Springs fall 2015 vol 54 no4

Fall 2015

The International Magazine of Spring Manufacture

A Publication of the Spring Manufacturers Institute / Vol. 54, No. 4

SMI’s Metal Engineering eXpo is Here!

Full eXpo Story 22 Technology Affects Our Business in Many Ways 34 Winning the Talent Wars 47 Metal Engineering eXpo Exhibitor Preview 53 Pay it Forward, Pay it Back 33 Flashback: The Veteran and the Spring Industry 28 Hire a Vet: It Helps the Bottom Line 41 2001 Midwest Rd., Suite 106 Oak Brook, IL 60523-1335 Change Service Requested

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President's Message From Hap Porter

Ladies and Gentlemen, Start Your Engines!

Though I must profess I’m not a NASCAR fan, I do know that before the start of each race a designated individual barks out these famous words over the loudspeaker: “Ladies and Gentlemen, Start Your Engines!”

I’m told by my NASCAR-loving friends that after this big announcement takes place, the roar of 43 engines starting simultaneously can be quite deafening — so you better have a good set of earplugs!

As we approach the start of the inaugural SMI Metal Engineering eXpo, our engines are revving in anticipation of Tuesday, Oct. 20, when we cut the ceremonial ribbon to open the show. Though the roar may not be of the same deafening kind, it will be no less celebrated throughout the Charlotte Convention Center after all the hard work that has taken place over the past two years to make this show a reality.

If you are sitting on the fence about attending the show, please read carefully through this issue of the magazine and the supplement that was attached with the mailing to our readers in the U.S. and Canada.

The SMI Metal Engineering eXpo, which is a combination of an educational/technical symposium and a general trade show for our industry, is the result of a rigorous strategic planning process conducted by SMI over two years ago. The mandate for this event came from your strong membership feedback and the needs you expressed. This event is for you!

The education and technical symposia will be held over two days, Wednesday, Oct. 21 and Thursday, Oct. 22 from 8 a.m. to 10 a.m. and is divided into six specific tracks to cover a broad range of member needs. These include: business practices; manufacturing; culture, leadership and motivation; technology; business environment; and materials/testing. We have engaged a strong group of presenters and members should enjoy a world class learning experience.

We have assembled an impressive lineup of exhibitors who are ready to help expose you to new products, processes and services. I know you will want to support them with your presence and the opportunity to present your employees with some things they may not have seen before.

I want to take a moment to thank Dan Sceli, the president and CEO of Peterson Spring. Dan has served as the chairperson of our trade show committee. It has been a team effort through the many people who volunteered their time to serve time on the committee, but there’s no doubt that any outstanding effort takes place because someone steps forward to lead.

SMI has worked hard to meet the needs of our industry and we are looking forward to a great event. The only thing that will make it even better is your presence, so please consider joining us.

If you have a set of earplugs, I have no problem if you want to bring them along. After all, our goal is to make some noise in Charlotte to celebrate this great industry of ours!

SMI Executive Committee President: Hap Porter, SEI MetalTek Vice President: Mike Betts, Betts Company Secretary/Treasurer: Steve Kempf, Lee Spring Immediate Past President: Steve Moreland, Automatic Spring Products At Large: Bert Goering, Precision Coil Spring Co. Executive Director: Lynne Carr

SMI Board of Directors Tim Bianco, Iowa Spring • Mark DiVenere, Gemco Manufacturing • Simon Fleury, Liberty Spring • Ed Hall, Spring Team • Gene Huber Jr., Winamac Coil Spring • Charly Klein, Fox Valley Spring • Bill Krauss, Vulcan Spring • Don Lowe, Peterson Spring • Bill Marcum, MW Industries • Melanie Orse, Sound Spring • Jennifer Porter, SEI MetalTek • Dan Sceli, Peterson Spring • Bill Torres, Gibbs Wire and Steel • Jeff Wharin, Bohne Spring • Ted White, Hardware Products • Steve Wunder, Duer/Carolina Coil

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

Springs Magazine Committee Chair, Ted White, Hardware Products • 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 Goldberg, 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 credits: ©iStockphoto.com/kasto80, ©iStockphoto.com/sturti, molaruso/Shutterstock.com

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It’s just how we’re Proud of 80 years of service to you.

Thank you for making us your trusted source for spring, wire form and fastener manufacturing solutions. From our humble 1935 beginnings as a small local Chicago service center to now being one of the world’s largest steel wire stocking distributors, one goal has remained true — to help you bring your ideas to life.

Count on ISW for: • • • • •

A complete inventory of competitively-priced carbon, stainless and non-ferrous wire and strip More than 400,000 sq. ft. of warehousing, strategically located throughout North America Innovative logistics management services, for inventory efficiencies and cost savings Expert materials knowledge throughout our support staff Custom wire and strip services, including straighten and cut, torsion straightening, spooling, and recoiling

To learn more about our steel wire solutions, visit www.industeel.com or call us today.

© 2015 Industrial Steel & Wire Company

Come visit us at Booth #710 at the SMI Engineering Expo in Charlotte Chicago IL 800-767-0408

Houston TX 800-767-0408

Bristol CT 800-767-4792

Cleveland OH 800-767-4434

Los Angeles CA 800-767-0485

SPRINGS / Fall 2015 / 3

Charlotte NC 800-767-0089

Contents 39 61

22 50 FEATURES 22 SMI's Metal Engineering eXpo is Here!

DEPARTMENTS 41 Flashback

2 President’s Message

24 It's All About Technical Education

47 Winning the Talent Wars

7 Global Highlights

30 CTE Panel Will Examine Industry's Future Workforce

50 Diamond Wire Helps Make Grass Springs for Children's Museum of Pittsburgh Display

By Gary McCoy

33 Understand Health, Safety and Environment Issues for Your Springmaking Business

Value Analysis

By Paul V. Farrell

By John F. Dini

53 SMI Metal Engineering eXpo Exhibitor Preview

34 Technology Affects Our Business in Many Ways

COLUMNS

39 SMI Members: Consider Hosting a Manufacturing Day Event

OSHA VPP: Is It Worth Pursuing?

By Laura Helmrich-Rhodes

By Paul Menig

15 Be Aware Safety Tips

19 Dean of Springs

What You Need to Know About Stress Relieving

By Dan Sebastian

4 / SPRINGS / Fall 2015

Ladies and Gentlemen, Start Your Engines!

12 Regional Spring Association Report 61 Springmaker Spotlight

On The Move: A Profile of Phil Jones and Industrial Spring Corporation of Kansas City

By Gary McCoy

69 Book Corner 71 CTE News 73 Inside SMI 75 Committee Connection 77 New Products 79 Advertisers’ Index 80 Snapshot

Nina Fazio Williams, Diamond Wire Company

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Global Highlights North America The Engineering Society of Detroit (ESD) h a s n a med, Roy Li n k, chairman and CEO of Link Engineering Co., as the recipient of the 2015 Horace H. Rackham Humanitarian Award. This award is ESD’s highest honor. In order to receive this award, the individual must exemplify “mer itor ious tech n ica l accomplishments for the benef it of ma n k i nd on either a local, national or Roy Link international level.” Their efforts must result in “extraordinary achievements in civic, business, public-spirited or humanitarian endeavors.”

Link received a Bachelor of Science in mechanical engineering from Michigan State University in 1967, and an MBA from MSU in 1968. He worked for three years as a senior systems analyst at the former Detroit-based computer maker Burroughs Corp. before joining the family business in 1971. He became Link Engineering’s president and CEO in 1989.

After joining Link Engineering, he quickly became involved in ESD, starting with its Young Engineers Council, of which he is a past chair. Link also served on ESD’s awards committee and its nominating committee, and was treasurer and vice president of ESD before serving as its board president in 1984-85. He was named to the ESD College of Fellows in 1988, and later served on the Fellows Executive Committee. Link also is chairman of the board of the Horace H. Rackham Engineering Foundation, which has as its main mission the ongoing support of ESD. Under Link’s leadership, Link Engineering has grown into a global designer and manufacturer of test systems to simulate the actual in-service performance of vehicle components in the laboratory, including brakes, transmissions, wheels, tires, clutches, axles, bearings and other components.

The D.R. Templeman Company, a family-owned manufacturer of springs and wire forms based in Plainville, Connecticut, announced it is installing a 360panel, 111-kilowatt (kW) solar photovoltaic (PV) system

on the rooftop of its manufacturing facility. The company selected Standard Solar, Inc., a leading solar energy company specializing in the development and financing of solar electric systems nationwide, to develop the project and install the system.

The array, expected to produce 127,000 kilowatt-hours of power per year, will cover one hundred percent of the manufacturing facility’s energy needs and offset nearly 90 metric tons of carbon dioxide annually, which is equal to the amount of CO2 emissions sequestered each year by a 70-acre U.S. forest.

“As a manufacturer with a 77-year history, we realize the importance of preserving the environment. We are committed to doing our part by controlling the usage of resources in our manufacturing processes,” said Richard Williams, president of Templeman Co. “Our decision to go solar directly reflects our company values by actively promoting sustainability through the efficient use of clean, renewable resources.

Standard Solar has been extremely helpful throughout the design, application and financing processes and we are very grateful for their guidance and expertise.”

