping them to become more globally competitive.

For those of you who are not currently members of the SMI, I strongly encourage you to contact Lynne Carr at the SMI headquarters, or visit the website at www.smihq.com and complete your application for membership. You will find that joining the SMI and participating in all the products and services that it offers can enhance the success of your company. I know first-hand, as we have been members for 46 years!

The mark of any great organization is its ability to maintain its relevance in a rapidly changing world. The SMI has done that for 80 years. As we begin our 81st year, the SMI is deeply engaged in a robust strategic planning process to assure that the SMI maintains its leadership position in the industry and relevance to spring manufacturers across the continent for the next 80 years. We plan to introduce the new strategic plan during our annual convention in Hawaii in February; hope to see you there!

On behalf of the North American spring industry and the SMI membership, I want to express a special thanks to the previous 32 SMI presidents, who served over the past 80 years, for their leadership, commitment and vision.

Those past presidents, along with the myriad volunteer board and committee members, have built a great organization we can all be proud of. Thanks!

Happy 80th Anniversary Spring Manufacturer’s Institute … Here’s to the next 80!

Steve Moreland President, Automatic Spring Products stevemoreland@automaticspring.com

2 / SPRINGS / Fall 2013

Tom Armstrong, Duer/Carolina Coil • Torsten Buchwald, KernLiebers USA • Ann Davey, John Evans’ Sons • Mark DiVenere, Gemco Manufacturing • Chris Fazio, Diamond Wire Spring • Kurt Gillespie, Century Spring • Richard Guimont, Liberty Spring • Gene Huber Jr, Winamac Coil Spring • Miko Kabeshita, Ark Technologies • Charly Klein, Fox Valley Spring • Bill Krauss, Vulcan Spring • Don Lowe, Peterson Spring • Bill Marcum, MW Industries • Richard Rubenstein, Plymouth Spring • Dan Sceli, Peterson Spring • JR Strok, Mohawk Spring • Bill Torres, Gibbs Wire and Steel • Jeff Wharin, Bohne Spring

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

Springs Magazine Committee Chair, Richard Rubenstein, Plymouth Spring • Reb Banas, Stanley Spring & Stamping • Lynne Carr, SMI • Raquel Chole, Dudek & Bock • Ritchy Froehlich, Ace Wire Spring & Form • Bud Funk, Fourslide Products • Bill Marcum, MW Industries • Brett Nudelman, International Spring • Tim Weber, Forming Systems • Europe Liaison: Richard Schuitema, Dutch Spring Association • Technical Advisors: Loren Godfrey, Honorary Member • Dan Sebastian, Honorary Member 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) 495-8588; Fax: (630) 495-8595; Web site www.smihq.org. Address all correspondence and editorial materials to this address.

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

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

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

Do not reproduce without written permission.

Cover art created using an image from: ©iStockphoto.com/tovfla

SPRINGS / Fall 2013 / 3

Contents

29

39

FEATURES 29

SMI Celebrates Its 80th Anniversary

By Gary McCoy

39

Past Presidents Speak

By Gary McCoy

47

Flashback A Message From the President of the United States

49

Inside a Steel Service Center

By Stephen Kraft

51

Kern-Liebers Texas Celebrates 25 Years

COLUMNS 19 Be Aware Safety Tips Don't Let Your Job Grind to a Halt

By Jim Wood

21 IST Spring Technology Cautionary Tale: Heat Treatment Oxide

By Mark Hayes

25 Technical Times Shot Peening Related Spring Failures

By John "Jack" Sujak

49

DEPARTMENTS 2 President’s Message Happy 80th Anniversary, SMI

7 Global Highlights 16 Regional Spring Association Report 53 Springmaker Spotlight Surviving the Tests of Time: A Profile of Associated Spring

By Gary McCoy

61 Inside SMI 65 New Products 67 Advertisers’ Index 68 Snapshot Don Lowe, Peterson American Corporation

4 / SPRINGS / Fall 2013

CSX Hybrid

CSX

CSX & CSX Hybrid From complicated to REALLY difficult spring making requirements, the Herdon CSX Series and CSX Hybrid Series make the difficult easy. Equipped as a standard 16-axis “All Servo” former they both significantly reduce set-up times while increasing production rates. Couple that with rotary wire and multiple single and dual servo spinners the impossible suddenly becomes possible at an affordable price. No matter what level of spring making requirement you’re being asked to perform, RK Trading’s line of CSX and CSX Hybrid machines offer something for everyone and make the difficult easy.

WWW.RKTRADINGUSA.COM

847-640-9771

SPRINGS / Fall 2013 / 5

Enhanced Efficiency Through Intelligent Process and Quality Control tube

bend autopitch pro

opticut

bestspeed

spring torque

accuratebend cockpit

control adaptivecontrol

wire magna

Functions and Control Programs: IDEN PROCESS CAPABILITIES DVANCE QUALITY CONTROL ASTER SET-UP TIMES NCREASE OUTPUT AND PROFIT PTIMIZE PROCESSING SPEED TRENGTHEN COMPETITIVENESS

:WYPUN *VPSPUN -VYTPUN 4HJOPULZ

>PYL )LUKPUN -VYTPUN 4HJOPULZ

Contact us today to see what iQ can do for you.

>PYL :[YHPNO[LUPUN *\[[PUN ,UK >VYRPUN 4HJOPULZ

;\IL )LUKPUN -VYTPUN 4HJOPULZ

5HPS *OHPU -LUJL 4HJOPULZ

©iStockphoto.com/DNY59

Global Highlights North America Betts Company has hired Bob Herold as vice president of sales. Herold is responsible for all sales activities at Betts Company’s two manufacturing divisions, BettsHD and Betts Spring Manufacturing.

Most recently Herold was vice president of product development and sales at Trail-Gear Inc., a manufacturer of off-road equipment. Prior to that assignment he was senior director of field services for 3VR Security Inc., and spent 15 years at Pelco Manufacturing in a variety of roles.

"Bob cont ributes a n e x ten sive b a c k g r ou nd i n sales and engineering to our team," said Bill Betts, vice president, Betts Compa ny.

"His commitment to customercentric support and passion for innovation will drive future growth for Betts Company in Bob Herold targeted transportation and industrial markets."

Herold earned a bachelor's degree in mechanical engineering from LaSalle University and an MBA in international business from California State University, Fresno.

Herold volunteers his time as a board member for the San Joaquin Valley International Trade Association (SJVITA) and is a guest lecturer at the California State University, Fresno, School of Business. He has also worked with the university's business and engineering schools on special projects.

For more information, visit www.Betts1868.com, phone 559-498-3304, or email info@Betts1868.com.

Also at Betts, the Betts Spring Manufacturing division has launched its new website at www.BettsSpring.com.

The site is part of a new branding initiative showcasing Betts Spring Manufacturing, one of three operating divisions of Betts Company, a six generation family owned and managed business established in 1868.

"We are excited to launch our dedicated Betts Spring Manufacturing website,” said Bob Herold. “Visitors will find it easy to navigate and rich with content focused on our capability to serve. While well known for our

automotive and off-road high performance springs, we serve many other industrial markets with custom designed solutions of superior quality. Our new website features many of these industrial applications."

The site features a new introductory video, highlighting manufacturing capabilities. In addition, a new overview brochure is available for download.

“Newcomers to spring manufacturing seeking an understanding of processes and materials will find our website provides a wealth of information,” explained Joe Devany, director of operations, Betts Company.

Devany, who leads Betts Spring Manufacturing, says the commitment to quality in product design and business process is evidenced by achieving ISO 9001-2008 certification.

He points out that visitors to the site can view the latest news about the Betts Spring Manufacturing division and conveniently sign up for a subscription to its newsletter.

For more information, visit www.BettsSpring.com, phone 559-498-3304, or email info@BettsSpring.com.

MW Industries announced in July the acquisition of Mohawk Spring, a custom precision spring manufacturer.

MW Industries is a portfolio company of Genstar Capital, a leading private equity firm.

Headquartered near Chicago in Schiller Park, Ill., Mohawk manufactures precision springs, wire forms, and rings for a broad and varied base of over 300 unique customers. The main industries served by Mohawk include heating, cryogenics, hydraulics, electrical distribution, ir rigation, computer technology, home applia nce, construction equipment, medical devices, and aerospace.

The company’s products are used as components for both consumer end users and industrial applications. Typical end products include valves, regulators, coupling devices, pumps, door mechanisms, and electronic assemblies.

Mohawk is ISO-9001 certified.

Bill Marcum, CEO of MW Industries, said: “Mohawk has shown strong performance with an ability to maintain and build on long-standing customer relationships.

We share the same strategic vision as the Mohawk management team and now, as part of the MW family, we believe we can help build on the company’s established brand to develop new accounts within high growth industry sectors, as well as provide additional products to existing customers.”

SPRINGS / Fall 2013 / 7

Global Highlights

Marcum added that the company has completed five acquisitions in the last two years and is currently evaluating a number of additional strategic acquisitions from its robust pipeline.

Connecticut Spring & Stamping (CSS), a manufacturer of precision parts for the medical, aerospace, firearms and defense industries worldwide, announced that it has developed its own in-house apprenticeship program to train enough skilled workers to meet its capacity and continue to grow the company. Tailored to the skill sets

required for tool and diemakers and various spring coiler setup operations, CSS’s program replaces formerly statefunded training for skilled manufacturing workers. A diverse group of 11 people are currently enrolled in the program, including five minorities and two women.

CSS’s in-house apprenticeship program was created to meet the need for workers for the company’s rapid growth rate, which is running at 20 to 30 percent, year over year.

The program includes specific tracks for CNC production set-up, press and fourslide diemakers, stamping press set-up operator, fourslide set-up operator, and heat set set-up operator. To fund the program, CSS takes full advantage of available grants, including the Connecticut Department of Labor's 21st Century Skills Training Program and the Advance Training Grant Program.

Under the direction of a qualified training instructor and using the same guidelines established by the state apprenticeship program for becoming a certified skilled worker in Connecticut, apprentices are trained in tasks assigned to each competency (basic, intermediate, and advanced) for each position. After successfully completing each competency, the apprentice receives an increase in compensation.

"Well-paid manufacturing jobs requiring manual skills are out there, and as the skilled workforce ages, it is becoming more and more difficult to fill critical positions with trained employees," says Kathy Bellemare, director of human resources at CSS. "What training exists has a nearexclusive focus on non-manufacturing skills. While we are extremely proud of the program we have developed, we still hold out hope that technical institutions and local community colleges will step up to fill the void by establishing training programs and internships to meet the needs of manufacturers."

For further information, please visit www.ctspring.com or call 860-677-1341.

Anchor Lamina America, Inc. announced the hiring of Michael Purchase as president of the company, a nd Ted Ph illips a s d i rec tor of business development.

8 / SPRINGS / Fall 2013

Global Highlights

Previously, Hahn held a die process engineering position with ThyssenKrupp Budd (Troy, Mich.) for eight years. A graduate of the University of Michigan, Hahn holds a bachelor’s degree in mechanical engineering, in addition to his license as a professional engineer in the state of Michigan.

Based out of the company’s Farmington Hills, Mich. headquarters, Purchase will oversee operations in the U.S. and China and lead the company’s foray into new global business opportunities. Bringing with him a diverse background in the metal machinery and components industries, he most recently served as president of Kaydon Corporation’s Specialty Products Group, with operations in North America and Japan. Purchase holds a bachelor of science in mechanical engineering from the University of Michigan and a master of science in engineering and manufacturing administration from Western Michigan University.

Phillips is responsible for sales in Michigan and all U.S. regions east of Michigan. He will be instrumental in strengthening customer coverage for this region and growing sales for the component brands of Danly, IEM, Lamina and Lempco. Phillips brings with him a long history in the industrial distribution industry and most recently served as vice president of sales for Paragon Technologies (Warren, Mich.). Phillips holds both an MBA from Madonna University and a bachelor’s degree in business administration from Eastern Michigan University.

Also at Anchor Lamina America, Inc., Donald L. Hahn, P.E. has been promoted to the position of senior engineering manager. Hahn, who most recently served as components technology manager for the Lamina Hydraulics line at Anchor Lamina, has more than eight years’ experience with the company and the metal forming industry. Hahn will lead the company in the development of new products and will also oversee improvements to its current product offering, contributing to the overall success of both the company and its customers globally.

™

ISO 9001 REGISTERED

el

Donald Hahn, P.E.

HSM, the new name of Hickory Springs, has named Gregg Greulich corporate vice president of innovation and technology.

Responsible for developing a vision for the growing engineering and resea rch and development tea m, Greulich will use his leadership and management skills to help ensure the execution of strategic goals, including the development of a portfolio of integrated products across the company’s Transportation Solutions, Bedding Solutions, Furniture Solutions and Diversified Solutions business units.

“Welcoming Gregg to our team is the next step in our efforts to build out our engineering and research and development capabilities,” said Dwayne Welch, executive vice president, chief marketing and innovation officer.

“Last year, we opened the Corporate Innovation and Research Center, which provides a setting for customers and vendors to work collaboratively on new products, programs and services while enabling HSM to leverage

ual Q t f ra c r Ai

e St y it

Don’t Crash and Burn Searching for 4130 Aircraft Quality Steel!

Admiral stocks fully certified 4130 in both aircraft quality and commercial quality. In fact, darn near all of our low and high carbon and alloy steels are certified to Aeronautical Material Specifications (AMS). So check your flight plan and buzz on by.

Our quality and service will have your job flying at mach speed!

For More Information, Set Your Course In Our Direction!

4152 West 123rd Street • Alsip, Illinois 60803-1869 800-323-7055 • Fax: 708-388-9317

www.admiralsteel.com e-mail: sales@admiralsteel.com Admiral is a registered trademark of Admiral Steel LLC. Alsip, Illinois.

Reg. No. 2430959. All rights reserved.

SPRINGS / Fall 2013 / 9

Global Highlights

Gregg Greulich

its expertise and respond rapidly to changing customer and market demands.

“Today, the outstanding qualities and experience Gregg brings to his position will further enhance that capability,

100% in ade M

rica

Ame

STOCK & CUSTOM PRECISION SPRINGS FOR INDUSTRY • For all applications with ranges from .003”–.750” wire diameter.

• Extensive inventory ready to ship with over 1.5 million parts in stock, including die springs.

• Custom design work with quick delivery.

• Most estimates returned within 24 hours.

www.diamondwire.com 1-800-816-5613 Convenient locations throughout the US – Northeast, Southeast and Southwest.

contributing to growth at HSM by improving our ability to offer HSM customers the latest materials and manufacturing techniques, helping them achieve their design visions while supporting our transition from a components manufacturer to an integrated solutions provider.”

Greulich comes to HSM with 12 years of management exper ience i n t he engi neer i ng a nd resea rch a nd development arena. Prior to joining HSM, he held the position of senior director, engineering, tooling and program management at Evenflo Company, Inc., Miamisburg, Ohio, and served on a global management team with direct organizational leadership responsibility for infant care durable product programs. His resume also includes management positions with Sunbeam Products, Inc., Maytag Corporation and Whirlpool Corporation.

Greulich ea r ned a bachelor of science deg ree in mechanical engineering from the University of Evansville, Evansville, Ind. He also holds a master of business administration degree, earned through work at the University of Evansville and the University of Transylvania, Xavier, Lexington, Ky. To learn more about HSM, visit the company’s website at www.hsmsolutions.com.

Mount Joy Wire is excited to announce the addition of 25-year wire manufacturing veteran and Six Sigma Green Belt John Schleicher as the new director of technical services for the company.

In this crucial role, Schleicher will manage and develop quality and process improvements for Mount Joy Wire's growing global business. It is an excellent opportunity for him to apply nearly three decades of shop floor engineering experience and help grow the Mount Joy brand.

Schleicher is known in the industry from his years in operations and engineering at New York Wire and Teledyne McKay, both located in York, Pa. Schleicher has a B.S. in industrial and manufacturing engineering from Penn State, an M.S. in technology management from the University of Maryland and holds a quality management and methods certificate from Penn State and is a certified Six Sigma Green Belt.

Tom Duff, CEO and president of Mount Joy Wire, says of Schleicher, “We are excited to have John joining the Mount Joy Wire team. His experience in quality and process improvements is a perfect fit with our strategic initiatives.”

Timothy W. Selhorst, president and chief executive officer for American Spring Wire Corporation (ASW), announced the promotion of Jim Rudolph to vice president and general sales manager. In this capacity, Rudolph oversees the sales of all of ASW products including valve spring wire, commercial spring wire, shapes and flats, and

10 / SPRINGS / Fall 2013

Global Highlights

PC Strand. Jim now directs ASW’s sales service, technical service, and production planning responsibilities.

“Throughout Jim’s 15 years of service to ASW, he has brought great energy and success to each of his assignments. Early on, he led the commercial spring wire team to achieve new record levels of shipments. He spent five years building the sales team at J&L Wire, and initiated the platform of sales that has led to that company’s continued success. Most recently, and while overseeing our PC Strand sales, Jim re-engaged in our spring wire selling efforts to shore up our market share in these key product segments. I look forward to seeing Jim’s impact on Valve Spring Wire and ASW’s other specialty wire items,” commented Selhorst.