The project is being funded through an operating lease. This type of financing is designed to make the acquisition of solar affordable by combining tax efficiency with the Connecticut Zero Emissions Renewable Energy Credit Program (ZREC). The Connecticut ZREC program provides utility customers who generate their own power using zero emissions renewable processes, such as solar photovoltaics, with production based payments for 15 years, in addition to their avoided electric cost savings.

Founded in 1938, The D.R. Templeman Company is one of the region’s leading spring manufacturers. It supplies springs and wire forms to a broad market that includes medical devices, electronics, inspection instruments, alternative energy devices, electromagnetic controls, appliances, hardware, locks, hand and power tools, consumer products, packaging, fire protection equipment, jewelry, motors, pumps, valves and more.

Bill Torres, president and CEO of Gibbs Metals, has announced the promotion of Jim Mintun to the position of vice president of sales, Northeast.

A 1984 graduate of The College of Wooster (Wooster, Ohio), Mintun joined Gibbs Metals in August 1984 as an inside sales representative in Gibbs’ South Bend, Indiana facility. He has held several positions within the company including operations manager in Indiana, a brief stint in outside sales internationally in the U.K., district sales

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Global Highlights

manager in Gibbs’ Painesville, Ohio facility and as director of marketing. In the new role, Mintun will be responsible for all outside sales in the Northeast as well as the sales office at Gibbs’ New England location in Southington, CT. “Jim is very well qualified for this new position. He is a pleasure to work with and is highly respected by our employees, our vendors and our customer base,” said Torres.

Central Wire Industries, Ltd. (CWI) is excited to have Tabitha Herbst join the Union, Illinois team as sales coordinator. Herbst joins CWI after years of experience with purchasing of raw material for a very reputable spring manufacturer. She is responsible for growing spring and shape wire as well as all other CWI products. Herbst can be reached at 815-923-4927.

Vulcan Spring and Manufacturing Co., a leading designer and manufacturer of flat steel springs and related assemblies for diverse global markets, has appointed Brad Gorg to the position of applications engineer. In this role, Gorg is responsible for technical sales and engineering support in the industrial segment of Vulcan Spring’s domestic and international markets.

In making the announcement, Don Jarvie, vice president of sales and marketing, stated, “Brad’s experience and education adds an exciting amount of talent to our growing sales organization. He will help Vulcan Spring

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Brad Gorg

continue its expansion by offering our customers a level of technical support that is unsurpassed in the industry. “ Originally from the Philadelphia area, Gorg has a bachelor’s of science degree in aeronautical engineering from Embry Riddle Aeronautical University. He is also a licensed pilot. This engineering education combined with his experience in the industrial, aerospace and military segments adds significant strength to our organization, added Jarvie.

Obituaries It is with deepest sympathy that SMI announces the death of Vincent “Jim” Sacco July 11, 2015, at the age of 90.

Born in Paterson, New Jersey, Sacco worked at Little Falls Alloys for 60 years, where he served as president, and later chairman for 35 years.

A WW ll U.S. Navy veteran, Sacco leaves behind his beloved wife of 65 years, June, and daughters Jamie and Cara, as well as three grandchildren.

“Known for his fairness in all aspects of business and loyalty to his employees, Jim counted many friends in the wire and spring industries. He will be greatly missed but his legacy of friendliness and steadfast decency will endure,” said Don Fellman of Little Falls Alloys.

SMI regrets to report that Curtis J. Nicolio died unexpectedly Wednesday, July 8, at Geisinger Community Medical Center, Scranton, Pennsylvania.

Nicolio was born in Scranton, March 22, 1965, a son of Jack and Barbara (Bolash) Nicolio of Mayfield, Pa. He was a member of Sacred Heart of Jesus and Mary Parish Jermyn. He was a graduate of Lakeland High School, class of 1983; Penn State University, where he earned a degree in mechanical engineering; and Marywood University, where he earned his master’s degree in business administration. Nicolio was employed for more

Global Highlights

than 25 years with Sandvik Steel as vice president and general manager and recently became CEO of Lesjofors.

One of Nicolio’s aspirations was to retire and become a truck driver.

Nicolio, also known as “Gus” to some friends, loved more than anything to spend time with and spoil “the girls,” nieces Tiffani and Morgan.

They were the light of his life, as he

was for them. Friends remember that there was never a shortage of his quick wit and on-point dry humor.

Nicolio lived every day to the fullest by traveling the world and spend i ng t i me w it h h is fa m ily, because he believed that the best time of his life was every new day of his life. As he often said, “Well, Pop, another day shot in the arse.”

Nicolio is also survived by two sisters, Johna Sedorovitz and her husband, Ed, Mayfield; and Leann Nicolio, Peckville; a brother, Glen Nicolio, Mayfield; Curt’s companion, Stephanie Solan; two nieces, Tiffani and Morgan Sedorovitz; three aunts, Irene Romeo, Parma Baggetta and Joan Telech; and several cousins.

Services were held in Mayfield, Pennsylvania.

International Exhibitor registrations for wire 2016 – International Wire and Cable Trade Fair, and Tube 2016 – International Tube and Pipe Trade Fair, are going strong. To date, 920 exhibitors from 46 countries have reserved 630,800 square feet of exhibit space at wire 2016. The 741 companies from 41 nations at Tube 2016 occupy 516,700 square feet. Both events will he held concurrently from April 4–8, 2016 at the fairgrounds in Düsseldorf, Germany.

As in the past, countries with p a r t ic u l a rly s t r on g e x h i bit o r s participation at wire 2016 are Italy, Belgium, France, Spain, Austria, the Netherlands, Switzerland, Turkey, the UK, Sweden and Germany. A large number of registrations have also been received from overseas, including the U.S., South Korea, Taiwan, India, Japan and China. wire 2016 will feature machinery for the production and finishing of wire, tools and auxiliary materials in process engineering as well as materials, special wires and cables. It will also cover innovations in measurement, control and test engineering. The trade fair will occupy halls 9–12, 16 and 17, featuring wire, cable and glass fiber machinery, wire and cable products as well as wire and cable trade. Innovations in metal forming will be shown in hall 15 and hall 16 will house mesh welding machinery and spring making technology.

At Tube 2016, the countries with the largest numbers of exhibitors

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Global Highlights

are again Italy, the UK, the Netherlands, Austria, Switzerland, Poland, Spain, Turkey and Germany. The largest participation of overseas exhibitors are from the U.S., India, South Korea and China.

Tube 2016 covers the full range of pipe and tube manufacturing, processing, treatment and trade. The spectrum includes raw materials, pipes, tubes and accessories, machinery for the production of pipes and tubes, preowned machinery as well as tools for process engineering, auxiliary materials, measuring, control and test engineering.

The line-up also includes pipelines, OCTG technology, profiles and machinery and the Plastic Tube Forum (PTF).

Halls 1 and 2 will focus on pipe accessories, while the pipe trade and pipe manufacturing can be found in Halls 2, 3, 4, 7.0 and 7.1. As last time, the China Pavilion will be in Hall 2.

Metal forming will occupy hall 5, while halls 6 and 7a will feature tube processing machinery. Mechanical engineering and construction will be presented in hall 7a. Halls 1 to 7.0 will also include profiles for a wide range of applications. The special show PTF will be presented in Hall 7.1.

For further information on visiting or exhibiting at wire or Tube 2016, contact Messe Düsseldorf North America, 150 North Michigan Avenue, Suite 2920, Chicago, IL 60601.

Telephone: (312) 781-5180; Fax: (312) 781-5188;

Email: info@mdna.com; Visit our web site http://www. mdna.com; Subscribe to our blog at http://blog.mdna.com; Follow us on twitter at http://Twitter.com/WireTube_MDNA For hotel and travel information, contact TTI Travel, Inc. at 866-674-3476; Fax: 212-674-3477; Email: info@ ttitravel.net; www.traveltradeint.com Japan Society of Spring Engineers (JSSE) held its semiannual Lecture Meeting, including a poster session, and Annual General Meeting at the WINC AICHI in Nagoya June 12.

Eight general lectures, one research committee report and one special topic lecture were presented to 161 attendees in a hall of the WINC AICHI. The opening speech was presented

by Isao Otani, a vice-chairperson of JSSE in charge of general affairs and a managing officer of NHK Spring Co., Ltd. The titles of general lectures and presenters were: • Synthesis of Carbon Nano Coil and Its Mechanical Property, by Yoshiyuki Suda of Toyohashi University of Technology • Relation between Magnetization and Setting in Spring Steel, by Shigeo Kotake of Mie University • Analysis of Nonlinear Deformations in a Coiled Wave Spring (CWS), by Atsumi Ohtsuki of Meijo University

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Global Highlights

• Simplified Design Formulae for Contact-type Spiral Springs, by Takuro Matsumoto of Hayamizu Spring Co., Ltd. • A Trial Plan regarding the Rigidity of Cold Rolled Steel, by Masayoshi Shimoseki of Nihon University • Effects of Young’s Modulus on the Flexural Rigidity of Cold Rolled Steel, by Takuro Aiki of Hayamizu Hatsujo Co., Ltd. • FEM Analysis of Plastic Deformation caused by Microshot Peening and the Effect of Structural Refinement caused by Micro-shot Peening on Fatigue Strength, by Takaki Yokoi of Togo Seisakusho Corporation • Effects of Hardness on Improving Fatigue Limit of Steel with a Crack by Shot Peening, by Keiji Houjou of Oyama National College of Technology • Report from the Research Committee on Fatigue Limit Diagram of Compression Coil Springs,

by Hiroyuki Suzuki of Piolax Inc. and a vicechairperson of the committee The special topic lecture was “Controlled Suspension for Automobiles,” by Hirofumi Inoue of Toyota Motor Corporation.