Vulcan Spring and Manufacturing Co. has made their website mobile device friendly for all smartphones a nd tablet s. Visitors ca n obta i n product information easily through the website, contact Vulcan’s product specialists, and even purchase stock spring products on the go.

Vulcan Spring and Manufacturing C o. i s a le ad i n g de s i g n e r a nd manufacturer of flat steel springs and related assemblies for diverse global markets. The mobile and tablet friendly version of the Vulcan Spring website is available 24 hours a day, seven days a week, and is compatible with any platform, including iPhones, iPads (iOS) and Android operating systems.

C at h e r i n e Ty g e r, m a rk e t i n g coordinator for Vulcan, states, “Just launch your browser on your smart phone or tablet a nd enter w w w. vulcanspring.com in the address bar.

You can also use your search engine by typing in Vulcan Spring to get access; it’s that easy!” Tyger continues, “By using a responsive design, the information you see on your mobile device carries over from our website.

This ensures you will see up to date information at all times.” The site also offers helpful videos which can be viewed on mobile devices.

I n add it ion to c u stom pa r t s, Vulcan offers stock springs for express order, which can now be purchased through a phone or tablet. When further information is desired, you can fill out the contact form or simply touch

the “click to call” phone number to dial Vulcan Spring directly.

Fo r m o r e i n f o r m a t i o n , v i s it w w w. v ulca nspring.com; contact t he compa ny at sales@vulcanspring. com, or call 215-721-1721.

NICKEL. COBALT. TITANIUM. STAINLESS. 50+ reasons to select Elgiloy as your exotic alloy supplier.

Strip, Foil, Wire and Bar. Precision rolled strip: Wire diameters: Bar diameters: Shaped wire

.001 to .100 .001 to .825 .062 to .750

10 lbs to 10 tons, delivered to meet your schedule.

To find out more, contact us at wire@elgiloy.com or strip@elgiloy.com or call 888-843-2350.

Rolling to Meet Your Schedule

Strip & Foil

Wire & Bar

Elgiloy

Elgiloy

Haynes Alloys

Hastelloy B3

Hastelloy B3

Hastelloy C22

Hastelloy X

Hastelloy C276

Hastelloy C22

Inconel 600

Hastelloy C276

Inconel 601

Inconel 600

Inconel 625

Inconel 601

Inconel 718

Inconel 625

Inconel X750

Inconel 718

Monel Alloys

Inconel X750

MP35N

Incoloy 800

Nimonic 90

Alloy L 605

NiSpan C

Monel 400

Rene 41

Titanium Alloys

Alloy 20

CP Grades 1,2,3,4,7,9,11 Elgiloy Specialty Metals www.elgiloy.com Elgiloy is a trademark of Elgiloy Specialty Metals MP35N is a trademark of SPS Technologies Haynes 25 is a trademark of Haynes International, Inc.

Beta 21S Rene 41

A-286 AL6XN 300 Series Stainless

SPRINGS / Fall 2013 / 11

Global Highlights

Jim Zawacki, the chairman of GR Spring & Stamping I nc. (GR S & S) i n Grand Rapids, Mich., has published a new book with Don Klein.

“Mov i n g For w a r d” takes readers through t he ins a nd outs of running a profitable business in the new economic times.

The book is available on Amazon. com for $18.99 a nd the Kindle version is $14.99. According to the book’s description at Amazon.com, “Their words of advice come from hands on experience and are essential to anyone who is ready to roll up their sleeves and get on track for success. The dialogue and humor will have you laughing as these two, through their years of experience in manufacturing, share their ideas and offer valuable insights learned throughout the years.”

This is the third book that Zawacki and Klein have published. The authors first book, “It’s Not Magic,” was

a novel written about GRS&S after the purchase in 1985.

Magic Inc. is the name of the company in the novel published by MSU Press in 1998. A companion piece, “It’s Not Magic Workbook,” was published at same time.

Zawacki says the workbook shows how to accomplish some of the successes described in “It’s Not Magic.”

Zawacki says, “‘Moving Forward’ is a sequel to ‘It’s Not Magic’ showing what happened to Magic Inc. in the last 15 years since the first book was published.” Inserted in the chapters are the views, comments, and recommendations of the authors about what's happening in our society today.

International Specialist wire manufacturing company Alloy Wire International has recently achieved certification to the prestigious and demanding ‘Aviation, Space & Defense’ Quality Management Standard AS 9100.

The announcement comes following completion of a project conducted in conjunction with Kidderminster based consultancy Initiative Quality and Safety Limited, resulting in Alloy Wire’s certification with UKAS accredited certification body, SGS. Founded in 1946, Alloy Wire International is a world leader in the manufacture of precision drawn round wire,

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

12 / SPRINGS / Fall 2013

Global Highlights

Mark Thompson, and Alloy Wire International’s technical director Pete Lambe.

Thompson stated, “CertiďŹ cation to AS 9100 offers an excellent way of demonstrating a ďŹ rm commitment to a company’s pursuit for continual improvement and excellence in the Aviation, Space & Defence sector.â€? Alloy Wire’s managing director Mark Venables added: “We have a lean and user-friendly business management system that is simple and very easy to follow, enabling us to manage the business in a more effective, consistent and pro-active manner. We are proud to be one of just 15,000 worldwide with this approval.â€?

Japan Society of Spring Engineers (JSSE) held its semiannual lecture meeting, including a poster session, and annual general meeting at Tokyo Denki University in Tokyo on June 6. Eight lectures and one special lecture were presented to 157 attendees in a hall on the Tokyo Senju Campus of Tokyo Denki University. The opening speech was presented by Dr. Toshio Hamano, a vice-chairperson of JSSE in charge of general affairs and a managing officer of NHK Spring Co., Ltd. The special lecture, entitled “The Front Lines of Ultrasonic Non-destructive Inspection and Materials Evaluation,� was presented by Dr. Koichiro Kawashima of Materials Diagnostics Laboratory.

Five technical posters were displayed in another hall on the same campus. A brief explanation was given by

Your source for the best in close tolerance strip and edged products.

rolled at, and shaped wire in a comprehensive range of high performance nickel alloys.

Alloy manufactures wire from 0.025 mm to 21mm diameter to exacting speciďŹ cations for a wide variety of applications, including precision springs and components for use in gas turbines, oil, chemical and process plant, aerospace, nuclear, marine and electronics industries, mecha n ica l sea ls, med ica l i mpla nt s a nd genera l engineering applications.

With the ever-increasing emphasis and commercial pressures on striving for improvements in quality assurance and product reliability, Alloy Wire International realized that certiďŹ cation to the internationally accredited AS 9100 ‘Aviation, Space & Defense’ quality management standard would elevate their quality system status to an elite level achieved by only some 15,000 companies worldwide. Boeing was instrumental in this standard and continues its importance today. Alloy Wire engaged Midlands-based consultancy Initiative Quality & Safety Ltd. to support the scope extension of their existing ISO 9001 quality registration to AS 9100.

The consultancy project was delivered and managed

by Initiative’s managing director and QUENSH consultant

strip: cold rolled high carbon/pre-tempered spring steels, coated, low carbon stainless, copper based alloys and aluminum ultra-narrow width, close-tolerance slitting edging: round, square, semi-round, deburred, custom, etc. oscillate (traverse) and ribbon wound coils ISO 9001:2008 Certified 35 years experience for product and service excellence tel. 847.537.2881 toolkinginc.com Wheeling (Chicago), Illinois 60090 USA

SPRINGS / Fall 2013 / 13

Global Highlights

a representative for each of the posters on the speaker’s platform followed by question and answer sessions at the posters. The top two posters were selected based on the participants’ vote. The ďŹ rst place poster, Making Surface Defects of High Strength Steel Harmless by Shotpeening— Inuence of Crack Shape, was from Makiko Nakagawa of Yokohama National University, et al. The second place poster, Application of Coil Springs to Medical Equipment— Embolization Coil, was created by Shuji Isozaki of Piolax Medical Devices, Inc. Five certificates of Spring Technological Heritage were presented to four spring manufacturers to express JSSE’s appreciation for their preservation of machines of historical value.

The annual general meeting was held following the lecture meeting in a conference room on the same campus.

The meeting was led by Mr. Sugawara, a trustee of JSSE in charge of general affairs and a general manager of Horikiri Inc. During the meeting ďŹ ve proposals, including the biannual re-election of trustees, were approved.

At the post-meeting reception, Dr. Motoaki Osawa, a vice-chairperson of JSSE in charge of publication and a professor of Tokyo Denki University, made the opening speech, followed by guest speaker Kanji Inoue, the executive director of Japan Spring Manufacturers Association.

Nineteen participants gathered near JR Tokyo Station early on June 7 and visited the National Astronomical Observatory of Japan Mitaka Campus and the Japan Aerospace Exploration Agency Chofu Aerospace Center. Q

Top: JSSE presented ďŹ ve certiďŹ cates to four spring manufacturers in appreciation for preservation of machines of historical value. Lower left: Dr. Motoaki Osawa of Tokyo Denki University speaks at the reception. Lower right: Presentation of a technical poster at the meeting.

²² )URP 'HVLJQ ² WR ² )LQDO ,QVSHFWLRQ ²²

x

635,1* '(6,*1 62)7:$5( x $YDLODEOH DV VWDQG DORQH VRIWZDUH RU VXEVFULSWLRQ EDVHG ZHE DSSOLFDWLRQV

x

x 0XOWL ODQJXDJH DYDLODELOLW\ Âą (QJOLVK Âą )UHQFK Âą

x x

x 8S WR VSULQJ W\SHV FRPSUHVVLRQ H[WHQVLRQ

x

*HUPDQ Âą ,WDOLDQ

x x x x x

WRUVLRQ UHFWDQJXODU ZLUH FRPSUHVVLRQ FRQLFDO GLVF VSLUDO DQG QRQ VWDQGDUG FRPSUHVVLRQ ,QFOXGHV (1 ',1 60, %6 ,6 -,6 VWDQGDUGV IRU GHVLJQ WROHUDQFH PDWHULDOV 2XWSXWV LQFOXGH VSULQJ GUDZLQJ IDWLJXH OLIH SUHGLFWLRQV DQG UHOD[DWLRQ HVWLPDWHV )OH[LEOH VRIWZDUH OLFHQFH RSWLRQV 6SULQJ 'HVLJQ 6HUYLFH 1HZ GHVLJQV RU YDOLGDWLRQ )UHH WULDOV DQG PRUH LQIRUPDWLRQ DYDLODEOH IURP ZZZ VSULQJFDOFXODWRU FRP ZZZ VSULQJPDWHULDOV FRP

635,1* 7(67,1* 0$&+,1(6 /RDG 7HVWHUV IURP 1 WR N1 IXOO VFDOH 7RUTXH 7HVWHUV IURP 1P WR 1P IXOO VFDOH 1RQ $[LDO )RUFH 0DFKLQHV )DWLJXH 0DFKLQHV VLQJOH PXOWL VWDWLRQ 6)7 2XU QHZHVW DGGLWLRQ WR WKH )DWLJXH 7HVWLQJ 0DFKLQH UDQJH

,67 6(59,&(6 x x x

7HFKQLFDO +HOSOLQH 0HPEHUVKLS 6XEVFULSWLRQ EDVHG FRYHULQJ WKH FRPSOHWH 6SULQJ 6XSSO\ &KDLQ 7HVWLQJ 6HUYLFHV 6SULQJ )DLOXUH 3URGXFW 'HVLJQ 0DWHULDO (QYLURQPHQWDO $QDO\VLV 6WDWLF DQG )DWLJXH WHVWLQJ XS WR N1 (OHYDWHG WHPSHUDWXUH 7UDLQLQJ FRXUVHV $ FRPSUHKHQVLYH UDQJH RI LQ KRXVH DQG WDLORU PDGH FRXUVHV GHOLYHUHG ZRUOG ZLGH

)RU PRUH LQIRUPDWLRQ FRQWDFW LVW#LVW RUJ XN RU YLVLW RXU ZHEVLWH ZZZ LVW RUJ XN 1LFKROV ,QWHUQDWLRQDO 0DFKLQHU\ 6\VWHPV &R 1,06&2

+HQU\ 6WUHHW 6KHIILHOG 6 (4 8.

,QVWLWXWH RI 6SULQJ 7HFKQRORJ\

7HO

)D[

( PDLO LVW#LVW RUJ XN ,QWHUQHW ZZZ LVW RUJ XN

14 / SPRINGS / Fall 2013

% 7UHPRQW $YHQXH 'DYHQSRUW ,$ 86$ 7HO )D[ (PDLO LQIR#QLPVFR FRP ,QWHUQHW ZZZ QLPVFR FRP

SPRINGS / Fall 2013 / 15

©iStockphoto.com/Scott Hirko

Regional Spring Association Report Pittsburgh-Ohio Region Meets

By Russ Bryer, Spring Team, Inc. I n a n ef for t to r ev ive SM I’s Pittsburgh-Ohio region, a group of springmakers met on June 26 at the Youngstown Business Incubator (YBI) in Youngstown, Ohio. Representatives of the following companies attended: Ace Wi re Spring, AM W Spring, Diamond Wire Spring, Elyria Spring, Marik Spring, Penn-Elkco Spring, Spring Team, and Yost Superior.

Chris Fazio from Diamond Wire and Greg Bedrick from Marik Spring agreed to assume leadership of the chapter and will plan our next meeting.

After the meeting, the group toured the National Additive Manufacturing Innovation Institute (NAMII), which is a public-private partnership with member organizations from industry, academia, government, and workforce development resources all collaborating with a singular, shared vision.

NAMII’s goal is to t ra nsition additive manufacturing technology to the mainstream U.S. manufacturing s e c t o r a nd c r e at e a n ad apt ive work for c e c ap a ble of not on ly meeting industry needs, but also increasing domestic manufacturing competitiveness.

NAMII is organized and managed by the National Center for Defense M a nu f ac t u r i ng a nd M ac h i n i ng (NCDMM), which brings a background s t e e p e d i n e x p e r ie n c e w it h i n the defense, additive, and general manufacturing industries and a proven track record of developing and deploying manufacturing innovation. NAMII is a national asset significantly different than traditional research institutes.

Based in Youngstown, NAMII is built upon an extensive network of additive manufacturing technical

expertise surrounding a regional manufacturing cluster within the eastern Ohio, western Pennsylvania and West Virginia “Tech Belt” region.

We had a comprehensive overview a nd tou r of 3D m a nu f ac t u r i n g m ac h i nes i n va r iou s m ater ia l s including 302 stainless by Kevin Collier, the NAMII factory manager.

Most of us were only familiar with 3D modeling plastic and composites, but not metals. The world of prototyping will never be the same.

WCSMA Will Hold Bi-annual Tabletop Expo

By Debra Donley, FTR Metals and WCSMA Past Chairman Members of the West Coast Spring Manufacturers Association (WCSMA) had an excellent time August 3 at our annual, sold out Angels game outing. In addition to watching the Angels win, members enjoyed a huge tailgating party in the parking lot before the game! The WCSMA would like to thank Newcomb Spring and Tru-Form for providing the fabulous food and drink for this event.

Next on our agenda is the bi-annual Tabletop Expo on Thursday, October 24 at the Holiday Inn in La Mirada, Calif. With an eclectic mix of vendors

16 / SPRINGS / Fall 2013

who supply products, materials, equipment and services, this is a must-attend trade show for everyone in the spring manufacturing and metal forming industries. There is no need for attendees to pre-register and admission is free. Come enjoy free hors d’oeuvres, a cash bar and great door prizes.

We h ave a n e xc it i n g l i s t of exhibitors already signed up and are still accepting applications for more. For additional information, event flyers and exhibitor registration forms, please visit www.wcsma.us.

O u r f i n a l event of t he ye a r will be ou r fall golf outing a nd

dinner at Skylinks in Long Beach on Thursday, November 14. We are looking forward to a fun day of golf at this new venue and will once again feature a comedian at dinner to entertain everyone. Non-golfers are welcome and encouraged to join us for cocktails and dinner. This is one of the WCSMA’s most popular outings, so mark your calendars, dust off your golf shoes and get ready to have a great time.

For more information, visit the WCSMA Facebook page or www. wcsma.us.

CASMI Awards Scholarships The C h ic a go A s so c i at ion of Spring Manufacturers (CASMI) has a n nou nced its 2013 schola rship class. Family members of CASMI company employees competed for 16 schola rships in 2013. Fif teen undergraduate scholarships of $1,500 each and one $2,500 graduate school scholarship were awarded to the following students.

Scholarship applications for 2014 will be available in February 2014.

CASMI’s next event will take place on Thursday, October 17 at Manzo’s Ba nquet s i n A rli ng ton Heig ht s, Ill. The association will hold its “SpringWorld 2014 Kick Off” dinner.

CASMI will close out the year with its member dinner/holiday party on Thursday, December 12 at The Great Escape in Schiller Park, Ill. For more information, visit www. casmi-springworld.org.

$1,500 CASMI Undergraduate Scholarship Winners Student Name Lizbeth Arreola Daniel Milewski Daniel Kinderman Carol Chang Emily Lenczowski Monika Morawa Lukasz Los Katherine Harper Augustus Lukens Zac Campbell Erinn Komschlies Brian Kahn Anthony Iuliano Evan Kuhl Aashutos Patel

Employee Name Rafael Arreola Janusz Milewski Thomas Kinderman Der-Form Chang Zak Lenczowski Wally Morawa Pawel Los John Harper Cathleen Lukens Randy Campbell Donn Komschlies David Kahn Anthony and Mary Iuliano Kevin Kuhl Bharti Patel

Company Name All-Rite Industries All-Rite Industries Associated Spring Automatic Spring Coiling Dudek & Bock Spring Company Dudek & Bock Spring Mfg. Excel Spring Gall Machine Company Midwest Spring and Stamping Oshkosh Coil Spring, Inc. Oshkosh Coil Spring, Inc. Perfection Spring & Stamping Rapid Wire Forms Rockford Spring Company Termax Corporation

$2,500 Terry & Jerry Reese Post-Graduate Scholarship Winner Student Name Amanda Iuliano

Employee Name Anthony and Mary Iuliano

Company Name Rapid Wire Forms

Stainless Steels, Nickel Bases, Copper Bases, Carbon Steels, and Aluminum

50 McDermott Rd. North Haven, CT 06473 unitedwirecompany.com 800.840.9481 SPRINGS / Fall 2013 / 17

Regional Spring Association Report

NESMA Continues to Lead on Manufacturing Education

By Ted White, Hardware Products Recent NESMA a r ticles have talked about t he association's efforts to coordinate several disjointed prog ra ms to promote tech n ica l educat ion i n t he Connecticut school systems. We have enjoyed a modicum of success in these efforts, and now it would appear as though the original effort has blossomed into a more formidable challenge.

Recently Michael Brault, NESMA board member and vice president of Ultimate Wire Forms in Bristol, Conn., has been appointed by the mayor of Bristol to the “Task Force on Jobs Creation.” Michael, a driving force in technical educational coordination, has now added jobs creation to his list of volunteer activities.

Michael will serve on the task force as the NESMA representative with members from Main St. Community Foundation, Capital Workforce partners, Army Strong, and the superintendents of education. The goal will be to form a technical advisory committee from this group, along with guidance counselors, school administrators, and local business leaders.

18 / SPRINGS / Fall 2013

Once t he task force has been formed, one of its goals is to convince business to take ownership of the aging work force. Government and education simply cannot solve the issue in today's environment. The two biggest obstacles it must overcome is the so called "conventional wisdom" within the educational system: 1) high Michael Brault school education should be singularly focused on college preparatory and 2) parental influence on their children that manufacturing is a dead end.

As an item in “Global Highlights” (see page 8) on Connecticut Spring & Stamping illustrates, the need for a younger generation of springmakers is so great that several companies are either instituting or re-instituting an apprenticeship type program for spring manufacturing.

The techniques will be very different than before. My own (very limited) understanding of setting up a mechanical coiler was that it was as much an art form as it was science.

Now with the CNC operating systems, machine set up has migrated from an art form to more of an objectively calibrated approach. That is not to say that intellect and creativity are not still important, but now those valuable attributes can be saved electronically and then reproduced the next time that particular spring is needed.

The task force and the technical advisory committee will focus on updating technical school curricula so that it meets the current needs of the local and regional businesses.

All of this does not mean that NESMA is moving on and leaving education coordination behind. On the contrary, many of the other board members and the Central Connecticut Chamber of Commerce are still very active in these efforts.

As a matter of fact, it would appear as though NESMA is becoming more of a force in this regard. NESMA is grateful to the principal of Bristol Tech, Joyce Mowrey, and manufacturing coordinator Ben Russell, for taking us under their wing and counseling us on the challenges and rewards of technical education.

Now more than ever, NESMA desires to work with its education and employment partners to coordinate and create an environment inside of Connecticut where manufacturing and technical education can return to their appropriate and vital positions. Q

Be Aware Safety Tips

, Don t Let Your Job Grind to a Halt

By Jim Wood

©iStockphoto.com/GlenJ

G

r i nders i n t he spr i ng indust r y ca n be a n indispensable tool, but they can also be dangerous.

Large production grinders u sed to g r i nd spr i ngs a r e u su a l ly wel l g ua rded a nd op e r at e d by e x p e r ie n c e d, trained personnel, but small pedestal and bench grinders are often overlooked as a potential serious hazard. Careless use of these machines can cause serious injury to eyes, fingers, hands and arms. Take the time to prevent grinder injuries by following a few safe work practices.

The Ring Test A defec t ive or c r ac ked grinding wheel will break if it is used. Prevent this hazard by testing a new wheel when it is unpacked and each time it is mounted. The same goes for discs. Suspend lightweight wheels from the hole with your finger or small wooden dowel. Set heavier wheels vertically on a hard floor. Then tap the "tap point," one or two inches from the outer edge and 45 degrees from the vertical center line. Tap a light grinding wheel with a light tool such as a screwdriver handle and a heavy wheel with a mallet.

If the wheel or disc is in good condition, you will hear a clear metallic ring.

Prevention Inspections Inspect grinding machines daily to make sure the spindle cover and tongue guards are in place and properly aligned so that they are not in contact with the wheel.

Set the tongue guards 1/4-inch or less from the wheel. If the grinder is equipped with a glass shield, make certain it's clean, unscored and in place. Also make sure that the grinder frame is mounted securely and doesn't vibrate during operation and that the speed is correct for the wheel

being used. Bench and pedestal grinders should always be mounted to a solid, secure surface.

The work rest should be securely clamped and positioned within 1/8-inch of the wheel with its height on the horizontal center line of the machine spindle. Never adjust the work rest when the machine is running; you could catch a finger between the rest and the wheel, or the rest could bump the wheel causing it to break. The clamp that holds the work rest should always be tight.

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 630-495-8588 or via e-mail at regs@smihq.org.

SPRINGS / Fall 2013 / 19

When You Work Follow these safe work practices and make them part of the operator routine.

• Always wear a face shield, goggles or safety glasses to protect eyes from flying particles. (This is especially important when using wire brush wheels, as wire tends to break off.)

• Never wear gloves when using polishing or buffing wheels. A glove can catch in the machine and drag your hand against the wheel. Use a jig or fixture to hold small items, never use bare hands.

• Hold material with a relaxed grip to prevent vibration.

• Never remove guards or guard fasteners.

• Don't touch any moving parts.

• Operate within the manufacturers recommended speeds. Never try to alter the machine or its wheel speed.

• Have rutted, uneven or rough wheels dressed immediately to smooth out the wheel surface.

• When using a wet grinder, make sure that the floor is rough and shoes are slip resistant to prevent slips and falls.

20 / SPRINGS / Fall 2013

• All dry grinders must be equipped with a dust collecting exhaust system.

Jim’s Regulatory Tip: As previously reported in the Summer 2012 issue of Springs, OSHA revised its Hazard Communication Standard (HCS) to align with the United Nations' Globally Harmonized System of Classification and Labeling of Chemicals (GHS). The first compliance date of the revised HCS is December 1, 2013. By that time, employers need to have trained their workers on the new label elements and the new Safety Data Sheet (SDS) format. Q

IST Spring Technology

Cautionary Tale: Heat Treatment Oxide

By Mark Hayes

D

uring a recent IST training course in China, a delegate asked many questions about the changing color of 302 stainless steel spring wire during spring production at his factory. This prompted another delegate to ask about the colors arising during the manufacture of springs made from music wire. This is not the first time that such questions have been asked, so it seems to be a good subject for a cautionary tale. The first point to note is that the color changes in both materials have the same root cause, but the colors are not real - they are merely a trick of light.

Whenever steel is exposed to temperatures above ambient, the oxygen in air reacts with the steel surface and an oxide will grow. Steel will always have oxide on its surface because it will form naturally at ambient temperatures, but that oxide is much too thin (measured in nanometers) to be seen.

I ndeed, t he ex istence of t his ox ide is seldom acknowledged for carbon steel in most texts, but rest assured it is there. Stainless steel is assumed to have a chromium oxide on its surface, and this explains why it does not go rusty. The surface of both carbon steel and stainless steel oxidizes in air to form an oxide that confers corrosion resistance, and this brings the first cautionary aspect to this tale. Oxidation and corrosion are separate phenomena, but they are frequently confused. A quick Internet search for “oxidation of steel” will bring up many articles on corrosion, a few articles on high temperature oxidation, but almost none on ambient temperature oxidation.

The main oxides of iron are Fe2O3 or FeO, which are said to be respectively red or black in color and this is true when the oxide is micrometers thick. However, the oxide which forms on a bare steel surface in air is nanometers thick and is, to all intents and purposes, colorless and translucent. This very thin oxide confers corrosion resistance and, as springmakers already know, steel springs do not generally go rusty red in their factory despite having no protection from oil at various stages of manufacture. We will talk more about this later. The formulas for rust (Fe2O3·nH2O and FeO(OH)·Fe(OH)3) contain H because rust occurs due to the reaction of oxygen and water with a spring surface.

The nanometer thick oxide formed on bare steel surfaces is colorless and so cannot be seen on carbon or

stainless steel. However, most carbon steel springs are heat treated in air at 390-660°F (200-350°C) after coiling, and this will cause the oxide to grow thicker. At 435°F (225°C) the oxide is thick enough to refract the yellow part of incoming white light, so the springs appear to turn yellow.

However, carbon spring steel wire often has a phosphate coating with some soap and, as the surface is quite black prior to heat treatment, the yellow color is not usually apparent unless the wire surface is particularly bright. At 525°F (275°C) the oxide is thick enough to refract another part of incoming white light, so the springs appear to be blue if the original black wire surface permits. So, the heat treatment colors are a trick of light as the translucent oxide refracts incoming light rather than actually coloring the steel surface.

The oxide colors are more readily seen after spring end grinding. A yellow color indicates that the grinding did not heat up the ground end excessively, and the same

Mark Hayes is technical advisor to the Institute of Spring Technology (IST) in Sheffield, England. He is also the principal trainer for the spring training courses that the Institute offers globally. Readers are encouraged to contact IST at ist@ist.org.uk with comments about this cautionary tale, and with subjects that they would like to be addressed in future tales.

SPRINGS / Fall 2013 / 21

join the best 7 – 11 April 2014 Düsseldorf, Germany International Wire and Cable Trade Fair

Meeting point: wire 2014 in Düsseldorf!

Join the best – welcome to the world’s leading trade fair for the wire and cable industry! To find comprehensive information about the latest innovations in wires and cables, manufacturing machinery and equipment, look no further! It is all on display at the world’s most important exhibition – the meeting point for international experts, specialists and global market leaders. A focal point at wire 2014: The growing importance of copper wires in automotive engineering, telecommunications and electronics.

An important date in your calendar – your visit to wire 2014 in Düsseldorf!

www.wire.de

Wire, Cable, Fibre Optic, Wire Products and Machinery

Spring Making

Fastener Technology

Mesh Welding Machinery

For show information: Messe Düsseldorf North America 150 North Michigan Avenue Suite 2920 _ Chicago, IL 60601 Tel. (312) 781-5180 _ Fax (312) 781-5188 info@mdna.com _ www.mdna.com For hotel and travel arrangements: TTI Travel, Inc. Tel. (866) 674-3476 _ Fax (212) 674-3477

22 / SPRINGS / Fall 2013

can be said if the end coil goes light blue. However, the grinding may have been abusive if the color was dark blue or black; these colors can be used as a simple but effective quality control check for the grinding process.

If carbon or silicon chromium spring steel is shot peened, it is common practice to apply a low temperature heat treatment (or warm prestress) afterwards in order to recover the relaxation resistance, which is adversely affected by shot peening. The shot peening removes any oxide from previous processes and leaves the spring surface bright but vulnerable to corrosion. The oxide will grow back at ambient temperature but, in conditions of 100 percent humidity, rust may form prior to the oxide.

In tropical or monsoon-affected countries, springs can be seen to go rusty red soon after they emerge from the peener.

As a result, it is good practice to get freshly peened springs into an oven as soon as possible, and make that corrosion resistant oxide grow. Carbon or silicon chromium springs will go an agreeable yellow color if the heat treatment is carried out at 435°F (225°C) – a temperature commonly used for this process.

Up to now it has been stated that the colors on carbon and low alloy steel and on stainless steel have the same root cause. This is correct, but the temperature required to cause 302 stainless steel to go a light yellow color is much higher than that required for carbon steel. The yellow color is just visible if the heat treatment temperature after coiling is 660°F (350°C), and spring manufacturers often limit the stress relieving to this temperature so as to avoid the darker yellows that would appear at 750-840°F (400450°C). However, many customers frequently say that they don’t want to receive yellow springs – and this is despite the fact that heat treating stainless steel compression springs at higher temperatures than 660°F (350°C) will improve their relaxation and fatigue performance. If good performance is required and an absence of the yellow color, then springmakers should employ a pickle and passivate process after heat treatment. The first (pickle) removes the oxide which is causing the yellow color, while the second (passivate) puts in place a very thin, adherent oxide that is too thin to give the yellow color but has excellent corrosion resistance.

The moral of this cautionary tale is that the thin oxide on spring steel is beneficial and the apparent colors formed can be used as a simple quality control tool in production. Q

For over 25 years, Zapp has been providing the spring industry with the highest quality, best performing products which far exceed the industry standards. Our state-of-the-art mill facility located in Dartmouth, Massachusetts, offers a convenient supply chain that insures continuity and reliability.

At Zapp, no matter how we slice it, our precision quality and outstanding customer service always shine through.

East Coast Service Center, 100 Benton St., Stratford, CT 06615 Tel 203.386.0038 Fax 203.502.6681 www.zapp.com

SPRINGS / Fall 2013 / 23

FZ Series: A new generation is here.

Ü+, * ? * Ü

-*Ü, , Ü 2 *¡ 80,000 Rings Per Hour* Increase productivity & reduce your scrap rate with the new FZ Series, our fastest spring coilers ever. *3/8 inch diameter ring achieved with .23 wire on a standard FZ10 Spring Coiler

SPX PRECISION COMPONENTS 300 FENN ROAD NEWINGTON, CONNECTICUT 06111 TEL 860 594 4300 FAX 860 667 4667

www.spxfenn.com

Watch It Now! Search Torin FZ10 on YouTube, visit http://www.youtube.com/watch?v=ksgGN8Gtt2g, or simply scan QR code to view.

24 / SPRINGS / Fall 2013

Technical Times

Shot Peening Related Spring Failures

By John "Jack" Sujak

T

he benefits of shot peening springs are well known.

The impact of the shot onto a spring’s metal surface causes multiple dents in the material. The dents affect the metal by creating a layer of compressive stresses within the material. These compressive stresses impart the main benefit of increasing the resistance to fatigue failures since a tensile stress from an applied load would have to exceed the compressive stress at the surface before becoming strictly tensile.

A secondary benefit is the resistance to stress corrosion.

For stress corrosion to occur, three requirements need to be met; a corrosive agent and a susceptible material under a tensile stress. The formation of the compressive stresses at the surface then negates the presence of the tensile stresses, thereby leaving only two of the three requirements.

Coverage and intensity are the two factors by which shot peening is measured. Coverage is the measure of how completely a surface is impacted with the shot and can be measured visually or indirectly. In order to achieve the benefits mentioned above, a surface requires as close to 100 percent coverage as possible. This can lead to excessive, or over-shot peening, in order to achieve as close to 100 percent coverage. Intensity encompasses numerous variables such as velocity, size, weight and hardness of the shot. If any of these are not closely monitored during the processing step, not only will the effectiveness of the shot peening be reduced, there is a possibility they can detrimentally affect the surface of the spring as well.

In a review of failed springs sent to the Exova-Glendale Heights lab over past few years, failures related to overpeening or using too high a shot velocity was found in three instances. This indicates shot peening related spring failures to be relatively uncommon. In the three instances no other material defects were revealed during the investigations.

Two of the three cases will be discussed here.

The first instance was a torsion spring of square wire that failed after 70k cycles instead of the expected 200k cycles. Visual examination revealed the spring surface to have an orange peel texture but no signs of wear at the ID, indicating a lack of support at the ID. The hardness was checked and averaged 47 HRC indicating the spring was properly heat treated. A section of the spring with

Figure 1. SEM image of fracture origin on torsion spring of square wire.

Figure 2. SEM image of the side view of the fractured spring showing apparent dents on the corner.

the fracture surface was placed in the scanning electron microscope (SEM) for examination and the fracture origin was determined to be at the corner of the wire (Figure 1).