Five technical posters were displayed in another hall of the same building. A brief explanation was given by 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’ voting. The First Place poster was “Foundation Study for Capturing Character of a Fracture Surface to Determine the Fracture Type,” by Akira Ueno of Ritsumeikan University, et al. The Second Place poster was “Improvement of Fatigue Limit of a Welded Joint by Shot Peening and Development of Quantitative Prediction Method of the Improvement,” by Ryutaro Fueki of Yokohama University, et al.

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

The meeting was led by Hideki Yamamoto, an adviser to JSSE and a vice president of Horikiri Inc. During the meeting, five proposals, 2014 Annual Business Report, 2014 Settlement of Balance Report, 2015 Annual Business Plan, 2015 Budget and Election of Trustees, were approved.

A reception was held after the annual general meeting in the same hall where the posters were displayed. Dr. Yuji Nakasone, a new chairperson of JSSE and a professor of Tokyo University of Science, made the opening speech, followed by the guest speech by Nobumichi Ohno, the chairperson of Japan Spring Manufacturers Association (JSMA) and the president of Mitsubishi Steel Manufacturing Co., Ltd. Susumu Yamamoto, an honorary member of JSSE, made a toast to the development of the spring industry and the participants’ health. n

join the best: 4-8 April 2016 Düsseldorf, Germany I www.wire.de 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 of wire 2016: the growing importance of copper wires in automotive engineering, telecommunications and electronics.

An important date in your calendar — your visit to wire 2016 in Düsseldorf!

International Wire and Cable Trade Fair

Wire, Cable, Spring Fibre Optic, Making Wire Products and Machinery

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

wir1602_84,1x237,2_US.indd 1

06.08.15 11:42

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©iStockphoto.com/Scott Hirko

Regional Spring Association Report NESMA Scholarship Fund Expands

By Ted White In March 2010, NESMA created a scholarship fund to be administered

by The Main Street Community Foundation (which administers many such scholarships). The scholarship was funded with an initial $50,000 and income generated from the seed money would be distributed in two $1,000 scholarships annually. It was the hope that this would make the scholarship fund perpetual in nature. NESMA decided if there were ever a shortfall the association would make a donation to augment the generated income.

Five years ago, NESMA was really just a Connecticut association. However, in those five years NESMA has strived greatly to live up to its name as The New England Spring & Metalstamping Association. As a result, several of the scholarship requirements had to be modified.

With help from The Main Street Community Foundation, changes to the scholarship program were spearheaded by NESMA members Lynette Nadeau of Southington Tool & Manufacturing and Scott Kirkpatrick of Radcliff Wire. The two scholarships are different in their nature, so I have highlighted the revisions separately.

Our scholarships have a much broader reach now and truly reflects that we are a New England association. For more information on NESMA, visit www.nesma-usa.com.

12 / SPRINGS / Fall 2015

Award 1: One $1,000 Scholarship Award #1 to a graduating senior attending high school in a New England state — Connecticut, Maine, Massachusetts, New Hampshire, Rhode Island, and Vermont.

(These locations were added to include the whole of New England and not just Bristol, Connecticut, as the requirements stated previously.)

Eligibility Requirements: • Pursuing post secondary education in an accredited manufacturing / mechanical skilled trades program or engineering • Evidence of successful completion of courses relevant to your chosen field (changed from needing at least a 3.0 GPA).

• Community Service • Financial need is considered Letter of Recommendation Requirements: Two letters of recommendation, one of which must be from a math or science teacher and one from someone who knows you well.

Essay Requirement: Write an essay addressing your desire to enter your chosen field and state your career goals. Limit your thoughts to no more than one page.

Award 2: One $1,000 Scholarship Award #2 to a graduating senior, currently enrolled student or student returning to school and who is a child of or grandchild of an employee or owner of a NESMA member company in good standing.

Eligibility Requirements: Pursuing post secondary education Community Service Financial need is considered Letter of Recommendation Requirement: One letter of recommendation which demonstrates work ethic in employment, academics or school / community activities.

This can be from a coach, employer, teacher or someone else who know you well.

(Changed from two letters of recommendation) Essay Requirement: Write an essay addressing your desire to enter your chosen field and state your career goals. Limit your thoughts to no more than one page.

Regional Spring Association Report ©iStockphoto.com/Scott Hirko

CASMI Holds Race Event and Golf Outing The C h icago Associat ion of Spring Manufacturers, Inc. (CASMI) was scheduled to hold its annual “Day at the Races” September 17 at Arlington Park Race Track in Arlington Heights, Illinois. The event allows CASMI members and SpringWorld exhibitors, along with industry colleagues and members of the Mid-West Fastener Association, to get toget her in a casual a nd enjoyable networking environment.

CASM I held it s a n nua l golf outing June 4 at Indian Lakes Resort in Bloomingdale, Illinois. Some of those who won prizes are pictured here.

Effective July 1, CASMI and SpringWorld have a new address, phone and fax number.

350 S. Poplar Avenue Elmhurst, IL 60126 Telephone: 630-359-4273 Fax: 630-359-4274 For more information on CASMI, visit www.casmi-springworld.org.

Pittsburgh/Ohio Spring Association Holds Summer Meeting

WCSMA Will Hold Golf Tournament and Tabletop Show

The Pittsburg-Ohio Spring Association met on July 14 and heard presentations from SMI executive director Lynne Carr and Laura Helmrich-Rhodes, SMI’s independent regulations compliance consultant.

Carr gave the nearly 25 attendees an update on the upcoming SMI Metal Engineering eXpo. She encouraged everyone to join the event in Charlotte, which will take place from Oct. 19-22, 2015 at the Charlotte Convention Center.

Helmrich-Rhodes discussed many of the top issues related to the state of health, safety and environment (HSE) for manufacturing, including the top 10 Occupational Safety and Health Administration (OSHA) violations for all U.S. manufacturing and the spring industry specifically.

She also looked at OSHA’s published agenda items, including the status of the combustible dust regulation and amputation prevention national emphasis program.

She concluded her presentation with an overview of SMI Safety Services.

The West Coast Spring Manufacturers Association (WCSMA) will hold its annual golf tournament and dinner Thursday, Nov. 12. More details on the event will be announced soon.

WCSMA has rescheduled its bi-annual Tabletop Expo to Thursday, Jan. 21, 2016 from 3 p.m. to 7 p.m. at the Holiday Inn in La Mirada, California The Expo is an eclectic mix of vendors who supply products, materials, equipment and services, and 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. Attendees will enjoy free hors d’oeuvres, a cash bar and great door prizes.

Vendors who wish to exhibit can download a registration flyer at www.wcsma.us. To keep in touch with WCSMA activities, be sure to visit www.wcsma.us. n

SPRINGS / Fall 2015 / 13

14 / SPRINGS / Fall 2015

Be Aware Safety Tips

OSHA VPP: Is It Worth Pursuing?

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

H

Connecting with one’s state consultation program ave you ever considered how you could keep OSHA from randomly knocking at your door? Do you think takes upper management commitment. Anything a state about how you might fare if an OSHA inspection OSHA consultant identifies as a serious hazard must be were to occur today? Well, OSHA is placing greater fixed. This could mean significant expenditures for your emphasis on the performance of company safety programs company.

Most companies want to find truly serious hazards that and the agency has issued a National Emphasis Initiative for amputations. Our industry now has an increased have been overlooked. If a “wall-to-wall” evaluation seems overwhelming, consider requesting a “limited visit.” This likelihood of programmed inspections.

Company management might consider stretching type of approach will “keep the blinders on” so to speak, toward something that will exempt them from programmed and allow OSHA to concentrate on a particular problem or program such as Hazard inspections, the Safety Upon receiving SHARP recognition, OSHA exempts that Communication program, and Health Achievement R e c o g n it ion P r o g r a m worksite from OSHA programmed inspections during the Lockout/Tagout program or ergonomics issues.

(SHARP). This status is Some states may a Voluntary Protection SHARP certification period. Some companies celebrate this Program (VPP) for small award by recognizing employee engagement in safety and not of fer limited visit eva luat ions. Once t he c o m p a n i e s, o b t a i n e d supervisor commitment. Sometimes a U.S. Congressman recommended changes through your state’s OSHA have been implemented, presents the SHARP flag to the company along with o n - s it e c o n s u lt a t io n . the consultant will ask SHARP recognizes small OSHA consultation and inspection officials. you if working towards business employers who operate exemplary injury and illness prevention programs. t he SHAR P status is being considered. Not every It is similar to the VPP Star and Merit awards which company who uses consultation enters the SHARP are sought by large organizations as hallmarks of safety process. After agreeing, both a safety and an industrial excellence. In the June 2015 survey of SMI members, hygiene consultant will be assigned. They each evaluate approximately 97 percent of respondents said they had less the worksite and written programs to get a sense of than 500 employees. This size is specifically the objective management commitment and the success of the safety program. A complete list of expectations can be found on of the consultation projects.

Acceptance into SHARP is an achievement status the OSHA website. that singles out a company amongst business peers as a model for worksite safety and health. Upon receiving SHARP recognition, OSHA exempts that worksite from OSHA programmed inspections during the SHARP Laura Helmrich-Rhodes, CSP, Ed.D., is an independent regulations compliance consultant certification period. Some companies celebrate this to the Spring Manufacturers Institute (SMI). A award by recognizing employee engagement in safety and former member of PA/OSHA Consultation, she supervisory commitment. Sometimes a U.S. Congressman is an associate professor in the Safety Sciences presents the SHARP flag to the company along with OSHA Department at Indiana University of Pennsylvania consultation and inspection officials. This is a big deal where she teaches graduate and undergraduate classes on topics such as OSHA standards, safety and worth a celebration! A list of the SHARP recognized communications, workers’ compensation and companies, by state, can be found on the Federal OSHA human relations. Rhodes is available for safety website. Check out companies in your area who have advice and information. Contact SMI at 630-495committed to this status.

8588 or laurahrhodes@gmail.com.

SPRINGS / Fall 2015 / 15

Certainly, the greatest drawback to this initiative is would be inspected. A reduction in penalty amounts that a company voluntarily opens itself to government can be awarded for management’s proactive approach to inspection, unlike OSHA compliance officers who could protecting employees under a “Good Faith” reduction. report you to EPA, IRS or Immigration. If an OSHA A continuous improvement approach to employee Consultant notes possible discrepancies while on-site, safety, such as the SHARP recognition, protects workers and displays concern for they are not obligated to complete federal agency Perhaps one of the many significant benefits is access to their well-being.

As a former PA/OSHA referrals. This separation highly qualified safety and industrial hygiene professionals consultant, I can suggest of c on s u lt a t ion a nd free of charge. The objective of the OSHA State a few things to consider compl ia nce of f ices shows OSHA’s sincerity Consultation Programs is to help companies who ordinarily before opening the doors to a government agency. in improving employee would not hire a full-time safety professional due to cost. First, obtain an OSHA safety and health. standards checklist and Perhaps one of the many significant benefits is access to highly qualified conduct an in-house wall-to-wall mock inspection of safety and industrial hygiene professionals free of charge. your own. Assign portions of the list to department The objective of the OSHA State Consultation Programs managers, and possibly the safety committee. If many is to help companies who ordinarily would not hire a physical hazards are present, determine why those exist full-time safety professional due to cost. In a June 2015 and address the causes.

A second consideration is the written program portion survey of SMI members, over 68 percent said they do not have a full-time safety manager, making the free service of the safety efforts at the facility. Are the required written programs in place and are they used? A tried and true a worthwhile consideration.

A company participating in the SHARP program audit tool that OSHA continues to offer on their website is would have very few, if any, serious violations if an OSHA the Program Evaluation Profile (PEP). This is an excellent inspection were to occur. A formal employee complaint, rating measure. If the score seems low, then set goals for death, any amputation, loss of an eye or accident requiring improvement. Work on deficient areas to increase the hospitalization are reasons that an exempt company score. Any employer, regardless of size or maturity of their safety program, should use this type of assessment to measure the impact of their safety efforts.

Whether using the tools suggested above, or hiring a safety and health consultant to conduct a preliminary “mock” inspection, reaching for inspection exemption status is a worthwhile consideration. Positive interactions with OSHA can go a long way, and in the words of management guru Peter Drucker, “If it’s not measured, it doesn’t get done!” n

Useful Links SHARP program description https://www.osha.gov/dcsp/smallbusiness/sharp.html List of state consultation programs https://www.osha.gov/dcsp/smallbusiness/consult_ directory.html Program evaluation audit tool https://www.osha.gov/dsg/topics/safetyhealth/pep. html#f195 https://www.osha.gov/dcsp/smallbusiness/sharp_sites. html

16 / SPRINGS / Fall 2015

Thank you for attending

SpringWorld® 2014

Over 2,700 Spring Industry Professionals were in attendance.

SpringWorld provides a unique opportunity to network with other spring manufacturers and wire formers: •

The premiere spring show since 1960.

•

A global showcase for suppliers to the spring and wire form industry from 15 countries.

•

See the newest technology available to improve your productivity, quality and service.

•

One-on-one discussions with others who share your concerns offering new insights for your business.

•

Attend free educational seminars offered by exhibitors on the show floor.

We’ll see you again for

SpringWorld® 2016 www.casmi-springworld.org

October 5-7

Donald E. Stephens Convention Center Rosemont, IL SPRINGS / Fall 2015 / 17

Visit us at SMI Metal Engineering Expo Booth #310

18 / SPRINGS / Fall 2015

Dean of Springs

What You Need to Know About Stress Relieving

By Dan Sebastian

S

tress reliving is one of the single most important things that a springmaker must understand. Too many springmakers go through the motions in cookbook like procedures without a basic knowledge of why and what is happening.

Metallurgy 101 All metals are bound together by electronic bonds between the elemental molecules. This force is like a spring in its unloaded state and generally occurs with the molecules aligning in some form of cubic structure.

When we stretch, compress Basic Structure or twist a metal, the forces act (Body Centered Cubic) like microsprings pulling or twisting the metal back into its original shape. If we exceed the elastic limit or the torsional a yield point, we force the metal to take a permeant set with the energy (force) we use to bend a a or twist it into shape. Some of the energy is dissipated in the form of heat (that’s why springs are hot when we coil them), while the rest of the energy is stored in the metal by stretching the electronic bonds (microsprings) that bind the material together. The extra energy stored is a residual stress. In the process of making a spring we bend, twist, stretch, compress, twist or it can be some of those things or all of the above, to get the spring looking like we want. The problem is the stored energy (residual stress) is often in a different direction than the way we are going to use the spring, which makes the residual stress bad for the spring.

In a few cases, residual stresses from forming can enhance the spring’s performance. When we set out a spring we put in residual stresses that are opposite in direction to the compressive stresses, so the result helps us. If we put in 10,000 psi residual stresses from setting out a spring, when we subject it to what we would calculate as 100,000 psi, the spring actually is experiencing only 90,000 psi because of the 10,000 psi residual stress. The same is true in torsion springs if we only stress them in the direction of forming.

Before Forming

After Forming with Residual Stress Added

a

a

a

a

a

a

In the case of materials like music wire or other materials that get their strength from cold forming (most stainless steels), we force the residual stresses in a longitudinal direction along the axis of the wire which is opposite to the forces of a helical spring, so they add to the strength and are beneficial residual stresses.

Why We Stress Relieve and How it Works Stress relieving is the process of heating up a spring to a temperature that allows the negative residual stresses to be dissipated. In stress relieving we are trying to have the temperature match the amount of energy in the residual stresses. When we reach that equilibrium temperature, the stored stresses are transferred to the heat sink sounding it.

It is like a boat in a lock; when the water level is the same on both sides of the lock, the boat can sail away. Similarly, when the temperature and the stress are the same the stresses are relieved. All that said, it is sometimes difficult to determine the exact right temperature. The recommended or historical temperatures we use, are usually sufficient in most cases to relieve the stresses. Keep in mind the actual perfect temperature for a spring with an index of three is marginally different than a spring with an index of 12.

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

SPRINGS / Fall 2015 / 19

Stress relieving usually does not create a metallurgical change in the basic material structure. The perfect stress relief would be when the hardness is just starting to change, because at that time a metallurgical change in the material structure is in a stable condition. In the case of material like music wire, hard drawn MB, or some stainless steels, the stress relieving temperature is a compromise between what will minimize the negative bending and torsional stresses and the highly directional stress from the wire making process.

We can actually see that stress relieving is working in carbon steels because the diameter of a spring gets smaller between coiling and stress relieving. In the case of austenitic stainless steels (300 series), the diameter actually gets larger because the basic metallurgical structure is changing to a martensitic structure (which is larger in cubic size) from an austenitic structure. It is also why it exhibits magnetic proprieties.

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Is Time Critical?

Another important aspect of stress relieving is the amount of time that is required. It is principally an energy related event, so temperature is paramount but time is also important. It is critical that sufficient time for the entire part, including the core, reach the critical temperature. The more densely packed the springs, or the faster the belt speed in continuous ovens, can serve as an insulator preventing all the spring and springs in the load from reaching temperature. A good rule of thumb is that the core of the part or load should be at set temperatures for between two to five minutes. Moving parts through the oven too quickly will result in under stress relieved parts, which can impair the spring performance.

The time between forming and stress relieving can also be a critical factor, especially when dealing with high strength materials. Chrome silicone based materials are known to fracture if not stress relieved in a timely manner (no more than one hour on regular tensile and much less on high tensile versions). The wire manufacturing practice (method and time of tempering) can affect the sensitivity to cracking post forming.

Summary Stress relieving is a simple, basic process that in most cases allows a spring to function as designed. It is critical to the process. So like any properly designed manufacturing process, it should be monitored with statistical process to assure product integrity. There are a number of methods that can be used, from temperature measurements, belt speeds, change in diameter, amount of set a spring takes, and others.

It is both temperature and time dependent, so it is important to monitor and control both. n

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SMI’s Metal Engineering eXpo is Here!

by Gary McCoy

Highly Anticipated Event Promises Unparalled Information and Training Watching, Waiting. Wondering.

SMI Thanks its Sponsors The SMI Metal Engineering eXpo would not be possible without the generous support from its sponsors.

Industrial Steel & Wire Visionary Sponsor American Spring Wire Gibbs Wire InterWire Products Suzuki Garphyttan Platinum Sponsors WAFIOS Machinery Corp.