John “Jack” Sujak is a metallurgical engineer at Exova in Glendale Heights, Ill. He is responsible for conducting failure and root cause analyses as well as reviewing standard metallurgical engineering work. His eight years of experience in the metallurgical field also includes prior work at a metal packaging company and at a commercial heat-treater. He can be reached at 630-221-0385, ext. 76223 or email John.Sujak@exova.com.

SPRINGS / Fall 2013 / 25

Figure 3. Optical micrograph displaying a white layer of untempered adiabatic martensite and crack resulting from the peening operation.

Rotating the fractured spring in the SEM to view the side of the spring showed dents apparent on the corner (Figure 2).

A metallographic cross-section was taken in the transverse direction parallel to the fracture surface and examined using an optical microscope. There was no partial or complete decarburization visible in the examined cross-section. Upon etching, a white layer of untempered adiabatic martensite was observed at the wire corner (Figure 3). Due to the brittle nature of this white layer compared to surrounding tempered martensite, the presence of it creates a stress riser for fatigue to initiate upon loading.

Figure 4. SEM image of the fracture origin at the ID of a compression spring.

Here, a crack is visible between the white layer and the surrounding tempered martensite. Also visible are multiple small pieces of spring material that have separated from the spring resulting from the peening operation.

The second instance involved a prematurely fractured compression spring. Following removal of the black coating from the spring surface, a section of the spring containing the fracture surface was placed in the SEM for examination.

The fracture origin was determined to be at the inner diameter (ID) of the spring (Figure 4). This is a typical

Untangle your spring problems

D-Tangler 2000 Do tangled springs, rings, clips, etc. tie up your production?

Just drop your tangled material into the input tube and almost simultaneously your material will dispense from the output untangled and ready for production.

Start saving time, money and hours of frustration.

It can’t be any simpler!

Smart Solu ons.... ....for Tangled Springs DISPENSE WORKS INC

Made in the USA

www.d-tangler.com

phone 815-363-3524 • fax 815-363-8089 • info@dispenseworks.com

26 / SPRINGS / Fall 2013

Figure 5. Closer SEM image of the spring surface showing multiple mechanical dents in line with the fracture origin.

location for fractures to initiate on a compression spring, as this is where the operational stresses are at a maximum.

Closer examination of the ID surface of the spring showed numerous mechanical impressions in line with the fracture origin (Figure 5).

Hardness testing on a transverse section of the spring indicated an average hardness of 53 HRC, indicating proper heat treatment. As in the previous instance, a cut was made on the fractured spring section adjacent to the fracture surface and the cut section mounted and polished. The cross-section was etched and then examined

High & Low Carbon Strip Steel

Pre-Tempered Strip

Electrical Strip

Figure 6. Optical micrograph showing the white layer of untempered adiabatic martensite at a mechanical impression on the ID.

using an optical microscope. No partial or complete decarburization was apparent on the cross-section. A white layer of untempered adiabatic martensite was observed at one of the mechanical impressions at the ID (Figure 6). The combination of the untempered martensite in the white layer resulting from the shot peening dents at ID, where the operational stresses are at a maximum, created the stress riser that eventually led to failure. Q Reference: Metals Handbook, Vol. 5, Ninth Edition, American Society for Metals, Metals Park, Ohio, 1982.

Alloyed & Advanced High Strength Steel

Phosphate Coated Strip

Flat Rolled Wire

Shaped Wire

Perfection Comes From Precision – That’s What We Do We’ve been defining quality since 1829. As leaders of the worldwide steel market, we produce and internationally distribute 600,000 tons of steel each year.

Our unmatched customer care combined with our cutting-edge, state-of-the-art technologies enable us to develop highly-specialized and application-oriented products. Together we’ll make the perfect team to ensure that you get precisely what you need for your project.

Let’s start building a strong relationship today.

CDW Service Center s 5221 West 164th Street s Cleveland, OH 44142 s p: 216-267-5500 s f: 216-267-5533 s e: sales@cdw-db.com s w: www.cdw.de

SPRINGS / Fall 2013 / 27

5L^ PKLHZ ZWYPUNPUN [V TPUK&

)YPUN [OLT [V SPML ^P[O

>HU[ [V JYLH[L HTHaPUN WYVK\J[Z& >P[O 0:> `V\ ^PSS >L»YL VUL VM [OL ^VYSK»Z SHYNLZ[ Z[LLS ^PYL Z[VJRPUN KPZ[YPI\[VYZ ZV ^L JHU WYV]PKL H JVTWSL[L SPUL VM ^PYL [V OLSW `V\ I\PSK IL[[LY ZWYPUNZ MHZ[LULYZ ^PYL MVYTZ HUK TVYL >P[O ZP_ SVJH[PVUZ [OYV\NOV\[ [OL <UP[LK :[H[LZ ^L PU]LU[VY` H ^PKL YHUNPUN ZLSLJ[PVU VM JVTWL[P[P]LS` WYPJLK MLYYV\Z ^PYL UVU MLYYV\Z ^PYL HUK ZWLJPHS[` Z[YPW >L IHJR V\Y X\HSP[` WYVK\J[Z ^P[O Z\WWS` JOHPU ZVS\[PVUZ ]HS\L HKKLK MHIYPJH[PVU ZLY]PJLZ HUK \UTH[JOLK KLKPJH[PVU [V `V\Y [V[HS ZH[PZMHJ[PVU

;V SLHYU TVYL HIV\[ V\Y Z[LLS ^PYL ZVS\[PVUZ ]PZP[ ^^^ PUK\Z[LLS JVT VY JHSS \Z [VKH` 0UK\Z[YPHS :[LLS >PYL *VTWHU`

*OPJHNV 03 28 / SPRINGS

/V\Z[VU ;?

/ Fall 2013

)YPZ[VS *;

*SL]LSHUK 6/

3VZ (UNLSLZ *(

*OHYSV[[L 5*

By Gary McCoy

Many things began back in 1933, including the drive-in

©iStockphoto.com/tovfla

theater — a classic form of American entertainment that was born in Pennsauken, N.J. Not far away in Buffalo, N.Y., another big attraction came to the main stage, the Spring Manufacturers Association (SMA). SMA got underway with a dedicated group of charter members (see complete list on page 30) under the direction of Fuller F. Barnes, president and James W. Campbell, vice president.

SPRINGS / Fall 2013 / 29

SMA, the fledgling organization, was the direct result of the National Industrial Recovery Act (NIRA), which became law in June 1933. Under its provisions, the National Recovery Administration (NRA) was established. The NRA instituted industry-wide codes aimed at eliminating unfair trade practices, reducing unemployment, establishing minimum wages and maximum hours, and guaranteeing the right of labor to collectively bargain. Ultimately, 557 basic codes and 208 supplementary codes were adopted, affecting some 22,000,000 workers. Companies that subscribed to the NRA codes were allowed to display the "Blue Eagle" emblem, symbolic of cooperation with the codes.

As part of the NRA process, springmakers met in groups in New York City and Detroit and in a general meeting in Buffalo in August 1933. As a result of these meetings, SMA was formed with Barnes as president (see original letter from Barnes that was mailed to spring manufacturers across the country). A committee was appointed to work out a code for the industry.

With the number of spring plants being relatively small, compared to industry as a whole, it was finally necessary to accept a code under which a large number of industries, similar to the spring group, could operate.

This was known as the Fabricated Metal Products Manufacturing and Metal Finishing and Metal Coating Industry. It included about every group unable to have a code of its own. The code established a 40-hour week and minimum hourly rates of 40 cents for males and 35 cents for females.

Although the NIRA was declared unconstitutional by the Supreme Court on May 25, 1935, SMA survived and became an indispensable part of the precision spring industry.

As part of the NRA process, springmakers met in groups in New York City and Detroit and in a general meeting in Buffalo in August 1933. As a result of these meetings, SMA was formed with Barnes as president. A committee was appointed to work out a code for the industry.

SMA Becomes SMI Because of the increasing attention and new emphasis given spring technology by members, at the June 1961 meeting at The Broadmoor Hotel in Colorado Springs, Colo., SMA went through a name change and became the Spring Manufacturers Institute (SMI).

According to a story at the time, “Meeting programs were being devoted more and more to subjects relating to materials, manufacturing, testing, etc. and more attention was being given to spring standards and spring design.

The term ‘Institute’ it was felt, would more aptly describe the association and the new course of the organization.”

Due to t he increasing tech nica l natu re of t he organization, in May 1973 a Technical Membership category was added for manufacturing suppliers to the industry (see list of original associate members on page 33).

Spring Standards According to SMA minutes, initial work on Spring Standards started at a meeting of the Eastern division of SMA, February 20, 1935, when a formula for figuring

&KDUWHU 0HPEHUV The following list contains the charter members of SMA. Sixteen of these companies are still members of SMI (highlighted in bold), with some now under different names. Their current location is in parentheses.

30 / SPRINGS / Fall 2013

• ABC Spring Company, New York • American Coil Spring Company, Muskegon, Mich.

(Hines Corporation as part of Michigan Spring & Stamping) • American Spiral Spring and Manufacturing Company, Pittsburgh • American Spring and Manufacturing Company, Holly, Mich.

• American Steel & Wire Company, Chicago • The Wallace Barnes Company, Bristol, Conn.

(Barnes Group Inc./Associated Spring) • Barnes-Gibson-Raymond, Inc., Detroit (Barnes Group Inc./Associated Spring) • California Spring Company, Los Angeles • Chicago Coil Spring Company, Chicago

• Cleveland Wire Spring Company, Cleveland • Cuyahoga Spring Company, Cleveland • Duer Spring & Manufacturing Company, McKees Rocks, Pa. (Duer/Carolina Coil Inc., Greer S.C.) • Dunbar Brothers Company, Bristol, Conn.

• Eaton Manufacturing Company, Detroit • John Evans' Sons, Philadelphia (Lansdale, Pa.) • Chas. Fischer Spring Company, Brooklyn • General Spring Company, Cincinnati • The Wm. D. Gibson Company, Chicago • Humason Manufacturing Company, Forestville, Conn.

• Hunter Pressed Steel Company, Lansdale, Pa. • W.B. Jones Spring Company, Cincinnati • Kline Spring Company, Cleveland

)XOOHU ) %DUQHV /HWWHU

Fuller F. Barnes, Associated Spring, leader in the establishment of SMA in 1933.

• Kokomo Spring Company, Kokomo, Ind. (Peterson Spring purchased in 2010 and closed plant) • Lee Spring Company, Brooklyn, N.Y. • L H D Spring Corporation, Waltham, Mass.

• F. N. Manross & Sons, Forestville, Conn.

• Midwest Spring Manufacturing Company, Chicago (Mid-West Spring & Stamping Inc., Romeoville, Ill.) • Miller & Van Winkle, Inc., Brooklyn • Muehlhausen Spring Company, Logansport, Ind. (MW Industries, Rosemont, Ill.) • New Britain Spring Company, New Britain, Conn.

• Newcomb Spring Company, Brooklyn (Decatur, Ga.) • Peck Spring Company, Plainville, Conn.

(Part of Economy Spring owned by MW Industries)

• Precision Spring Corporation, Detroit (Peterson Spring) • Raymond Manufacturing Company, Corry, Pa. (Barnes Group Inc. /Associated Spring Raymond, Maumee, Ohio) • The Timms Spring Company, Elyria, Ohio • United Spring Corporation, Brooklyn, N.Y. • United States Steel Wire Spring Company, Cleveland • Washburn Wire Company, New York • Wickwire-Spencer Steel Company, New York (W.B. Jones Spring Co. Inc., Wilder, Ky.) • The Yost Superior Company, Springfield, Ohio

SPRINGS / Fall 2013 / 31

tolerances in springs was presented for consideration. At the annual meeting of the association held in April 1936 in Cleveland, tolerance charts, specification sheets, a design chart and data sheet were presented to members for their comments and suggestions.

Work continued on the development of this material and, at the annual meeting in 1940 when approval was voted, it was referred to as the "Standards for Mechanical Springs" booklet. At the annual meeting in 1947, it was voted "to enlarge on the present pamphlet, ‘Standards for Mechanical Springs,’ adding 1941-1943 information deemed necessary and desirable." Work on the expanded Standards was completed in 1949 and 26,000 copies were distributed by the time of the annual meeting in December.

Revisions were made in 1959, 1962 and 1964, and the entire format was reconstructed in 1968. The SMI Standards Committee in 1970 prepared a companion publication, a "Spring Design Handbook."

This brief text of basic material was tailored to be used with the SMI "Standards for Compression, Extension, Torsion and Flat Springs." In preparing this design text, the committee kept in mind its possible use by engineering schools and colleges and by engineers new in the spring industry.

In 1972, the “Standards Manual and Design Handbook” were combined into a single publication. The SMI Standards Committee, under the chairmanship of E. J. Hamilton, produced a revised “Handbook of Spring Design” in 1977.

This edition offered a large amount of new information, including vastly expanded tables of properties of spring

32 / SPRINGS / Fall 2013

materials and design data on three types of springs not included in the 1972 edition: spiral torsion springs, power springs, and constant force springs. The handbook was revised again in 1981 under the guidance of the technology committee, chaired by Alex Rankin.

The latest edition of the “Handbook of Spring Design” was updated in 2002.

SMI continues to maintain an extensive library of references guides and manuals to educate the spring industry. Available titles include: • “Fundamentals of Spring Design” • “Compression, Extension, Torsion and Garter Springs” • “Other Springs” • “Testing and Tolerancing” • “Encyclopedia of Spring Design” - Includes the complete set of the above four volumes in one convenient binder.

• “Handbook of Spring Design” • “Slide Forming Concepts Manual” • “Springmaking Concepts Book” • “Mechanical Springs” by A.M. Wahl With the advent of computers, SMI has led the way and is now on version seven of its Advanced Spring Design software.

Well-Known Speakers The dress and atmosphere of SMI annual conventions has changed over the years, but there has always been an emphasis upon attracting top speakers to address the membership.

The list of speakers that have appeared before SMI members is a cornucopia of leaders in business, politics and sports.

At the celebration of SMI’s 50th anniversary, the annual meeting was held at the Boca Raton Hotel and Club in Boca Raton, Florida. A record attendance of 491 was reported. A session titled “Breakfast with Gale Sayers” provided SMI members with the chance to hear from the Hall of Fame Chicago Bears halfback who “presented a brief film and then discussed motivation, meeting change in one’s life, and improving productivity and quality.”

Sayers concluded his presentation by noting that, “We have explored the outer edge of our solar system, but have yet to master the potential of our people.”

Later in the meeting, former Notre Dame football coach Ara Parseghian shared his guidelines for success.

Other notable speakers who’ve appeared at SMI meetings include President Richard M. Nixon at the 31st annual meeting at the New York Hilton, President Ronald Reagan (before he was in politics in 1964), Senator Thomas Dodd, NBC anchor Chet Huntley, New York Giant great Kyle Rote and Harry Stuhldreher, one of the legendary “Four Horsemen” of Notre Dame fame.

Right: Original SMI headquarters in Bristol, Conn.

Below: Former SMI past president A.A. Bonde, Jr., Accurate Spring (center) with William H. Thompson Jr. and then actor and speaker Ronald Reagan, who addressed the 1964 SMI summer meeting at the Del Monte Lodge at Pebble Beach, California.

Lower Right: Notable speakers have addressed SMI meetings over the years. Pictured after his 1964 address to the SMI convention (l-to-r) are then former Vice President Richard M. Nixon and Harry C. Barnes, Associated Spring.

$VVRFLDWH 0HPEHUV In May 1973 a “Technical Membership” for manufacturing suppliers to the industry was established. SMI now simply calls them Associate members. The original 26 technical members are listed below and the companies that are still members of SMI are highlighted in bold. Some are now under a different name and/or location. Current name and location is in parentheses.

• American Spring Wire Corporation, Bedford Heights, Ohio • Associated Spring Corporation, Wallace Barnes Steel Division, Bristol, Conn.

• Bekaert Steel Wire Corporation, New York (Bekaert Corporation, Orrville, Ohio) • Bendix Corporation, Industrial Tools Division, South Beloit, Ill. • The Carlson Co., Oceanside, New York • Continental Steel Corporation, Kokomo, Ind. • AB Garphytte Bruk, Garphyttan, Sweden (Suzuki Garphyttan Corp., South Bend, Ind.) • Gavlick Machinery Corporation, Torrington, Conn.

• Gibbs Wire & Steel Company, Southington, Conn.

• Johnson Steel & Wire Company, Worcester, Mass.

• Jones Metal, Inc. (J & S Metals, Inc.), Forestville, Conn.

• Laclede Steel Company, St. Louis Lion Precision Corporation, Newton, Mass.

• National-Standard Company, Niles, Mich.

• New England High Carbon Wire Corporation, Millbury, Mass.

• Perfection Heat Treating Company, Chicago • Precision Steel Warehouse, Inc., Franklin Park, Ill. • Radcliff Wire, Inc., Bristol, Conn.

• Seneca Wire & Manufacturing Company, Fostoria, Ohio • Sleeper & Hartley Corporation, Worcester, Mass.

• Spring Manufacturers Supply Company, Forestville, Conn.