Gold Sponsor Central Wire RK Trading Bronze Sponsors

22 / SPRINGS / Fall 2015

Those words all describe the feelings of many in the spring and metal forming industry as the launch of the inaugural SMI Metal Engineering eXpo is now just a short time away. The event will take place from Oct. 19-22, 2015 at the Charlotte Convention Center.

Uniquely designed as a combined educational/technical symposium and a general trade show for the spring and metal forming industry, the genesis of the event all started because of a rigorous strategic planning process conducted by SMI more than two years ago.

“The mandate for this event came from strong membership feedback we received at our meeting in Tucson in 2013 during the strategic planning exercise we went through,” said Hap Porter,

SMI president. “We listened to the needs expressed there by our members. The show is the culmination of a lot of hard work on the part of SMI staff, volunteers and Tradeshow Logic, the company we hired to help manage the show.”

This issue of Springs serves as an introduction to the show.

You’ll find plenty of details on the technical symposia, which will be held over two days, Wednesday, Oct. 21 and Thursday, October 22 from 8 a.m. to 10 a.m., and is divided into six specific tracks to cover a broad range of member needs. These include: business practices; manufacturing; culture, leadership and motivation; technology; business environment; and materials/testing.

You will find detailed listings of all the presentations you and your employees would like to attend starting on page 25. We also have special reports on the HSE session with SMI’s Laura Helmrich-Rhodes, and the panel of springmakers who will look at career technical education and how it can impact the workforce of tomorrow in the industry.

“We have engaged a strong group of presenters and members should enjoy a world-class learning experience,” explained Porter. “When you combine all the sessions, it is 24 hours of training that is specific to our industry.

Where else can you get this type of valuable information?”

The trade show, which will take place over three days, features exhibitors from multiple areas including coiling, grinding, ovens, shot peening, testers, inspection, wire suppliers and many more.

There’s also helpful section on page 53 that provides booth numbers and a description of each company that will be exhibiting at the eXpo. Go to our show website to see the latest floor plan and list of exhibitors who will be there: www.metalengineeringexpo.org/ exhibit/2015-floor-plan/ The host city for the eXpo, Charlotte, has a thriving downtown area where the Convention Center is located.

Within walking distance of the Convention Center are many hotel and dining options.

If you are NASCAR fan, you won’t want to miss the reception we are holding from 6:30 p.m. to 9:30 p.m. Wednesday, October 21 at the NASCAR Hall of Fame that features NASCAR legend Dale Jarrett. Tickets are required for this event and will sell out quickly.

“I hope to see many SMI members in October,” said Porter, “because SMI has worked hard to meet the needs of our industry and we are looking forward to a great event. “ All registration, hotel and educational session details for the SMI Metal Engineering eXpo are available at the official website for the show, www. metalengineeringexpo.com. n

Don't Forget....

Get Your Hotel Reservations If you are coming to the eXpo, you will want to make your hotel reservations right away.

The Westin Charlotte Hotel is conveniently located right next door to the Charlotte Convention Center, and is the headquarters hotel for the SMI Metal Engineering eXpo. In addition to the Westin Charlotte, please consider staying at one of the Metal Engineering eXpo 2015 official hotels: • Aloft Charlotte Uptown @ the EpiCentre • Hampton Inn Charlotte Uptown • Hilton Charlotte Center City • Hilton Garden Inn Charlotte Uptown • Hyatt Place Charlotte Downtown • Sheraton Charlotte Hotel All hotels are within a four or five block walking distance to the convention center. Transportation is not provided. The Metal Engineering eXpo 2015 housing cutoff date is Sept. 22, 2015.

Hotel space may be available after that date, but is not guaranteed.

Don't Miss These Events An opening reception will be held on the show floor of the SMI Metal Engineering eXpo Tuesday, Oct. 20 from 5 p.m. to 6:30 p.m.

Through the sponsorship of Industrial Steel & Wire, SMI will hold a reception Wednesday, Oct. 21 at the NASCAR Hall of Fame, which is adjacent to the Charlotte Convention Center.

The three hour reception from 6:30 p.m. to 9:30 p.m. will feature an appearance by NASCAR legend Dale Jarrett. Tickets are required for this event.

“SMI shares in the excitement of launching our new Metal Engineering eXpo in Charlotte, in the heart of NASCAR country,” said SMI president, Hap Porter. “The opportunity to visit the NASCAR Hall of Fame and meet Dale Jarrett is a wonderful opportunity not to be missed.”

SPRINGS / Fall 2015 / 23

SMI Metal Engineering eXpo

SMI Metal Engineering eXpo Schedule

Monday, October 19 2 p.m. to 6:00 p.m.

Registration

Tuesday, October 20 6:30 a.m. to 6:30 p.m.

10:30 a.m. to 11 a.m.

11 a.m. to 6:30 p.m.

5 p.m. to 6:30 p.m.

Registration Ribbon Cutting and Exhibit Floor Grand Opening Exhibit Hall Open Welcome Reception (Exhibit Hall Floor)

Wednesday, October 21 7 a.m. to 5:30 p.m.

8 a.m. to 8:50 a.m.

9 a.m. to 9:50 a.m.

9:50 a.m. to 10:30 a.m 10:30 a.m. to 5 p.m.

5 p.m.

6:30 p.m. to 9:30 p.m.

Registration Technical Symposia – Six Tracks (a complete listing and description of each session can be found on page 25) * Business Environment * Business Practices * Culture/Leadership Motivation * Manufacturing * Materials and Testing * Technology Technical Symposia – Six Tracks * Business Environment * Business Practices * Culture/Leadership Motivation * Manufacturing * Materials and Testing * Technology Break Exhibit Hall Open Open Supplier Night NASCAR Hall of Fame Reception with special guest Dale Jarrett (ticket required)

Tuesday, October 22 7 a.m. to 3:30 p.m.

8 a.m. to 8:50 a.m.

9 a.m. to 9:50 a.m.

9:50 a.m. to 10:30 a.m 10:30 a.m. to 3 p.m.

3 p.m.

24 / SPRINGS / Fall 2015

Registration Technical Symposia – Six Tracks (a complete listing and description of each session can be found on page 25) * Business Environment * Business Practices * Culture/Leadership Motivation * Manufacturing * Materials and Testing * Technology Technical Symposia – Six Tracks * Business Environment * Business Practices * Culture/Leadership Motivation * Manufacturing * Materials and Testing * Technology Break Exhibit Hall Open Meeting Concludes

SMI Metal Engineering eXpo

It's All About Technical Education SMI’s Trade Show committee, with extensive help from the Technical Education committee, has put together 24 hours of technical education sessions for the SMI Metal Engineering eXpo. Called the Technical Symposia, the event features two days of technical education sessions spread out over six tracks on Wednesday, October 22 and Thursday, October 23. The one hour sessions will be held from 8 a.m. to 8:50 a.m. and 9 a.m. to 9:50 a.m.

To help you plan your time during your trip to Charlotte, we have included sessions under each track with a description and speaker bio.

Business Environment Track Wednesday, October 21, 8 a.m.

Steel Industry Overview John Anton, Director, Steel Service, IHS

Join us for an overview of what’s happening in the global steel industry and market.

We’ll discuss what to expect in the future and the probable impact on SMI members.

Anton is the primary ferrous metal analyst of the IHS pricing and purchasing service.

As head of the steel team, he oversees the analysis of production, demand, and prices for all ferrous products, along with raw materials such as iron ore and scrap.

The client base of steel buyers includes companies with steel purchases ranging from $10 million annually to $10 billion.

Anton joined IHS in 1995. Prior to that time, he was in the private practice of law, specializing in small business representation and in criminal defense work. Before attending law school, Anton worked at the

United States Department of Labor, Bureau of Labor Statistics, as an economist/statistician.

9 a.m.

Terms and Conditions of Sale – Pitfalls Gary Carboy, Shareholder, Cowles & Thompson, PC

“Terms and Conditions of Sale” is an area of potentially high exposure for companies that are not paying close attention. In this forum attorney Greg Carboy, a partner of Cowles & Thompson, who has extensive experience in product litigation, will lead a discussion regarding some of the most serious pitfalls that all suppliers need to consider when entering into an agreement to supply parts or materials.

As a shareholder in the tort, insurance and commercial litigation sections of Cowles & Thompson, Carboy focuses his practice in the areas of product liability, commercial litigation and transportation. He has over 25 years of experience representing corporate clients in a broad array of matters, including aviation product liability defense, coordination of the national defense in product liability claims, defending wrongful death actions, prosecuting and defending contractual disputes, contract negotiations and federal civil/seizure and forfeiture cases.

Thursday, October 22, 8 a.m.

Economic Update Tim Quinlan, Economist, Wells Fargo & Company

What’s next for the global and North American economies? Join us as economist Tim Quinlan shares his thoughts on what’s coming down the pike.

Quinlan is a vice president and economist with Wells Fargo Securities. Based in Charlotte, N.C., he provides analysis on the macro U.S. economy and major foreign economies. Domestically, he covers industrial production, manufacturing, and business investment spending. His international efforts concentrate on Japan, Canada, Korea, and Australia. Quinlans’s work has been published

in academic economic journals and his comments on the economy regularly appear in The Wall Street Journal, the New York Times and USA Today. He is also a frequent guest on National Public Radio.

9 a.m.

Steel Industry Overview John Anton, Director, Steel Service, IHS

(repeat of Wednesday, October 21 session)

Business Practices Track Wednesday, October 21, 8 a.m.

The State of Health, Safety and Environment Dr. Laura Helmrich-Rhodes, Independent Regulations Compliance Consultant, SMI

Meet SMI’s new regulatory consultant Dr. Laura HelmrichRhodes, CSP and take an in-depth look at the top 10 OSHA violations specifically for this industry. She will also review OSHA’s emphasis on amputation prevention. Resources for determining if you have combustible dust will be given. Her presentation is interactive and you are certain to learn something new. (Read more about this session on page 33.)

Dr. Rhodes, CSP is a board certified safety professional by examination through the Board of Certified Safety Professionals. Dr. Rhodes has a Bachelor of Science degree in Safety Sciences and a masters of arts in Industrial & Labor Relations both from Indiana University of Pennsylvania, home of the first accredited undergraduate safety program in the U.S. Her doctorate is in higher education administrative and policy studies from the University of Pittsburgh where her dissertation focused on the intersection of human resources and safety professions. Dr. Rhodes has been working with SMI since the summer of 2014.

SPRINGS / Fall 2015 / 25

SMI Metal Engineering eXpo 8 a.m.

Career Technical Education – What are the Options?

Moderator: Al Mangels, President, Lee Spring; Panelists: John Bagnuolo, COO, MW Industries; Mike Betts, Chairman & CEO, Betts Company; and John Dellalana, President, Rowley Spring & Stamping.

All companies in the metalforming industry need to develop more and better skilled employees. Join us as Mangels a panel of executives from four spring companies, based in different regions of the U.S., discuss options and alternatives for achieving this Bagnuolo important objective. (Read more about this session on page 30.)

Mangels is president of Lee Spring Company, a global Betts manufacturer of mechanical springs and related products that has had is headquarters in Brooklyn, New York since 1918. Mangels started at Lee Dellalana Spring in 1983 in production control and during his thirty plus year career at the company he has worked in manufacturing engineering, design engineering and management system integration until ultimately becoming president in 1999. Since then, Mangels has become well versed as a champion of continual improvement activities such as total quality management, lean manufacturing and business process re-engineering, and has seen the company grow to five facilities in the United States as well as having locations in Mexico, China, India and the United Kingdom.

Bagnuolo joined MW Industries in September 2013. He has more than 30 years of experience leading businesses around the world, including 15 years of P&L responsibility. His international experience includes managing businesses in the UK, Germany, France, Italy, Belgium and China.

He has a strong background in strategy development and process improvement. He successfully served in senior management roles at Rexam Healthcare, Chicago Metallic Corporation, Johnson & Johnson, Indalex Aluminum Solutions, and ITT. Bagnuolo also

26 / SPRINGS / Fall 2015

spent six years with the Danaher Corporation serving in two senior operating roles with VideoJet and Gendex/Kavo companies and two years as the corporate director of the Danaher Business System.

Betts is CEO and chairman of the board of Betts Company. For over 147 years and during six generations of continuous family ownership, Betts Company has innovated and provided products, services and expertise to help move vehicles, products and people productively and safely. Betts is active in community and industry advocacy, with current board assignments on the Fresno Business Council, Spring Manufacturers Institute, Lyles Center Advisory Board and the Center for Advanced Research and Technology.

Dellalana is president of Rowley Spring and Stampings in Bristol, Connecticut. He has spent his career in manufacturing, engineering and continuous improvement roles. He worked as operations director for Allied Signal, and vice president of integrated operations at DRS Technologies before joining Rowley in 2013. He has an electrical engineering degree from Penn State and an MBA from Rutgers.

9 a.m.

Improve Employee Wellness Sarah Szul, Wellness Consultant, Kapnick Insurance Group

This presentation will focus on performancebased wellness for small business. Learn what you can do to help reduce your company’s health care costs.

In her positions within Kapnick Insurance Group’s Wellness Department, Szul has worked with clients to help them develop a customized wellness strategy that will enable them to control rising health care costs while building a healthier, more productive work force. Several of her clients have won awards for their wellness programs, including the Best & Brightest in Wellness and the Healthiest 100 Workplaces in America. In addition to her work with clients, Szul has been a speaker at various conferences and seminars (MISHRM, Construction Safety Day, Assurex Employee Benefits Conference).

Culture, Leadership & Motivation Track Wednesday, October 21, 9 a.m.

How to Hire the Best Mark Lee, Owner, Management Solutions, LLC

Selecting the best job applicant isn’t always easy. In this session, human resources expert Mark Lee will share best practices in hiring. Leave with a better understanding of how to screen applicants to make sure you end up with the hire who is the best possible match for the job—and for your company.

Lee brings more than 25 years of sales and management experience to provide his clients with practical solutions to peoplerelated issues. His strong interest in the employee assessment and organizational development field stemmed from witnessing companies’ inability to identify and utilize effective tools to select, hire, and promote employees to positions that were a strong fit. Lee’s business-to-business success with companies – from small owner-operated firms to Fortune 500 companies – offers the expertise to assist you in solving your organization issues.

Thursday, October 22, 8 a.m.

Become a Better Leader David Wheatley, President, Humanergy

Expert David Wheatley shares insights that will help you maximize your leadership potential. Learn to develop your skills, perform better and improve customer service strategy. Leave with practical tips you can put into practice right away—or use to coach your team members.

Wheatley works with managers, 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 teams within manufacturing companies and credit unions.

Originally from Leeds, England, Wheatley is a former Scotland Yard police officer.

He is co-author of “50 DOs for Everyday Leadership: Lessons Learned the Hard Way (So You Don’t Have To).”

SMI Metal Engineering eXpo Manufacturing Track Wednesday, October 21, 8 a.m.

How to Have It All: Quality, Cost, and Performance Paul Menig, CEO, Tech I-M

Manufacturing expert Paul Menig says it is possible to have quality, cost and performance without having to make a trade-off. This session delves into examples of advanced manufacturing techniques used in other industries and related metalforming industries. Menig will review these examples to identify opportunities for improvement in our own industry. Learn integrated and automated solutions for the complex process of “Order-entry-to-cash-from-a-satisfiedcustomer” that your people can support.

As an in-trapreneur at Daimler, Eaton and General Electric, Menig has spent his entire career leading teams to create, develop and support high-tech products for multiple industries. His teams have worked on breast

scanners, cardiac monitors, self-guided bombs, nuclear reactors, programmable logic controllers, sensors, semiconductor processing equipment, radar systems, engines, transmissions, brakes, telematics and human interface devices. Through experience, Menig has learned “savvy technology” — the right technology, at the right time, applied properly — creates powerful results.

Thursday, October 22, 8 a.m.

Machine Set-Up: Coil & Grind Martin Dorn, CEO, G + M Dorn Drahttechnologie, and Carl Atwater, President, A.I. Technology, Inc.

Dorn

Atwater

This symposium will identify best setup practices for both coiling and grinding machines — then provide tips and ideas on how to automate either or both of these operations with one another. The critical characteristics of coiling setups will be scrutinized, teaching attendees how to

optimize each step to facilitate a defect-free and efficient grinding process. Next they will identify potential efficiencies that can be achieved in the grinding process, as well as talk about options for automatic feeds and other automation.

Dorn joined with his brother and father in 1988t to start G+MDORN, which is located in the heart of Germany’s spring industry.

They service the spring industry with grinding wheels and other technical equipment. Being a mechanical engineer he started to design his first Dorn grinders and G+MDORN focused completely on spring end grinding machines.

Atwater is president of A.I. Technology, a partnership between Carl and Alicia Atwater and Itaya Engineering Ltd. since 1997. He started making springs at Peck Spring in Connecticut in the 1970s.

He has worked with Itaya since 1984.

A.I. Technology is the agent for Gasden Ro ovens, Dorn Grinders, MicroStudio Testing Instruments and Spring Tooling Ltd.

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SMI Metal Engineering eXpo 8 a.m.

How to Have It All: Quality, Cost, and Performance Paul Menig (repeat of Wednesday session)

9 a.m.

Repeatability and Reliability…

It’s All in the Setup TBD

Presentation of best practices in setup for repeatability, speed and accuracy for slide forming machines. The session will also include an open forum section for those interested with questions and or ideas.

Presented by Keats Mfg. with cooperation of PMA forums on the subject as well.

Materials & Testing Track Wednesday, October 21, 8 a.m.

Update: Stainless Steel Shawn Chaney, Product Manager, Fort Wayne Metals

More medical devices are made from stainless steel than all other materials

combined. Device designers select stainless for its ideal balance of strength, corrosion resistance, mechanical properties and cost.

Applications include guide wires, catheters, staples, endoscopic devices, tools and a variety of coiled products. Join us for a discussion of the various grades and tempers for medical coil winding applications. Leave this session with an understanding of the material characteristics that result from the various melting methodologies, inclusion distribution and the resulting fatigue endurance limits.

Chaney is the product manager for non-medical applications at Ft. Wayne Metals Research Corp. in Fort Wayne, Indiana. Chaney has over 20 years of metals experience in the medical device, automotive, and power generation industries. He has co-authored technical papers and industry specifications in reference to metals and metals testing for organizations such as ASTM and ASM. His roles at Ft. Wayne Metals over the last decade have included the materials testing laboratory manager and product manager.