• Swedish Wire Corporation, Muskegon, Mich.

• Techalloy Company, Inc., Rahns, Pa. • Teledyne Rodney Metals, New Bedford, Mass.

• Torin Corporation, Torrington, Conn.

(SPX Precision Components, Fenn Division, Newington, Conn.)

• Ulbrich Stainless Steels & Special Metals, Inc., Wallingford, Conn. (North Haven, Conn.)

SPRINGS / Fall 2013 / 33

In the first issue of Springs, Jacobson hailed the publication as "another step in the forward march of the spring industry. Directed primarily to springmakers, we will continue, through this medium, to bring to members of our industry the latest developments in springmaking techniques, materials and good management practices."

Magazine Starts Early in 1961, G. Donald Jacobson, then president of SMI, presented the idea of a magazine published by SMI and devoted to spring technology and the industry in general. Following extensive exploration and study over several months, it was agreed at the annual meeting in December, 1961 to proceed with the publication. Volume 1, Number 1 of Springs appeared in May 1962 and in that issue Jacobson hailed the publication as "another step in the forward march of the spring industry. Directed primarily to springmakers, we will continue, through this medium, to bring to members of our industry the latest developments in springmaking techniques, materials and good management practices."

In the succeeding years, hundreds of articles tailored specifically to the needs of the spring industry have appeared. Springs has become the voice of the industry and a respected publication with a worldwide readership of over 10,000.

Professional Staff When SMA was established the first office was located in Buffalo, N.Y. In 1934 the office was moved to Bristol and was run by the leader of the Bristol Chamber of Commerce.

This arrangement continued for many years.

In fact, when George E. Underwood became the executive of the Bristol Chamber of Commerce he was also named secretary of SMA. He continued in this dual role for nearly 20 years.

By 1969, SMI activities had increased to the point where a full-time executive was required. Underwood assumed this post and an independent office was established in Bristol at 24-26 Stearns Street. The association recognized the ever-increasing scope of Underwood's responsibilities by electing him executive vice president in 1971.

When he retired in 1973, Springs headlined, "Mr. SMI Retires," and, regarding his tenure with the association, it was noted, "The responsibilities and the details that had to be handled increased immensely but George carried on so well that most of us just took it for granted that there would be no difficulties and if there were, that George would be on hand to straighten them out."

Af ter Underwood retired, SMI was led by F.R. Downs from 1973 to 1979. Downs helped establish the organization’s Annual Market Summary (formerly Market Trend Survey).

Just prior to Downs’ retirement, a decision was made to move the SMI office to a more centrally located area in the

34 / SPRINGS / Fall 2013

Above: The first three full-time executive vice presidents of SMI (l-to-r): Charles G. Whitechurch, George E. Underwood, and F.R. Downs Jr. Right and below: Golf has always been a part of SMI conventions.

Opposite page: The first issue of Springs appeared in May 1962.

SPRINGS / Fall 2013 / 35

winds through these articles is the role that individual volunteers played in shaping the organization and an overwhelming optimism about the future of the spring industry.

In the October 1973 issue of Springs the subhead at the end of the article proclaimed: “The Best is Yet to Be!” The article said, “It is no doubt gratifying for members, through this summary (a recap of the history of SMI), to look back over the past 40 years to note the gradual development of the SMI into a mature trade association with all its productive activities and valuable services provided.

“However, eyes should now be turned to new horizons — new goals. After all, doesn’t life begin at 40?”

While 40 years have passed since that magazine was produced, SMI members continue to express their gratitude for the association and its members.

With this issue of Springs we express a sincere, “Happy 80th Anniversary SMI!” It will be interesting to see what new developments and achievements that SMI makes as the voice of the spring industry. The sentiment continues that the “best is yet to come.” Q

"The responsibilities and the details that had to be handled increased immensely but George carried on so well that most of us just took it for granted that there would be no difficulties and if there were, that George would be on hand to straighten them out."

country. Since October 1979, SMI has been located in the Chicago area, with its current location in Oak Brook, Ill.

Volunteer Leaders The strength of SMI has always been in its executive committee, board of directors and committee members.

These dedicated volunteers have given of their time and energy to make SMI a better association.

Those who have held the office of president speak out in the article “Past Presidents Speak” found on page 39 to offer their perspectives on SMI’s past, present and future.

To The Future It is interesting to read the various issues of Springs that were published to celebrate the organization’s 40th, 50th, 60th, 70th and 75th anniversaries. The thread that

alloy wire international

when you need wire fast!

Manufacturers of nickel alloys in round & shaped wire

®

Call Toll Free: 1-866-482-5569 fax: 401-384-6757 email: sales@alloywire.com Alloy Wire International

36 / SPRINGS / Fall 2013

205 Hallene Road, Warwick, RI 02886 USA

www.alloywire.com

Some of the international tours sponsored by SMI to Europe and Asia.

SPRINGS / Fall 2013 / 37

$ ' 75$',1* //& Â&#x2021; 6SULQJ &RLOHUV Â&#x2021; :LUH %HQGHUV Â&#x2021; $XWR 'HFRLOHUV Â&#x2021; 6&$'$ 6\VWHPV

$ ' 75$',1* //& Â&#x2021; 6RXWK 0DLQ 6WUHHW Â&#x2021; 5RFN &UHHN 2KLR 86$

Â&#x2021; VDOHV#DGWUDGLQJOOF FRP Â&#x2021; ZZZ DGWUDGLQJOOF FRP

38 / SPRINGS / Fall 2013

Past Presidents Speak

D

uring the course of its history, 32 individuals have held the title of president of the Spring Manufacturers Institute (SMI). Up until 1961, when the name changed to SMI, the organization was known as the Spring Manufacturers Association (SMA).

The organization’s first president and founder, Fuller F. Barnes, Associated Spring, served twice as president, first as the founding president of SMA from 1933 to 1941, and then for a second term from 1943 to 1946. As a tribute to his leadership, Barnes was elected “Honorary President” for life in 1941.

We recently caught up with some of the past presidents who are still alive. Some are currently active in the spring industry, while others have retired. Whatever category they fall into, SMI’s past presidents continue to love and appreciate the industry that shaped their careers.

FRIENDSHIPS FORMED “I have always thought the greatest thing about SMI and the spring industry was its people,” recalled Park Blatchford, who served as SMI president from 1991 to 1993.

Blatchford retired from the Chestnut Group, Inc. when it was sold to MW Industries in 2005.

“Almost everyone I encountered during my 40 years in the industry was honorable, hardworking and enjoyable to be with,” explained Blatchford, “whether socially or while working on shared concerns for the spring industry in SMI. These folks were, and remain, friends!”

Some of the many SMI past presidents pose at the 75th anniversary annual meeting in Palm Springs (from l-to-r): Pete Peterson, Dick Witham, Alex Rankin, Dave Weber, Dan Sebastian, Park Blatchford, Don Jacobson, and Roy Vinderine.

SPRINGS / Fall 2013 / 39

Left: SMI annual meeting at La Costa Resort in California from the '70s. Pictured are past presidents Stanley R. Banas, Stanley Spring & Stamping (left), and John R. Beckwith, Associated Spring (right) with F.R. Downs, SMI executive vice president.

Below: SMI past president Alex Rankin (left) greets A.M. Wahl, author of "Mechanical Springs" at SMI's annual meeting celebrating the organization's 50th anniversary.

Opposite Page: Roy Vinderine and Reb Banas

The sentiment of friendship was echoed by many past presidents. Hugh A. Purnell, who was SMI president from 1968 to 1970, said his best memory from his time as the association’s leader was “the good friends I met at the spring meetings.”

Retired for many years f rom the Frank Hollister Co. and the Barnes Group, Purnell enjoys his time fishing at his log cabin on a lake.

Roy Vinderine served as SMI president from 2001 to 2003. Retired from Springco Industries, he still does some accounting work and volunteers his time at a cancer hospital in Toronto.

His term as SMI president was memorable because it occurred during the tragedy of 9/11, just before his first convention as the group’s leader. “Nevertheless, I think we were able to make strides in education and other areas that went some way toward ensuring the ongoing success of SMI.” Vinderine enjoyed working with the executive committee, board of directors and the various subcommittees. “On a personal level, Naomi and I have made some really good friends with whom we spent many enjoyable hours, in many beautiful and exciting venues.”

Still actively running GR Spring & Stamping Inc. in Grand Rapids, Mich. which now has over 600 associates in five locations, Jim Zawacki says he has not recently had time to be active in SMI. The president of SMI from 1999 to 2001, Zawacki said he and his wife, Joan, plan to attend future annual meetings.

In addition to running GR Spring & Stamping, Zawacki is busy with six kids and 20 grandchildren. Despite a recent back surgery, he still spends time playing tennis and even golf, spending time at the family’s summer log home and some time in Florida.

40 / SPRINGS / Fall 2013

“

I have always thought the greatest thing about SMI and the spring industry was its people,” recalled Park Blatchford. “Almost everyone I encountered during my 40 years in the industry was honorable, hardworking and enjoyable to be with, whether socially or while working on shared concerns for the spring industry in SMI. These folks were, and remain, friends!

”

Sebastian was president of SMI from 2005 to 2008 and cited networking as one of the greatest things about SMI. “SMI provides a forum for spring companies to network with each other, which is important because most spring companies do business with other spring companies,” he explained. “SMI also provides assistance in maintain a safe work place that meet all federal and state requirements. Our technical assistance program helps members with difficult issues.”

Sebastian says he’s enjoying his retirement, “while assisting my daughter and son-in-law find a business.”

When asked, “What is the greatest thing about SMI and the spring industry?” Zawacki immediately mentioned all the nice people he had met over the years. “The networking and sharing to help one another; a great place for technical information; annual conventions in fantastic locations with good speakers on timely topics, which supported all the networking,” said Zawacki. “A staff that is always willing to help you out and very cooperative, and leadership that keeps bringing new ideas forward for SMI to prosper.”

Reb Banas, president of Stanley Spring and Stamping, was SMI president from 2008 to 2010. He believes the greatest thing about SMI and the spring industry are SMI members and staff. “Both need each other and when we all get together twice a year, it makes all the efforts worthwhile.”

SMI’s most recent past president, Scott Rankin of Vulcan Spring near Philadelphia, says the greatest thing about SMI is the association’s “amazing” people.

“I think it is great that we have such a variety of companies and specialties in the industry,” Rankin explained. “I love the idea that we each do something unique and different under the category of springs.

“We get to help our customers solve their challenges with the help of other springmakers that have made it their specialty. I enjoy passing on a customer to another springmaker that I know will be much more suited to help them,” said Rankin, who was SMI president from 2010 to 2012. “Don’t get me wrong, I am not giving away all of our customers but actually solving their challenge in the best way for them. Customers remember that, some days.”

Though retired from his position as head of MW Industries, Dan Sebastian continues to be an active part of SMI as a member of the technical committee and providing assistance to SMI as a technical advisor.

FAMILY CONNECTIONS Several fathers and sons have served as SMI presidents.

Rankin’s father, Alex Rankin, was president from 1989 to 1991. He’s semi-retired now, but still active in the spring industry. “Scott now owns most of Vulcan and he is doing a fine job so there is no reason for me to get very involved in the operation of the company. I have become a consultant with a lot of history about the industry.”

Alex Rankin related that, during his time as president, the first computer spring design program was created by a member’s (Ed Hamilton) son. “It has come a long way since then, but everything has to start somewhere.”

Alex Rankin was also known for leading many overseas tours for SMI members. The tours consisted of 40 to 50 other SMI members and “was really the way to get to know the other springmakers.”

SPRINGS / Fall 2013 / 41

He continues, “Some of the best memories from my term as president was a tour we took after the Bermuda convention to Czechoslovakia right after the Berlin wall came down on July 21, 1990, and then to Austria, Germany, Switzerland, and Italy. Other tours we took after conventions were to France, Japan, Hong Kong, England, Canada, Hawaii, Puerto Rico, Sweden, Denmark and China.”

Alex Rankin said the trips allowed SMI members to visit suppliers of materials, machines, other spring associations and other springmakers. “We learned a lot about our global industry and it is a shame that our newer members are not doing this.”

He said he recalls not being able to afford the cost to attend his first convention and the tour. “So I chose the tour and met the group from the convention at the TWA terminal in New York. That was the correct choice.”

Another father and son duo to lead SMI were A.H. “Bud” Peterson Jr. of Peterson Spring, who passed away on June 12, 2011 and was president of SMI from 1970 to 1972, and his son, A.H. “Pete” Peterson III, who was SMI president from 1993 to 1995. He is retired and living in the Dominican Republic with the family of his wife, who’s a native of the country.

Peterson says the spring industry provides people with spunk and initiative. He views it as an avenue to become involved in an intriguing business with its own “peculiar black art and secrets.” He went on to say, “Becoming a part of this group gives one a feeling akin to joining a club after a trying apprenticeship. It also offers financial rewards and the opportunity for self-fulfillment.”

The quality of your products begins with the quality of our products

Radcliff Wire Inc. is a world leader in quality precision shaped and round wire.

We provide quick and award winning customer service by stocking the necessary raw materials with project capabilities from prototypes to production quantities.

An ISO Certified company with over 50 years of consistent quality and service providing precision fine wire with tight tolerance for a variety of industries.

860-583-1305

42 / SPRINGS / Fall 2013

www.RadcliffWire.com

“

It is amazing how many professional and personal friendships have ‘sprung’ from the meetings,” Jacobson recalled.

“I don’t know of any other industry where managers and owners are so willing to work together to solve problems and share their solutions.

”

He has a fond affection for SMI, having established the “Bud Peterson Memorial Scholarship” to honor his late father by providing a $2,000 scholarship to a deserving student of an SMI member company.

“SMI brings together the people involved in the business and makes them aware of what is peculiar to their business and gives them a feeling of being special,” said Peterson. “SMI also helps the members identify and execute projects of interest to members.”

Don Jacobson is also part of a father/son presidential duo. His father, the late G. Donald Jacobson, was SMI president from 1960 to 1962 and instrumental in the establishment of Springs magazine in 1962. Jacobson followed in his father footsteps and served as SMI president from 1995 to 1997.

Jacobson serves as chairman of the board of Newcomb Spring, splitting time working out of the company’s Tennessee office in the winter and the Connecticut office in the summer.

Like others, he cites people as the greatest thing about SMI. “It is amazing how many professional and personal friendships have ‘sprung’ from the meetings,” Jacobson recalled. “I don’t know of any other industry where managers and owners are so willing to work together to solve problems and share their solutions.”

Jacobson said during his time as president he really enjoyed meeting the “green dotters” (referring to the green dot sticker placed on the name tag of first time attendees).

“Being able to host their first reception, and to officially welcome them and talk about our organization was a great privilege,” said Jacobson.

MEMORIES SMI past presidents have fond memories of their term at the helm of the association, even when faced with challenging circumstances. Banas said he learned a tremendous amount from the president he followed, Dan Sebastian, and teaming up with Scott Rankin, the SMI staff and the board of directors. He said his challenge was

to guide the association through the “Great Recession,” along with a change in leadership at SMI. Of his term, Sebastian says, “We were able to expand our technical services, providing members with access to failure analysis and process and technical advice with people that were in the spring industry. It was also a time with the assistance of the executive committee that we were able to plan and execute those plans for a transition of leadership.”

“My best memory as SMI president was in Hawaii, when my suite was so large I think we had over 100 SMI attendees over for an after dinner get together,” Zawacki recalled. He says he always enjoyed having many past presidents continue to come to the annual meetings, since “it means a lot for the whole SMI membership.”

Zawacki said he always enjoyed bringing at least one of his children’s family to an annual meeting. “Probably the best time for all our grandkids was when we were at Disney World for the big dinner,” he recalls. “All the grandkids were bored, until the wall opened after dinner and there were all of the Disney characters plus games for the kids to play; wow!”

FUTURE THOUGHTS Zawacki believes the spring industry in the U.S. will do well because most of the companies’ technical superiority and employment of best practices. “Also, all the outsourcing that was done over the last 25 years, of products that needed our springs, are beginning to come back to the U.S.” He admonishes SMI to keep pushing for “more American jobs!”

Of the future, Blatchford first looks back at the past: From a manufacturing technology perspective, the most dramatic memory was seeing machine control changes from machines of cams and gears to electronics, which was an exciting although often unnerving (and expensive) transition.”

Blatchford believes this development saw the skills of the industry transition from “art” toward “science.”

As to the future of the industry, Blatchford sees a continuation and probable acceleration of the changes that occurred during the past several decades. He categorizes change into broad categories: • Technological changes in equipment, reducing labor hours but improving quality and requiring greater financial investment and skills development to stay competitive.

• Process changes in the way business is conducted and the further integration of customers’ and suppliers’ engineering, product development, procurement, quality and logistics activities.

• Industry consolidation aimed at more efficient use of investments and economies of scale.