Ready, to Roll, Reel Time.

28 / SPRINGS / Fall 2015

9 a.m.

Update: Coatings Gary Orosz, Applications Process Manager, PPG Industries, Inc. and Dr. Anthony Chasser, Senior Research Scientist, PPG Industries, Inc.

Here’s your chance to get up-to-date on coatings. The discussion will detail the differences between various Orosz paint coatings, including a comparison of the strengths and weakness of each. They will also outline proper application and processing. Presented by PPG Industries.

Orosz is an applications process manager with PPG Industries, Inc. with over 20 years of experience in the electrocoat industry.

During his career at PPG, he has spent time as a technical service representative, product specialist and equipment specialist.

In his current role, he is responsible for the successful integration of PPG’s electrocoat products into industrial finishing systems and equipment. This process includes the generation of system design specifications, engineering reviews, cost justification, R&D pilot system design and testing, and training to end

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SMI Metal Engineering eXpo users of electrocoat. He is on the board of directors for The Electrocoat Association.

As senior research scientist at PPG Industries, Dr. Chasser is responsible for introducing new chemistry to PPG’s commercial markets. He’s also involved in product development and intellectual contributions in silicone, epoxy, acrylic, polyester, rubber, polyurethane, polyurea and latex chemistries. Dr. Chasser has commercial experience, patents and technical expertise in powder coatings, water and solvent based coatings, bio-based resin development, inks, adhesives and 100 percent solids coatings.

Thursday, October 22, 9 a.m.

Metrology: Load Vector Analysis Larry Sheiman, Managing Partner, DtechXion Ltd (SAS)

This session will explore the latest trends in load testing capabilities including Load Vector Analysis. Discuss the benefits of utilizing these capabilities for your company and your customers. Presented by SAS Technologies.

Sheiman has spent 12 years as managing partner of DtechXion Ltd (SAS Inc.), with a main focus in spring force and optical geometric testing machines for both quality rooms and on-the-floor production testing.

Technology Track Wednesday, October 21, 8 a.m.

Additive Manufacturing (Rapid Prototyping) – Today and in The Future Todd Grimm, Founder and President, T.A. Grimm & Associates, Inc.

In his session, Grimm will explore the present and future of additive manufacturing (rapid prototyping) which will include a presentation on current materials and applications.

Grimm is 24-year veteran of the additive manufacturing/3D printing industry. From his work as a consultant, writer, author, speaker, editor and advisor, he was named

by The TCT Magazine as one of the 20 most influential in the additive manufacturing (AM) industry. Grimm is president of T. A. Grimm

& Associates, an additive manufacturing consulting and communications company. He sits on the board of directors of ARC Group Worldwide. He is also a columnist for The TCT Magazine and author of “User’s Guide to Rapid Prototyping.”

9 a.m.

Software Integration to Manufacturing Richard Dignall, Design Service Manager, Institute of Spring Technology

Hear Richard Dignall present his findings on integrating computers or CNC equipment with ERP systems. The discussion will include advantages, challenges—and feasibility.

Dignall joined IST in August 2005. After earning a degree in mechanical engineering, he took an unusual career path into sports engineering with a PhD on tennis balls, before returning to programming (which had always been an interest). He makes use of his engineering knowledge and programming skills to develop IST’s spring design software, test machine software and other projects.

Richard is also IST’s IT manager, looking after all things computer-related.

Thursday, October 22, 8 a.m.

Update: Residual Stress Dan Sebastian, Technical Consultant, SMI

Join us for a presentation on the preliminary findings of an SMI-sponsored project to identify a more cost-effective means for companies to use basic metallurgical tools to verify that parts have been properly stress relieved. The data for this study will be measured in micro hardness and confirmed with x-ray defraction technology. This study will help to establish new guidelines governing the temperature and time required for adequate stress relief.

Presented by: Dan Sebastian, SMI technical advisor, with input from the following SMI member companies: ASW, Gibbs, PAC, Liberty Spring, Associated Spring, Precision Coil Spring, and MW Industries.

Sebastian has had a 47-year career in the spring industry. He retired as the CEO of MW industries where he and his team rebuilt a former financially challenged subsidiary of Rockwell International into the largest producer and distributor of springs

in North America. He has also served as the past president of the Spring Manufacturers Institute, where he also served on the executive committee, board of directors, and as chairman of the technical committee.

In addition to his business and engineering career he has served on the faculty of corporate training groups and at community colleges.

8 a.m.

Software Integration to Manufacturing Richard Dignall

(repeat of Wednesday, October 21 session)

9 a.m.

The Effects of Shot Peening Dave Breuer, Director of Sales, North America – Metal Improvement Company, Curtiss-Wright

Learn the results of a study on the effects of shot peening on highly stressed, low fatigue cycle springs. Findings will be presented as fatigue life studies and as correlations to X-ray Diffraction results on study samples. This study will become the basis for a future SN curve to more accurately predict fatigue for high tensile chrome silicon springs with life expectancies of less than 10^5 cycles.

Breuer started with Curtiss-Wright: Metal Improvement Company in 1997 as a technical sales manager for the Milwaukee division. In 1999, Breuer moved on to a regional sales manager role. In 2002, he completed the Eighth Edition of “Shot Peening Applications,” which is the most widely read technical book on shot peening in the world. In 2013, Breuer was promoted to director of North American sales where he works with over 30 different profit centers promoting both shot peening and solid film lubricants.

9 a.m.

Additive Manufacturing (Rapid Prototyping) – Today and in The Future Todd Grimm

(repeat of Wednesday session)

n

SPRINGS / Fall 2015 / 29

SMI Metal Engineering eXpo

CTE Panel Will Examine Industry's Future Workforce

T

ravel around the spring industry and ask leaders what are among the greatest challenges they face as a company and most will quickly reply: “How to replace a talented workforce that is graying and will be retiring soon.”

Ideas for finding the next generation of workers for the spring industry will be among the topics discussed by participants in the SMI Metal Engineering eXpo session, “Career Technical Education – What are the Options?” The session is part of the business practices track and will take place Wednesday, Oct. 21, from 8 a.m. to 8:50 a.m.

The session will be moderated

by Al Mangels, president of Lee Spring in Brooklyn, New York. The panelists who will join him are John Bagnuolo, chief operating officer, MW Industries, Rosemont, Illinois; Mike Betts, chairman and chief executive officer, Betts Company, Fresno, California; and John Dellalana, president, Rowley Spring & Stamping, Bristol, Connecticut.

Dellalana says among the goals for the session on career technical education (CTE) are: 1) Identify the importance of workforce issues for manufacturing companies, specifically in the spring industry, at the present time as well as into the foreseeable future; 2) Describe the current state of workforce issues, based on the experiences of the panelists and any other comments that might be garnered from those attending; and 3) Provide whatever guidance to those attending on how they might address workforce and CTE issues for their specific company going forward.

30 / SPRINGS / Fall 2015

To achieve these goals, panelists will be asked various questions about the state of CTE in their region of the country. The goal is for the session to create dialog between the panelists and those in attendance.

The Need “Having a quality, work-ready local pipeline of talented applicants is critical to our future success,” explained Betts of his company’s workforce needs. “For the past three to four decades, our education

Betts will talk about some of the CTE efforts that are taking place in the Fresno area where Betts Company is located.

Dellalana will focus his remarks on the educational partnership that Rowley Spring and Stamping has developed with the Bristol Adult Education Center (BAEC). Last year the two entities launched the AEDAC (Adult Education Diploma and Certificate) program.

AEDAC is a GED/Skills in Manufacturing Certificate Program open

"Almost every equipment provider is searching for ways to reduce dependence on workers with 30-plus year of experience, not because there is a lack of appreciation for the value that experienced workers bring to the workplace, but because there is a shortage of these workers in the spring industry. As the talent pool shrinks, the right balance between technology and skills in the workforce needs to be found to be prepared for the future.” system in the U.S. has not supported career and technical education (CTE) programs in our high schools and colleges.”

Betts says this lack of support has resulted in not meeting the needs of advanced manufacturing businesses.

“Many programs that do exist today are underfunded and not supported with the latest equipment and appropriate instruction,” Betts went on to say. “Today’s multifaceted work environment requires our employees to have multidimensional capabilities and capacity, where in years past singular capability may have sufficed. Today’s work environments require our associates to work on teams where communication and interaction capabilities are equally important as technical capability.”

to adult learners at BAEC. This program is a partnership between BAEC and Rowley Spring and Stamping, which are located in the same building. This scenario creates a perfect logistical and collaborative setting for academic and hands-on training to create a strong and successful program. AEDAC targets adult learners and opens the door for many adults who do not have the financial capability to go back to school.

“AEDAC provides 50 hours of hands-on training on our manufacturing floor and an additional 70 hours of classroom training at the Adult Board of Education,” explained Dellalana. “The students get training on spring machines, quality and metrology, and fourslide machines.

We have hired four graduates from the program here at Rowley.”

SMI Metal Engineering eXpo Dellalana will discuss the program and the early success it has generated. Over 100 manufacturers are located in the Bristol area and many of those make springs and wireforms.

These companies, in order to continue to prosper, need a skilled labor force to replace their aging skilled-employee base. Local and state governments are being asked to address this issue. The Bristol Board of Education with its community partners is taking progressive steps to meet the needs of its students as well as the needs of its community.