SMI’S PAST PRESIDENTS > Fuller

F. Barnes*, Associated Spring, 1933-1941 and 1943-1946 > James W. Campbell*, 1941-1943 > Edward J. Byrnes, Jr.*, Wickwire-Spencer Steel Co., 1946-1951 > J.D. Culbertson III*, Duer Spring & Mfg., 1951-1955 > Harry C. Faust*, Paragon Spring, 1955-1960 > G. Donald Jacobson*, Newcomb Spring Corp., 1960-1962 > A.A. Bonde Sr.*, Accurate Spring Mfg. Co., 1962-1964 > L. Vaughan Barnes*, The Yost Superior Co., 1964-1966 > F.R. Downs Jr.*, Industrial Components, 1966-1968 > Hugh A. Purnell Jr., Hollister, Associated, SEI, 1968-1970 > A.H. “Bud” Peterson Jr.*, Peterson Spring, 1970-1972 > Stanley R. Banas*, Stanley Spring & Stamping, 1972-1974 > John B. Beckwith*, Associated Spring, 1974-1976 > William M. Marsh, Rockwell International Corp., 1976-1977 > Jack Bazz*, Bazz-Houston Co., 1977-1979 > George C. Underwood II*, Hardware Products Co., 1979-1981 > Steve Csonka, The Timms Spring Co., 1981-1983 > Richard N. Witham, Motion Dynamics, 1983-1985 > John R. Grace*, SEI MetalTek, 1985-1987 > Edward H. Lanke*, Wisconsin Coil Spring, 1987-1989 > Alex Rankin, Vulcan Spring, 1989-1991 > M. Parker Blatchford, Chestnut Group, 1991-1993 > A.H. “Pete” Peterson III, Peterson Spring, 1993-1995 > G. Donald Jacobson Jr., Newcomb Spring, 1995-1997 > Charles Pepka, Renton Coil Spring, 1997-1999 > Jim Zawacki, GR Spring & Stamping, 1999-2001 > Roy Vinderine, HS Spring Corp., 2001-2003 > Dave Weber, A.V. Weber Co. Inc., 2003-2005 > Dan Sebastian, MW Industries, 2005-2008 > Reb Banas, Stanley Spring & Stamping, 2008-2010 > Scott Rankin, Vulcan Spring, 2010-2012 * Deceased

SPRINGS / Fall 2013 / 43

• Continued “off-shoring” by some customers.

Springs and components destined for high volume, “assembly- labor” intensive products will continue to be challenged by “off-shoring” to low cost regions.

• Continued opportunities for export of products where skill or expertise, not labor cost is the dominant factor.

“So, in a n economy as robust a nd creat ive as North America’s, there will always be an abundance of opportunities for component manufacturers like springma kers, a nd pa r t icula rly ones who pu rsue specialties,” said Blatchford. “As a friend once commented, ‘There are riches in niches!’”

Alex Rankin said, “The spring industry is a necessary part of manufacturing and has a bright future.”

Scott Rankin agrees with his father that the future is bright for the spring industry.

“At one time I thought technology would take over where springs fit, but it seems as technology grows so does the need for springs. There is nothing else that does what a spring does in the same space and price,” declared Scott Rankin. “The springs keep evolving and the methods of manufacture keeps updating. We are going to be around for quite a while. The next generation will have fun with these products since the solutions will be more and more unique. We will need some very smart people following us into the industry to keep inventing and innovating the next generation of springs and materials.”

44 / SPRINGS / Fall 2013

“

The springs keep evolving and

the methods of manufacture keeps updating. We

are going to be around for quite a while. The

next generation will have fun with these products since the solutions will be more and more unique. We will need some very smart people following us into the industry to keep inventing and innovating the next

”

generation of springs and materials.

Peterson told us his perspective is shaped through capitalism, which he described as a form of creative destruction.

“Creative new technologies and business practices come along and replace (destroy) the old ones,” explained Peterson. “It’s a tough environment, and it’s our environment.

As long as the U.S. is a capitalist country, the U.S. spring business will reward those who see and adopt the best new technologies and practices, bring in and train good people, and dedicate themselves to their businesses.”

Regarding the future of the spring industry, Banas says, “Besides the competitive international pressure for supplying global OEMs, consolidation of springmakers will continue. It is imperative that we keep our group together and thriving through SMI’s efforts.”

With regard to the road ahead, Sebastian believes the future is strong but will at the same time be challenging.

“Our products are still critical in almost every mechanical and electro-mechanical device,” he explained.

“The challenge from foreign manufacturers will remain significant, but as wages, standards, and currencies rise it will decrease their operating advantage. As these costs rise for foreign manufacturers they will also be pressured by the innovation and creativity of North American entrepreneurs and manufacturers which will provide us with the ability to restore our markets.”

Jacobson is also optimistic about the future, but with a note of caution. “Investments in new machinery and training will enable us to become more productive, and stay competitive in a global marketplace. This is offset by government regulations which continue to hamper our industry’s growth, as well as manufacturing in general.”

Like most past SMI presidents, Jacobson sees “people” as an important part of the spring industry’s future.

“Having the next generation go into springmaking will probably be our biggest challenge,” Jacobson concludes. Q

ULBRICH STAINLESS STEELS ˂ SPECIAL METALS, INC. WWW.ULBRICH.COM

Specialty metals without limits.

Ulbrich has an impressive number of high-performance metal products that provide infinite solutions to precision industries.

By keeping pace with worldwide market demand, Ulbrich has always been—and always will continue to be — your trustworthy partner.

13 LOC ATIONS WORLDWIDE

800 243-1676

SPRINGS / Fall 2013 / 45

46 4 6 / SSPRINGS PRI PR P RING NGS N GS G S / Fall FFal Fa aalll 2013 220013

Flashback

Get ty Images

$ 0HVVDJH IURP WKH 3UHVLGHQW RI WKH 8QLWHG 6WDWHV

©iStockphoto.com/Hepp

SPRINGS / Fall 2013 / 47

48 / SPRINGS / Fall 2013

By Stephen Kraft

Inside a Steel Service Center >>

W

hen you order materials from a steel service center, scheduling is probably the most important part in slitting an order.

Scheduling instructs the operator as to what cuts are to be put on the slitter and what coils are to be used. In scheduling, we must consider the most economical setup pattern and also try to have the least amount of scrap possible.

Our customers’ specifications play an important part in scheduling, and coil size is a vital factor they must consider. Customers who have a maximum and minimum coil weight or outside diameter restriction must be watched closely.

After selecting the proper gauge and type of metal that the customer requires, the scheduler must select the coil that will give us: 1. The most economical setup.

2. The least amount of scrap.

3. A satisfactory product that can be used in the customer’s application.

Some customers, such as spring manufacturers, do not like small coils because one person may be operating more than one machine; when the coils are mounted in the presses, etc., they do not want to change coils any more frequently than necessary.

In scheduling, the best method is to try to go either full length through a coil or cut across the full width of the coil. At this point, the scheduler decides which is more economical and will produce less scrap. Let me give you an example: If a customer wanted 3,000 lbs. of 1” wide stock and the only coil available weighed 6,000 lbs. (24-1/2 wide), it would be more economical to put on 12 cuts and go full length through the coil than to put on 24 cuts or full width and only go half way through coil.

As you can see, the setup time would approximately twice as long with the 24 cuts, and would also create a small coil for restock; however, with 12 cuts we would leave a larger or longer restock coil as far as pounds per inch of width (PIW) are concerned.

As you order materials to help complete your spring manufacturing jobs, please keep these factors in mind so we can all work better together. Q ©iStockphoto.com/pixelprof

Stephen Kraft is the marketing manager for Precision Steel Warehouse. He may be reached at 847-455-7000 or email skraft@psteel.com.

SPRINGS / Fall 2013 / 49

50 / SPRINGS / Fall 2013

Kern-Liebers Texas Celebrates 25 Years

I

t was a Texas size celebration for Kern-Liebers on June 28, 2013!

On that day, more than 125 people came together to celebrate the 25th anniversary of Kern-Liebers Texas. It was also the opportunity to celebrate the 125th anniversary of its parent company, Hugo Kern and Liebers GMBH.

SMI president Steve Moreland (left) congratulates Kern-Liebers Texas on its 25th anniversary with Kerns-Liebers USA president and CEO Torsten Buchwald looking on.

Participants in the event had the chance to visit the Kern-Liebers Mexico plant in Rio Bravo and the Kerns-Liebers Texas plant in Pharr, Texas.

After plant tours in the morning and afternoon, the company held a cocktail reception and celebratory dinner party at The Club at Cimarron in Mission, Texas. Representing SMI were Steve Moreland, president and Lynne Carr, executive director.

Many representatives were present from Kern-Liebers, including Torsten Buchwald, president and CEO of Kern-Liebers USA, Inc.

Rebecca Holloway of Kern-Liebers served as the event coordinator for the Kern-Liebers Texas 25th anniversary celebration.

Congratulations to Kern-Liebers on this milestone achievement. Q

Torsten Buchwald, Kern-Liebers president and CEO, greets visitors to the Kern-Liebers Texas 25th anniversary celebration.

SPRINGS / Fall 2013 / 51

www.asbg.com

AS9100/TS16949

Engineering Precision Spring & Stamping Solutions

SINCE 1857

1.800.528.3795

FROM PROTOTYPES TO PRODUCTION

NEW WEBSITE LAUNCHING SOON!

52 / SPRINGS / Fall 2013

©iStockphoto.com/Björn Meyer

Springmaker Spotlight

Surviving the Tests of Time A PROFILE OF ASSOCIATED SPRING

By Gary McCoy

A

ssociated Spring, a business of Barnes Group Inc., is an organization that drips with the history of the spring industry. It is one of only a few companies in the U.S. that have been in the business of making springs for more than 150 years.

SPRINGS / Fall 2013 / 53

Tim Haller, who currently leads Associated Spring as president, appreciates the history of the company that stretches back to 1857 when the company was founded

by Wallace Barnes. He says that he is proud to lead the company with such a rich and long history that has “survived the tests of time.”

Haller said this had a big impact on customers when the Great Recession occurred a few years back. He says the history of the company “went a long way in assuring our customers that we were going to be here for the long haul.”

The history of Associated Spring and Barnes Group is closely intertwined with the development of the spring industry and what is now the Spring Manufacturers Institute (SMI).

The company was founded as the Wallace Barnes Company in Bristol, Conn., and when Wallace left the company in 1893, his son Carlyle Barnes took over. The company was initially known for making hoop-skirt springs.

But as Tom Barnes, chairman of the board, Barnes Group Inc., explained, the clock industry was very big in the Bristol area at the time, along with gun and bicycle manufacturing. He said the company quickly moved into bending wire to make springs for these industries “because the women’s hoop skirt fashion trend didn’t last very long, and we knew we needed to move past that.”

Barnes said pictures from that era showed men sitting down, but women were standing, because sitting

Fuller Barnes

54 / SPRINGS / Fall 2013

down with a hoop skirt was virtually impossible. “If the market (for hoop skirts) comes back,” said Barnes with a laugh, “we’re ready.

We could possibly do it with plastics now too.”

In 1913, Carlyle’s son, Fuller, took over as general manager of the company, which continued to grow through acquisitions.

After establishing a presence presenc in Canada in 1921, BarnesGibson-Raymond, Inc. was founded in Detroit in 1922. A year later, it was renamed Associated Spring Corporation.

During this time, Fuller Barnes was instrumental in starting the Spring Manufacturers Association (later changed to SMI) in 1933 and became the organization’s first president. You can read more about the history of SMI on page 29 and more about Fuller Barnes in the sidebar below.

Another significant milestone for the company occurred in 1946 when Associated Spring Corporation stock was offered over the counter to the public for the first time. In 1976, the company changed its name from Associated Spring Corporation to Barnes Group Inc. The entire history of Barnes Group was captured in the book, “Barnes: An American Enterprise,” which was

To his contemporaries, Fuller Forbes Barnes was a man of wide-ranging visions — and the drive necessary to attain them. After joining the company on his graduation from Yale in 1910, he quickly rose to treasurer, and in 1913, added the title general manager, continuing in those roles until the death of his father Carlyle in 1926, when he was elected president. Three years earlier, he had been the main force in putting Barnes together with two other family-owned companies to form Associated Spring.

Over the next three decades, he steered Associated Spring through major expansions, the Great Depression and World War II, handing over the reins in 1953 to his son Carlyle F. ("Hap") Barnes.

Fuller Barnes, who had become a recognized leader in industry, was the primary founder and first president of the Spring Manufacturers Association. He also served as an officer or director of many other organizations, including the Bristol Bank and Trust, Bristol Brass, Connecticut Light and Power and Southern New England Telephone.

For a while, he tried his hand at politics and was twice elected state senator from his

district, in 1929 and 1931. Perhaps closest to his heart, however, was the Bristol Hospital, for which he served as president and principal fund raiser for 30 years, helping it to erect a modern, well-equipped building in 1925.

An avid fisherman and golfer in his later years, Fuller became absorbed in a new challenge, the making of needlepoint tapestries, creating large pieces on classical and Biblical themes and crafting the frames in his home woodworking shop.

He also helped to develop Bristol's American Clock and Watch Museum, a unique collection of period timepieces started by his friend Edward Ingraham to celebrate the region's clock-making history. One of its main galleries, displaying a series of priceless grandfather clocks, is housed in a wing donated by Fuller Barnes. Named after his ancestor Ebenezer Barnes, it incorporates the original paneling and ceiling from Ebenezer's house, which was built in 1728 as Bristol's first permanent home.

(Originally written in the book, “Barnes: An American Enterprise,” and is reprinted with permission.)

THE COMPANY WAS FOUNDED AS THE WALLACE BARNES COMPANY IN BRISTOL, CONN., AND WHEN WALLACE LEFT THE COMPANY IN 1893, HIS SON CARLYLE BARNES TOOK OVER. THE COMPANY WAS INITIALLY KNOWN FOR MAKING HOOP-SKIRT SPRINGS.

Above: The original building for Associated Spring in Bristol, Conn.

Opposite page: Wallace Barnes, around 1863.

published in 2007 to commemorate the company’s 150 year anniversary.

Associated Spring Today Barnes Group Inc. is now divided into two segments, Industrial and Aerospace, with Associated Spring grouped within the Industrial side of the business. Barnes Group still calls Bristol home and Associated Spring, though its headquarters are in the Detroit area, still maintains a spring plant in Bristol.

Patrick Dempsey is the CEO of Barnes Group and the 11th person to serve in that role for the company. Tom Barnes’ father, Wally, who came out of law practice and politics to run the company, was the last family member to lead the day-to-day operations of the company. In 1991, he transitioned from CEO to chairman of the board.

As Associated Spring now describes itself, “Today, more than 90 percent of our business is precision-engineered, custom solutions. Utilizing our mechanical springs, wire forms, washers, reed and flapper valves, precision forming and assemblies, we design and produce products and services to meet your (customers’) specific requirements.

Applications range from automotive, telecommunications and consumer home products to medical devices, aerospace/ defense-related products and compressor components.”

Haller joined Barnes Group in October 2001 as division manager for Barnes Aerospace and was later named vice president of operations for Aerospace OEM (original equipment manufacturer). He switched to the industrial side of the company in October 2007 when he was named vice president and general manager for Associated Spring.

He has been president of Associated Spring since June 2008.

Prior to joining Barnes Group, Haller spent 15 years at a global jet engine manufacturer.

Haller says going from OEM to supplier gave him a dif ferent perspective. “I decided to make the switch from customer to supplier with the view that, by belonging to a smaller company, I might be able to do more in terms of my total contribution affecting the company.”

Being on the supplier side has taught Haller much.

Haller said he’s learned to compete for a customer’s business, maintain the business and grow it and that relationships and pricing become a factor when everything else is equal.

“As you move from the customer side to the supplier side, at least in my personal experience,” related Haller, “I gained a stronger appreciation for what it took to maintain that relationship where I didn’t have that same appreciation from the customer’s point of view.”

Reorganized Timing When Haller was tapped to take over Associated Spring in June of 2008, he was tasked with reorganizing the operations into focused factories or what Barnes Group calls “Centers of Excellence.”

6LQFH

&RPSUHVVLRQ 7HQVLRQ 6TXDUHQHVV 8QGHU /RDG 'LJLWDO 6TXDUHQHVV /DWHUDO /RDG 7RUVLRQ

0RGHO 7 ;< VDOHV#OLQNHQJ FRP 4XDOLW\ x

$FFXUDF\ x

5HOLDELOLW\

SPRINGS / Fall 2013 / 55

The Mainspring was a popular publication that Associated Spring published over many decades.

Haller said it was very clear on the aerospace side of the business which of the company’s six facilities made specific parts, but after joining Associated Spring, he quickly realized it was not so clear on the industrial side. “Many of our locations were able to produce identical types of springs. The tasking was to consolidate similar operations for differentiation from plant to plant, especially in the U.S. where Associated Spring has five divisions.”

He related that, in Associated Spring’s international operations, it is more of a “job shop” concept where they try to service the needs of many. They have three international locations in Mexico City, Brazil and Singapore.

“So what you find in our U.S. operations is that in each of five divisions, although they all know how to make springs, we try to specialize in unique product lines or market segments in each division.”

Haller says that allows Associated Spring to become more of an expert in the engineering, design and support of the customer.

The challenge for Haller was that his entrance as president of Associated Spring occurred at the same time as the Great Recession when he and his team were in the middle of developing and beginning to implement a reorganization plan.

Haller cited this as one of the greatest challenges for him and his team since he took over the helm at Associated Spring.

“To reorganize and do it in the middle of a recession was the most challenging aspect of what our team has been through in the past five years,” he said. “We came out of it very strong and ready for the next level of growth which we believe to be in automatic transmissions.”

Balanced Approach Associated Spring is one of t he la rgest spring manufacturers that service both automotive and industrial customers. Haller said having its business divided between the two sectors is like having a balanced stock portfolio.

He said when Associated Spring’s automotive business was slow, the industrial side was excelling. “Now that the industrial end markets are sluggish, our automotive segment is excelling,” he explained. “The balance between the two is comforting, in terms of our diversification.”

Haller says a lot of products produced by Associated Spring revolve around products that service transmissions.

He said they provide transmission products to the automotive, heavy and medium duty truck, construction and agricultural markets - which represents about two thirds of the company’s volume.

“The majority of our products are for automatic and manual transmissions,” said Haller. “We do Bellville washers, wave washers, retaining and snap rings, valve body springs, accordion springs, and torque converter clutch springs.”

56 / SPRINGS / Fall 2013

He said Associated Spring also does compression seat and spring assemblies (sometimes known as spring packs) for medium to heavy duty trucks.

Associated Spring has had a long history in the automotive business and racing. For many years the company produced a widely read newsletter called “The Mainspring.” In the spring 1965 issue, the publication reviewed the completion of the 1965 Indianapolis 500 race.

“Now that this year's famous Indianapolis auto race is history, the post mortems will turn up the brickbats and bouquets for those organizations that helped to make possible the results. The valve springs in the engines are one of those unobtrusive but vital parts that are being praised.

“Associated Spring Corporation is sharing in this praise because, to the best of our knowledge, all of the valve springs used by all 33 cars that started in the race were made by our B-G-R Division at its Ann Arbor, Mich., plant. More significant, though, is the fact that there were no valve spring failures in any of the engines.”

The company continues to produce racing valve springs, a technology that Associated Spring says has evolved tremendously over the last 10 years.

“Associated has a strong partnership with leading suppliers of racing engine components,” said Haller, “Comp Cams and Manley Performance, among others.”

This has led to a better understanding of various segments of the market and key customer requirements: lighter

“TO REORGANIZE AND DO IT IN THE MIDDLE OF A RECESSION WAS THE MOST CHALLENGING ASPECT OF WHAT OUR TEAM HAS BEEN THROUGH IN THE PAST FIVE YEARS.” springs and higher engine RPMs, without compromising fatigue life. The lighter spring requirement means a higher static stress spring which lead to improvements in materials and processes.”

Associated Spring says the key elements in the improvement of processes were a patented heat treating process to reduce material grain st r uctu re a nd a proprietary surface finish.

“This proprietary surface finish is key, as higher stressed race springs, unlike OEM springs, tend to be adversely affected at the surface,” explained Haller. “A basic law of physics is that a crack, no matter how tiny, has to be present to start the ‘failure’ process. Associated Spring processes help eliminate the possibility of any cracks.”

The company says it is already working on the next set of improvements in materials, designs and processes, with the goal of bringing these improvements to market in the next few years.

Tom Barnes: Continuing a Family Legacy Tom Barnes is the chairman of the board of Barnes Group Inc. and carries on the legacy of the Barnes family in the spring industry.

Though a family member no longer runs the day-to-day operations of Barnes Group, Tom Barnes represents the fifth generation of the family to be involved in the business.

Barnes says his family is quite proud of its heritage in the spring industry and its part in the founding of SMI. “We played a role in bringing the organization together in those early years when we were still a private company. It was a great relationship that friendly competitors had to start the organization,” said Barnes.

“Great uncle Fuller and those who helped him, all gathered and realized there would be a lot of benefit from having an association that could share problems and work together to train new springmakers,” explained Barnes. “That challenge continues today—to maintain the workforce and the skills of the people

you need to bend metal and make springs.

“I think SMI has done a great job in providing the vision and the impetus to work across the country with tech schools to get people to go into the spring industry and become springmakers.”

Even though it is now a public company, Barnes said the Barnes family is proud that it continues to have family ownership of around 17 percent.

“The family feels good that we played a part in helping spawn this industry,” explained Barnes of its legacy. “So many of our colleagues out there have made a good living and I think we can be proud of this industry and what it contributed to the Industrial Revolution in the United States.”

The number of family members in Barnes’ generation is around 22, with his children’s generation closer to 80.

The Barnes Group Foundation started in 1945 and is supported by Barnes Group Inc. and is committed to the support of education, the arts, civic and youth activities and health-related charities in the communities in which the company operates.

“We have prided ourselves all through our history regarding the importance of taking care of our employees and encouraging our employees to give back to the communities where they are located,” Barnes said.

Barnes explained that the company has a number of programs in place, including a matching gifts program, to encourage employees to contribute to charities in their communities.

“Giving back to our communities is a very important part of our culture.”

SPRINGS / Fall 2013 / 57

HALLER IS ESPECIALLY PROUD OF THEIR WORK IN OUTER SPACE. ASSOCIATED SPRNGS' POWER SPRINGS WERE USED

BY NASA TO HELP LOWER THE MARS ROVER, CURIOSITY, LATE LAST YEAR.

Engineer by Day, Dancer by Night When asked about any funny or weird experiences during his career, Haller immediately mentioned the time when he dressed up as a sumo wrestler to raise money for the United Way. â&#x20AC;&#x153;It was hot, sweaty and I got knocked on my back several times,â&#x20AC;? explained Haller. â&#x20AC;&#x153;But it was well worth it to raise a couple of thousand dollars for the local United Way chapter.â&#x20AC;?

For most people in middle age, it is not customary to already have two replacement hips, but when you know Hallerâ&#x20AC;&#x2122;s background it is not so unusual. As Haller confesses, his hips got worn out competing in ballroom dancing.

Haller and his wife, Barbara, are four-time United States Professional Theatrical Arts Ballroom Champions.

By winning this competition for the fourth time in 1999, the Hallers made ballroom competition history by becoming only the second theatrical arts dance team to

Associated Spring president Tim Haller (center) with Joaquin Davis, NPD engineer and Kim Richards, materials and process engineer.

win the title four times since the inception of the United States Ballroom Championships in 1971.

If you do a quick Google sea rch for â&#x20AC;&#x153;Tim a nd Barbara Haller,â&#x20AC;? youâ&#x20AC;&#x2122;ll ďŹ nd videos of the pair in various competitions and shows. Though now retired from competition, the couple still remain connected to ballroom dancing. They own Arthur Murray Dance Studios in Cincinnati and Dayton, Ohio.

Tim says Barbara once asked him, now that heâ&#x20AC;&#x2122;s on the other side of two titanium hips: â&#x20AC;&#x153;Do you wish we had not been competitive dancers?â&#x20AC;? With little hesitation, Haller told her, â&#x20AC;&#x153;Not at all. I wouldnâ&#x20AC;&#x2122;t trade it for anything. It

&$60, LV SURXG WR FKHHU IRU DOO RI WKH &KDPSLRQV RI WKH 6SULQJ 0DQXIDFWXULQJ ,QGXVWU\ 0DQXIDFWXUHUV DQG 6XSSOLHUV

:HÂśUH 3URXG WR %H RQ <RXU 7HDP -RLQ XV IRU 635,1* :25/'Â&#x160; 'RQDOG ( 6WHSKHQV &RQYHQWLRQ &HQWHU 5RVHPRQW ,/ 2FWREHU )RU LQIRUPDWLRQ YLVLW RXU ZHEVLWH RU FDOO

ZZZ FDVPL VSULQJZRUOG RUJ 58 / SPRINGS / Fall 2013

was a great run. We competed for 11 years and won the national title four times.â&#x20AC;?

With a laugh he says, â&#x20AC;&#x153;I was engineer by day and dancer by night. So it was an unusual combination.â&#x20AC;?

Future Plans While continuing to see growth for Associated Spring in the automatic transmission market, where they are making signiďŹ cant investments into the 8- to 10-speed technologies, Haller also sees growth in the industrial side of the business in alternative energy technology. â&#x20AC;&#x153;We currently make nuclear fuel rod springs and ďŹ&#x201A;exors for solar engines,â&#x20AC;? he said.

Heâ&#x20AC;&#x2122;s especially proud of their work in outer space.

Associated Springsâ&#x20AC;&#x2122; power springs were used by NASA to help lower the Mars rover, Curiosity, late last year.

Because of the companyâ&#x20AC;&#x2122;s aerospace certification, they also do work for Lockheed Martin and other defense contractors.

In addition to t he continued focus on product diversiďŹ cation, Haller says that their future will focus on new technology with emphasis on â&#x20AC;&#x153;design, manufacturing, and applications engineeringâ&#x20AC;? to provide customer solutions for â&#x20AC;&#x153;engineered products and systems, using state of the art processes and technologies.â&#x20AC;?

As Haller looks forward to the future of Associated Spring and all the new technology that will come forth, I asked what lessons he had learned during his career.

Haller said during his 25-plus years in manufacturing heâ&#x20AC;&#x2122;s learned that â&#x20AC;&#x153;change is unpredictableâ&#x20AC;? and â&#x20AC;&#x153;when change happens, youâ&#x20AC;&#x2122;ve got to be ready for it, whether itâ&#x20AC;&#x2122;s good or bad.â&#x20AC;?

One memory sticks out for Haller regarding change. â&#x20AC;&#x153;It was not that long ago in aerospace, we were planning for record volume sales of jet engines. And then, unfortunately, 9/11 came along, the twin towers were hit and the company I worked for at the time lost 40 percent of our volume overnight.â&#x20AC;?

He looks hopefully to the future and is optimistic that further change will be more positive than negative.

To be successful in the spring industry or in aerospace, Haller believes it revolves around being intimate with your customers and â&#x20AC;&#x153;predicting what the customer needs before he or she knows they need it.â&#x20AC;?

It ďŹ ts well with a statement on the companyâ&#x20AC;&#x2122;s website: â&#x20AC;&#x153;At Associated Spring, weâ&#x20AC;&#x2122;re committed to ďŹ nding new and better solutions to the problems our customers face; to responding quickly to customer demands with products that meet their needs and exceed their expectations; and to providing the worldwide capabilities of a global leader, assuring reliable delivery of quality components when and where our customers need them.â&#x20AC;?

With a strong history of customer loyalty and 157 years behind them, it does not appear that Associated Spring will be going anywhere soon. Q

)RU PRUH WKDQ D FHQWXU\ 0DSHV 3LDQR 6WULQJ &RPSDQ\ KDV EHHQ WKH EHQFKPDUN IRU VXSHULRU VSULQJ ZLUH :KHWKHU LWĹ?V PXVLF VWULQJV KHUH RQ (DUWK RU FXVWRP ZLUH IRU VSDFH H[SORUDWLRQ PDQXIDFWXUHUV ZRUOGZLGH WXUQ WR 0DSHV IRU FUDIWVPDQVKLS UHOLDELOLW\ DQG FRQVLVWHQW TXDOLW\ WKH\ FDQ FRXQW RQ 9LVLW 0DSHV:LUH FRP RU FDOO XV DW IRU FXVWRP ZLUH VROXWLRQV

MAPES WIRE TYPES & SIZES 3KRVSKDWH &RDWHG 0XVLF 6SULQJ :LUH

Ĺ&#x17D;

PPĹ&#x17D; PP

0LVVLOH :LUH +LJK 7HQVLOH

Ĺ&#x17D;

PPĹ&#x17D; PP

7LQ =LQF &RDWHG 0XVLF 6SULQJ :LUH Ĺ&#x17D;

PPĹ&#x17D; PP

7LQ &RDWHG 0XVLF 6SULQJ :LUH

Ĺ&#x17D;

PPĹ&#x17D; PP

$OXPLQXP =LQF *DOIDQp &RDWHG 0XVLF 6SULQJ :LUH

Ĺ&#x17D;

PPĹ&#x17D; PP

6SHFLDO $OXPLQXP =LQF *DOIDQp +DUG 'UDZQ :LUH

Ĺ&#x17D;

Ĺ&#x17D; PP

+DUG 'UDZQ 6SULQJ :LUH

Ĺ&#x17D;

PPĹ&#x17D; PP

6WUDLJKW DQG &XWWLQJ

Ĺ&#x17D;

Ĺ&#x17D; PP

7RUVLRQ 6WUDLJKWHQLQJ

Ĺ&#x17D;

Ĺ&#x17D; PP

WR

PP WR PP

6TXDUH :LUH )ODW :LUH QDWXUDO HGJH

[ WR PP [ PP WR [ PP [ PP

6SULQJ :LUHV -,6* 6:$ 6:% -,6* 6:3$ 6:3% (1 PLOLWDU\ VSHFLILFDWLRQV DQG RWKHUV &DOO IRU VSHFLDO ZLUH QHHGV DQG VROXWLRQV LQFOXGLQJ UHVWULFWHG WHQVLOHV DQG VL]H WROHUDQFHV *DOIDQ LV D UHJLVWHUHG WUDGHPDUN RI *DOIDQ ,QIRUPDWLRQ &HQWHU ,QF

ISO 9001: 2008 FHUWLILHG

0$3(6 3,$12 675,1* &203$1< 3 2 %2; _ (/,=$%(7+721 71 86$ _ )$;

LQIR#PDSHVZLUH FRP ZZZ PDSHVZLUH FRP

SPRINGS / Fall 2013 / 59

60 / SPRINGS / Fall 2013

Inside SMI ©iStockphoto.com/seraficus

Speakers Announced for Hawaii Meeting An impressive lineup of speakers is ready to address the 2014 SMI Annual Meeting at the JW Marriott Ihilani Resort and Spa in Oahu, Hawaii, February 8-11.

On Monday, February 10, David Wheat ley of Hu ma nener g y w ill present “Leadership is About Choice.”

Wheatley works wit h ma nagers, executives and community leaders who refuse to settle for the status quo, both professionally and personally.

An expert facilitator, trainer and coach, his primary focus has been facilitating and coaching leadership tea ms w it h i n ma nu fac t u r i ng companies and credit unions.

Originally from Leeds, England, Wheatley is a former Scotland Yard police officer. He is a graduate of Hendon Police Academy in London and an honors graduate of Lancaster University’s education progra m.

He ea r ned a ma ster’s deg ree i n organizational management from Spring Arbor University and is a Senior Fellow at the University of Maryland’s School of Public Policy. He is co-author of “50 DOs for Everyday Leadership: Lessons Learned the Hard Way (So You Don’t Have To).”

Two speakers are scheduled for Tuesday, February 11.

First up is Dr. Nariman Behravesh, an Iranian-American economist, and the chief economist and executive vice president of Global Insight.

Behravesh holds Ph.D. and M.A. deg rees i n econom ics f rom t he University of Pennsylvania, and a bachelor of science degree from the Massachusetts Institute of Technology.

He has appeared frequently on television on NBC, CNN, Bloomberg TV, and appears as an economic

analyst in updated episodes of the educational series Economics U$A and Inside the Global Economy. He is a frequent guest contributor to Tech Ticker at the Yahoo Finance website.

Behravesh is the author of “SpinFree Economics: A No-Nonsense, Nonpartisan Guide to Today's Global Economic Debates” (McGraw-Hill).

Colonel David Hunt, a Fox News wa r a nd ter ror ism ex per t, w i l l conclude the presentations on Tuesday February 11. Colonel Hunt has over 29 years of military experience including extensive operational experience in special operations, counter terrorism and intelligence operations.

Most recently, Colonel Hunt served as tactical adviser in Bosnia where he facilitated all national intelligence matters for the commander in chief.

Prior to this, he served as counter terrorism coordinator to the Summer Olympic Games in Seoul, Korea. In this capacity, Colonel Hunt planned, choreographed and implemented the first United States national response for an Olympic event in Korea in conjunction with Korean National Intelligence and the Korean Crisis Response Agency.

He has served as a security adviser for the Federal Bureau of Investigation as well as state and local police officials.

A graduate of Harvard University's J o h n F. K e n n e d y S c h o o l o f Government, Colonel Hunt holds a master's degree in English from Norwich University.

For more infor mat ion a nd to register for the 2014 SMI Annual Meeting, phone SMI at 630-495-8588.

David Wheatley

Dr. Nariman Behravesh

SPRINGS / Fall 2013 / 61

Inside SMI

Don’t Miss Upcoming Machine Guarding Webinar Jim Wood, SMI's independent regulations compliance consultant, will conduct a webinar on “Machine Guarding” on October 10 from 1 p.m. to 2 p.m. (CST).

“For a continuing program to improve safety at your facility, OSHA maintains that guarding must be made a part of each setup routine,” explained Wood. His informative seminar will concentrate on: · The most typical types of equipment found in springmaking facilities.

·

·

Various methods of guarding that have been acceptable to some OSHA inspectors without establishing a precedent.

Understanding OSHA guarding requirements and various guarding options available.

Wood has more than 30 years of practical manufacturing experience and is a certified instructor for the OSHA outreach program. Wood began working with SMI members in 1993 and, since then, has conducted numerous safety inspections and seminars.

With practical experience in plant safety, Wood was a manufacturing engineering and safety director for 13 years, and a vice president of operations for a major manufacturing corporation for 17 years. He mixes personal experience with touches of humor to create an educational and enjoyable program.

The registration fee for members is $129 per computer terminal and $179 per computer terminal for nonmembers.

To register visit the SMI website at http://smihq.org/public/education.html or phone SMI at 630-495-8588.

2014 SMI Scholarship Program Under Way

62 / SPRINGS / Fall 2013

©iStockphoto.com/Lukasz Gumowski

Through its regional and at-large scholarship program, SMI will give out $33,500 in scholarship aid in 2014 to the employees of SMI members and their family members.

Applications are now being accepted for the 2014 scholarship program, which is administered

by Scholarship America.

SMI will award nine regional scholarships in the amount of $2,000 each. Six at-large scholarships will also be presented.

New at-large scholarships for 2014 include: WAFIOS Innovation in the amount of $2,500, the Hugo Kern-Liebers Gmbh & Co. scholarship in honor of the company’s 125th anniversary for $2,500 and the Kern-Liebers Texas scholarship for $2,500 to recognize the company’s 25th anniversary.

The International Spring Scholarship increases to $4,000 for 2014 and will be awarded to two students in the amount of $2,000 each. In addition, the Callaghan-Hart Scholarship and the Bud Peterson Memorial Scholarship continue for 2014 in the amount of $2,000 each.

Check the SMI website for scholarship information or contact Lynne Carr at 630-495-8588.

Inside SMI

Past President Plays in Encompass Championship

Reb Banas, president of Stanley Spring & Stamping and past president of SMI, had the thrill of a lifetime in June. Banas played in the Encompass Championship at his home course, North Shore Country Club, in Glenview, Ill. The event, now a regular stop on the PGA Champions Tour, was held for the ďŹ rst time in the Chicago area in 2013 and featured a unique Pro-Am format. During the ďŹ rst two rounds of competition on Friday, June 21 and Saturday, June 22, Banas, along with other amateurs and celebrities, was paired with Champions Tour professionals.

A greater thrill for Banas was the fact that his son, Rebbie, served as his caddy.

SPRINGS / Fall 2013 / 63

Is your retirement plan headed in the right direction?

For information about getting your plan on track, contact Lynne Carr, General Manager, Spring Manufacturers Institute, at (630) 495-8588.

Your future. Made easier.® SMI is a separate legal entity and is not affiliated with the ING family of companies.

http://ing.us www.ingretirementplans.com Insurance products, annuities and funding agreements issued by ING Life Insurance and Annuity Company (“ILIAC”) One Orange Way, Windsor, CT 06095, which is solely responsible for meeting its obligations. Plan administrative services provided by ILIAC or ING Institutional Plan Services, LLC. All companies are members of the ING family of companies.

Securities distributed by or offered through ING Financial Advisers, LLC (member SIPC) or other broker/dealers with which is has a selling agreement.

64 / SPRINGS / Fall 2013 3019114.C.S-3 (8/11) © 2011 ING North America Insurance Corporation C#

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

New StepTracker Project Status Magnetic Whiteboards Help Organize Projects The new Do-Done StepTracker whiteboard is designed for project management and coordination, especially for teams who focus on productivity, process, quality, 5S and other lean manufacturing improvements.

“Our customers keep coming up with new ways to use the Do-Done StepTracker; product development, process improvement and employee training are just a few,” says Christian Krapf, spokesperson for Magnatag. “The boards provide a focal point for project participants. The easy to use Red-Green Flip-Over magnets show the status of each project as it moves toward completion so you can clearly see what’s done and where things are held up” continued Krapf. “They are flexible and easy to use, project step headings and names can be customized or changed on the fly using magnetic cardholders with printable inserts.”

HTC and Forming Systems announce New Spiral Spring Machine

The Do-Done StepTracker arrives ready-to-use with magnets and everything needed to operate it. Lines and lettering are heat-fused printed and can

be customized as you order online. For more information go to www.magnatag. com/ddxt or call 800-624-4154.

HTC Spring Machinery and Forming Systems, Inc. announce the latest release of the SS-3410 Spiral Spring Machine. Developed for efficient production of spiral springs with formed ends, the SS-3410 is a three axes machine equipped with touch screen interface for ease of operation, servo controlled feed, servo controlled shell cams for accuracy and performance, servo controlled winding for accuracy and dimensional control, in-line induction heating for bending pre-tempered materials, noncontact infrared sensor for machine stoppage in case of induction error, and cooling systems for tooling (air and water). The HTC SS3410 machine has a maximum wire range of 3.4mm x 10mm section (or equivalent).

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

SPRINGS / Fall 2013 / 65

New Products

RoboVent Introduces Major Breatkthrough in Clean Air Technology RoboVent, a leading U.S. manufacturer of ventilation and air filtration equipment for more than 24 years, has introduced its all-new Fusion 3 Series of fume and dust collectors. The Fusion 3 is completely assembled and doesn’t require any additional parts or equipment to be operational. With just two simple connections — electrical and compressed air — the Fusion 3 can be used in the most demanding welding, cutting and metalworking operations.

It is an all-in-one collector with a seamless integration of all the components necessary for an effective air filtration system: the cabinet, motor, blower, control panel, safety features and filters. Because the Fusion 3 is completely assembled prior to shipping, buyers skip the cost of on-site assembly and testing that is common with other collectors. A fully tested and functional collector with an integrated cabinet, base and particulate containment unit eliminates installation delays and expense.

“When we set out to restructure our product platform, we didn’t just want to create a new dust collector, we wanted

to make a much better collector,” said John Reid, president and CEO of RoboVent Product Group. “Our existing design was the benchmark in the industry, so we wanted to keep all the things that made it successful. But we knew there were things we could do to take it to the next level, to make it more capable, more powerful, yet so much simpler.”

One example of RoboVent’s success in building a fully integrated collector is the built-in control panel with its intuitive ePad touch screen panel. The ePad provides the ultimate control of the blower, filter differential pressure and the proprietary Dynamic Pulse cleaning system. The ePad also continuously monitors performance including diagnostic features and tracks maintenance. The Fusion 3’s advanced Dynamic Pulse cleaning is a system of integrated valves with a computer-synchronized double pulse action to virtually eliminate the redeposit of dust on filters that is common in other collectors.

“The filter cleaning system is one of the most critical components, and filter life can be dramatically improved

if you can prevent the dust from being redeposited on the filters. So we designed a synchronized pulse sequence.

Milliseconds after a filter is purged, the surrounding filters are given a secondary purge, so it neutralizes the airflow and propels the dust particulate into the collection area,” reports Jerry Douglas, RoboVent’s engineering manager.

Another important feature that the Fusion 3 offers is the SafeSensor particulate monitoring system. To help ensure the health and safety of the user, RoboVent has developed an advanced system that can detect a leak beyond the filters should one ever occur, and instantly shut the equipment down while triggering an alarm. The Fusion 3 also features the SnapLock Filter Clamp, a double rail clamping mechanism to ensure an airtight seal on every filter. The SnapLock also makes filter change-outs fast and easy without the need for any tools.

To learn more about the new Fusion 3 Series collector visit www.RoboVent.com.

Larson Electronics Releases Two New Products Larson Electronics has released a powerful explosion proof fluorescent emergency light designed to provide emergency backup operation, and the ability to withstand wet and corrosive environmental conditions. The HALPEMG-48-2L-T5HO Class 1 Division 2 Emergency Fluorescent Light is built from corrosion resistant materials and features T5 HO fluorescent tubes for high output and a built in battery backup system for continued operation in the event of power failures.

This light is designed to provide operators with a failsafe lighting solution that can withstand the rigors of operation in locations where corrosion and wetness is an issue. This explosion proof emergency light looks and operates like a standard fluorescent fixture, but incorporates a corrosion resistant housing and emergency backup battery system

66 / SPRINGS / Fall 2013

that provides a failsafe lighting option and the ability to withstand the effects of a corrosive operating environment. The housing on this unit is constructed with a glass fiber reinforced polyester housing with poured in gasket for reliable sealing and an impact resistant acrylic diffuser cover for even light distribution and high durability. Stainless steel latches provided added protection against corrosion and secure the acrylic diffuser to the housing to prevent drips and water intrusion.

Light output is provided by a pair of T5HO fluorescent lamps, which produce a combined total of 10,000 lumens of light output, making this unit ideal for illuminating larger areas such as work stations, walkways, storage areas, and anywhere large scale coverage is needed.

“We are getting more demand for emergency ballast equipped explosion proof lights and hazardous location

lights,” said Rob Bresnahan with Larson Electronics. “For a small incremental cost, operators can meet the requirements for Class 1 Division 2 emergency lighting, while still having a fully functional light fixture for daily operational use. It makes a lot more sense than purchasing and installing separate hazardous location lights, particular over doorways and exits. In addition, we can configure these lights for surface, pendant or wall mount.”

Also at Larson, an LED hazardous location pedestal light has been designed to provide high power illumination in an easily deployed package. The HAL-PM2X150-LED-100 dual LED Pedestal Mounted Hazardous Location Light provides protection in atmospheres where flammable gases and vapors may occasionally be present while offering the durability and longevity of LED solid state technology.

New Products

Larson Electronics, continued This light is designed to provide operators with a quickly deployed source of illumination that has all the safety and performance of dedicated permanent mount units. With lamp housings constructed of powder coated non sparking aluminum, 100 feet of SOOW abrasive and oil resistant cord, and a wet area approval rating, this unit is built to stand up to the demanding conditions of the industrial workplace. The LED lamps mounted to this unit are rated at 150 watts each and produce a total of 29,580 lumens. The lamp housings are constructed of aluminum with a durable powder coat ďŹ nish, have hinged tempered glass doors, and allow operation with voltages ranging from 120VAC to 277VAC. The rugged pedestal base on this unit provides a secure platform for easy light placement and includes an in-

tegral carrying handle with ergonomic grip for easy carrying from one location in the workplace to another. This pedestal mounted work light is UL rated Class 1 Division 2 Groups C and D is approved for use in wet areas and marine environments, making it an ideal lighting solution for hazardous locations where water resistance is an important requirement.

Visit LarsonElectronics.com for an extensive line of explosion proof lights, hazardous location lights, intrinsically safe lights, oil rig lights and explosion proof tank lights, or call 800-369-6671; call 903-498-3363 for international inquiries. Q

Larson Electronics HALP-EMG-48-2L-T5HO Emergency Fluorescent Light

Advertiser's Index A & D Trading (440) 563-5227 . . . . . . . . . . . . . .38 Admiral Steel (800) 323-7055 . . . . . . . . . . . . . . 9 Alex Industries (847) 298-1860 . . . . . . . . . . . . . .15 Alloy Wire International (866) 482-5569 . . . . . . . . . . . . . 36 Associated Spring (800) 528-3795 . . . . . . . . . . . . . .52 CASMI (630) 369-3466 . . . . . . . . . . . . . 58 CDW (216) 267-5500 . . . . . . . . . . . . . 27 Century Spring, Division of MW Industries (800) 237-5225 . . . . . . . . . . . . . 12 Diamond Wire Spring Co. (800) 424-0500 . . . . . . . . . . . . . 10 Dispense Works (815) 363-3524 . . . . . . . . . . . . . 26 Elgiloy Specialty Metals (847) 695-1900 . . . . . . . . . . . . . 11 Exova (866) 263-9268 . . . . . . . . . . . . . 20 Forming Systems Inc. (877) 594-4300 . . inside front cover, back cover

Gibbs Wire & Steel Co. Inc. (800) 800-4422 . . inside back cover Gibraltar Corporation (847) 769-2099 . . . . . . . . . . . . . 50 Industrial Steel & Wire (800) 767-0408 . . . . . . . . . . . . . 28 InterWire Products Inc. (914) 273-6633 . . . . . . . . . . . . . . 1 JN Machinery (224) 699-9161 . . . . . . . . . . . . . .18 Kiswire (201) 461-8895 . . . . . . . . . . . . . 60 Link Engineering (734) 453-0800 . . . . . . . . . . . . . 55 Mapes Piano String Co. (423) 543-3195 . . . . . . . . . . . . . 59 Messe Dusseldorf (312) 781-5180 . . . . . . . . . . . . . .22 NIMSCO (563) 391-0400 . . . . . . . . . 14, 32 North American Spring Tool (860) 583-1693 . . . . . . . . . . . . . .56 Proto Manufacturing (800) 965-8378 . . . . . . . . . . . . . 34 Radcliff Wire (860) 583-1305 . . . . . . . . . . . . . 42 RK Trading (847) 640-9371 . . . . . . . . . . . . . . 5

Shinko Machinery +81-6-6794-6610 . . . . . . . . . . . . .3 Simplex Rapid (563) 391-0400 . . . . . . . . . . . . . 48 Spectral Systems (800) 393-4747 . . . . . . . . . . . . . 41 Spring Manufacturers Institute (630) 495-8588 . . . . . . . . . . . . . 64 SPX/Fenn Division (860) 594-4300 . . . . . . . . . . . . . .24 Suzuki Garphyttan (574) 232-8800 . . . . . . . . . . . . . .46 Tool King (800) 338-1318 . . . . . . . . . . . . . 13 Ulbrich Stainless Steels (203) 239-4481 . . . . . . . . . . . . . .45 United Wire Co. (847) 840-9481 . . . . . . . . . . . . . 17 Vinston US (440) 972-1098 . . . . . . . . . . . . . . .8 Vulcan Spring & Manufacturing Co. (215) 721-1721 . . . . . . . . . . . . . 44 WAFIOS (203) 481-5555 . . . . . . . . . . . . . . .6 Zapp Precision Strip (203) 386-0038 . . . . . . . . . . . . . 23

SPRINGS / Fall 2013 / 67

Snapshot

Name: Don Lowe Company name, city and country:

Peterson American Corp., Southfield, Mich.

Brief history of your company: Peterson American is a storied manufacturer of engineered metal products, celebrating nearly 100 years of manufacturing springs, coiled rings, spring stampings and wire forms for the automotive and industrial markets.

Job title: Senior vice president, sales and marketing Birthplace: Wilmington, Del. Current home: Commerce Township,

Mich.

Family: Roberta (wife), and Evan

(adult son).

What I like most about being in the industry: The diversity of the products,

the dynamics of the markets and the ability to solve problems for customers.

Favorite food: Everything that’s bad

for me.

Favorite song/musician:

My most outstanding item of importance is: Attention to detail (some see this as

Everything Beatles.

more of a fault than a quality).

Hobbies: Motor sports, baseball,

I knew I was an “adult” when:

Corvette restoration, and hunting.

Favorite places: Historic locations, particularly in southern U.S. and Italy.

A really great evening to me is:

Spent with friends and family, enjoying company and surroundings.

/ SPRINGS Fall 2013 68 68 / SPRINGS / Fall/ 2013

All the bills became mine.

©iStockphoto.com/Tryfonov Ievgenii, nicholas belton

Don Lowe Peterson American Corporation

:K\ 3DUWQHU :LWK *LEEV" 2XU 3HRSOH Aaron Alejandro Alison Alisyn Allan Allen Anderson Andrew Ben Beth Beverly Bill Bob Bradley Brandon Brian Calvin Caralee Carlos Cathy Chad Christine Claire Claudia Cynthia Dale Dan Dana Daniela David Denise Derek Diana Dick Don Duane Eric Frank Gary George Gloria Greg Heather Hector Herb Jack Jared Jean Jessica Jim John Jonathan Joyce Juan Kathy Kelly Kenneth Kenny Kevin Lisa Luanne Manuel Maribel Marie Mario Mark Matt Michael Mike Neal Pablo Pat Paul Paula Peter Ray Ricky Robert Roger Rosetta Sandy Saul Sean Shawn Steve Susan Terrance Terry Tom Tommy Travis Tricia Vern Wayne Every successful organization counts on its people. At Gibbs we have a team of dedicated employees you can count on, too. Men and women who truly care about the work they do and the customers they serve. They are really a special group and theyâ&#x20AC;&#x2122;re yours at no extra charge when you choose Gibbs.

reliable people, innovation and leading edge technology, the lowest total cost and a commitment to customer service and responsiveness beyond traditional expectations. Thatâ&#x20AC;&#x2122;s why so many leading companies have chosen to partner with us.

Since 1956 Gibbs Wire and Steel has represented a combination of excellent quality product, knowledgeable and The People You Can Rely On For Wire And Strip

ZZZ JLEEVZLUH FRP

Connecticut

Indiana

Texas

California

North Carolina

Ontario

Mexico