Recruiting the Next Generation Bagnuolo wrote an article for the Winter issue of Springs on the “Spring Factories of the Future.” He says that much of what he wrote in the article will frame his remarks during the session in Charlotte.

He stated in the article that spring companies who rely solely on technology to create a competitive advantage will find that “everyone has access to the same machines and technology.”

As he points out, “The true measure of a successful spring factory in the future will require a more balanced approach.”

“Specifically, the need for skilled workers to operate the equipment will continue to drive productivity.

Almost every equipment provider is searching for ways to reduce dependence on workers with 30-plus year of experience, not because there is a lack of appreciation for the value that experienced workers bring to the workplace, but because there is a shortage of these workers in the spring industry. As the talent pool shrinks, the right balance between technology and skills in

the workforce needs to be found to be prepared for the future.”

For his remarks in Charlotte, Bagnuolo will reiterate that “keeping pace with technology will always be a part of a long-term strategy, but developing a process to recruit, train, and retain skilled labor and create a continuous improvement mindset will be the differentiator for success moving forward.”

He will talk about strategies that can be effective, including: • Growing talent: It is more effective and less expensive than recruiting from the outside.

Continuing education within the factory keeps workers engaged, efficient and motivated.

• Creating relationships with local trade schools that teach basic technical, math and problemsolving skills.

SPRINGS / Fall 2015 / 31

SMI Metal Engineering eXpo • Developing an apprentice program: This can allow companies more control of the talent pool.

• Have higher expectations when recruiting for all plant positions: There are people who want to learn and better themselves. Plant jobs can offer a path to providing a good life. Keep pay competitive, because rewarding workers who learn additional skills almost always have a positive payback.

• Succession planning: It is not only for salaried and leadership positions. The opportunity to have experienced tradesmen pass on their knowledge to apprentices is an invaluable opportunity, while saving time and money on training.

“These approaches may not sound like groundbreaking strategies,

but they are the key to creating and sustaining competitive advantage into the future.”

An Involvement in STEM In comparing the skill set of today’s worker with past generations, Betts believes that today’s manufacturing floor requires that STEM (science, technology, engineering and mathematics) education be embedded into all CTE curriculums.

“STEM education and critical thinking and problem-solving skills are required in literally every advanced manufacturing job today,” said Betts.

“Today’s machinery is more complex than years past. The days of knowing how to set up and operate a mechanical spring coiling machine are over.

Electronics and CNC machinery along with integrated ERP and complex communications requires

today’s workers to be more versatile and better educated than years past.”

Beyond technical skills, Betts sees the need for more.

“Business today looks to hire the very best people who understand and appreciate the importance of having complex problem-solving skills, the importance of living the company’s core values and the importance of being the right partner for the culture within the business where teamwork and quality communication is the norm.”

There’s a lot of information the panel hopes to convey. For those who are fortunate to attend the session in Charlotte, the four participants in the panel hope to be a catalyst to spark ideas so new programs can be developed in your area of the country to help you find your next generation of workers. n

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SMI Metal Engineering eXpo

Understand Health, Safety and Environment Issues for Your Springmaking Business

W

hat are health, safety and env i r on ment i s s ue s t h at could potentially derail your business? Dr. Laura Helmrich-Rhodes, SM I’s i ndependent r e g u l at ion s compliance consultant will help bring clarity to these issues and more in her presentation “The State of Health, Safety and Environment.”

Her session, part of the business track, will take place on Wednesday, Oct. 21 from 8 a.m. to 8:50 a.m. during the SMI Metal Engineering eXpo’s Technical Symposia.

Helmrich-Rhodes will review the most current information on: • Top 10 violations for all U.S. manufacturing, and the spring and metal forming industry specifically • OSHA’s published agenda items will be briefly explained, including status of the combustible dust regulation and the amputation prevention national emphasis program • Current data on the cost incurred by manufacturing to date for machine guarding violations • Several safety resources will be provided • Benchmarks for progress of your new GHS Haz Com program will be provided • An overview of SMI Safety Services

“Participants will be able to decide how their company compares to the most frequently cited standards for our industry and determine if their Hazard

Communication Program changes are up-to-date with the new Globally Harmonized System deadlines,” explained Helmrich-Rhodes.

“Understanding the profitability of safety efforts is important in purchasing and upgrading equipment and services so the cost of violations will presented.”

Participants will be able to decide how their company compares to the most frequently cited standards for our industry and determine if their Hazard Communication Program changes are up-to-date with the new Globally Harmonized System deadlines.

In addition to her work with SMI, Helmrich-Rhodes is an associate professor in the Safety Sciences department at Indiana University of Pennsylvania (IUP) in Indiana, Pennsylvania. She has been at IUP since 1992. IUP was the first accredited safety undergraduate degree program in the nation and now offers masters and Ph.D. degrees. She teaches at the undergraduate and graduate levels. Helmrich-Rhodes has taught general industry and construction

OSHA standards, including the development of laboratory exercises for students, fire protection and safety program administration. She also oversees senior level interns and arranges partnerships for the internship program.

In addition to teaching, HelmrichRhodes has been active in private consulting through Rhodes & Associates, and now Safety Geeks, LLC. Prior to full time teaching, Helmrich-Rhodes was an engineering representative for Royal Insurance and senior loss control representative for Kemper Insurance in Philadelphia, Pennsylvania. Her OSHA experience includes three years as an inspector/ consultant for the Pennsylvania OSHA Consultation Program.

She holds a B.S. in safety sciences, an M.A. in industrial and labor relations from IUP, and earned a Doctor of Education degree from the University of Pittsburgh in 2000.

Helmrich-Rhodes volunteers her time with the Indiana County Chapter of the American Red Cross.

She has served on the board of directors of the organization since 2012 and as a Disaster Action Team member. She was elected vice-chair of the chapter in July 2014. n

SPRINGS / Fall 2015 / 33

Technology Affects Our Businesses in Many Ways

By Paul Menig

I

Everett Historical/Shutterstock.com scyther5/Shutterstock.com

34 / SPRINGS / Fall 2015

was at a conference in late August on the future of trucking. I moderated a panel on autonomous vehicles and platooning, while others talked about the future of infrastructure, the future of workers (mostly drivers a nd tec h n icia n s) a nd r ea l world applications of future technology. The conference started with the futurist Dr. Michio Kaku giving an entertaining and eye opening picture of the future, f rom growing replacement orga ns for the body to enabling information everywhere through the Internet of Things. Dr. Kaku is like a modern day Carl Sagan and Einstein combined.

Let’s briefly look at how technology has affected the printing industry and use it to see how technology has and will impact the spring and metal forming industry. Printing started a long time ago with people laboriously writing things in or on stone, such as the famous Rosetta Stone and the cave drawings in France and elsewhere.

Eventually someone invented paper and ink and a new way of printing (handwriting) was established that lasted thousands of years. In fact, the process is still used, and 3M with its Post-it brand notes is very grateful.

Then, there was the watershed moment of the invention of the Gutenberg press 600 years ago. Finally, printing went from a slow, painful, individual process to one that could produce massive amounts of printed pages. There was, however, still pain in being able to set up the machine.

Speed ahead to the late 1800s and early 1900s. The mimeograph and carbon paper were invented, about the same time as the typewriter. Now people could quickly copy something. Set up was relatively easy for the mimeograph and teachers were ecstatic that they could provide assignment sheets for

I’m inclined to liken this to the early 1900s for printing and typewriters, where it was possible to create multiple, individualized copies of something by an individual with a small machine. I’d also argue that the future for spring and metal forming will go the same way as printing. We will move to even more individualized manufacture of formed metals using different techniques and even more computers. Certainly, 3D additive manufacturing is an excellent example.

This week I read of people believing the future will eliminate large inventories of old parts, as car dealerships will print the needed part on demand in their own back room. Metal parts are giving way to plastics, carbon

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their students. The typing pool of people was how many businesses responded to the invention of the typewriter, as they needed many things printed. Carbon paper made it possible for a single person to simultaneously make several copies of something. Large print orders for thousands of items were left to special print shops, which existed everywhere. In the 50s or so, the xerographic copy process was invented and put to use.

Over time, we went from large machines that were competing with print shops to the individual printer on most people’s desks today. We went from typewriters to computers. Dictation was a key skill in getting information from the head of a business onto paper for all the employees to read. Today, I talk to Siri on my watch and a text message is sent to several people to read on the electronic device of their choice. In short, printing went from a limited number of copies to massive volume production in print shops, to on-demand and personalized printing in our homes and offices, to electronic images with no hard copy.

Springs are not all that different. An example of a spring material that was laboriously manufactured by an individual in ancient times is the tweezer. Made of bronze, it was cast and formed by individuals initially. It probably advanced to the point of the equivalent in ancient times of the blacksmith shop. Thanks to the impetus of war, a major force in advancing technology, the bow (and arrow) is another example of a spring material. I’m sure someone has made a bow out of metal, but I know better the bows handcrafted out of wood in the old days. Today, those bows are made of carbon fiber and plastic materials.

It was less than 400 years ago that Hooke figured out the basic equation for the force of a spring. That insight, and the industrial revolution, created the need for more and more springs.

Springs quickly moved from being made carefully, one item at a time, to the machines from the early 1900s that produced springs in seconds, putting out as many as 100,000 in a day on a single machine that is unmanned and can work in the dark. I’ve seen many such machines as I’ve been visiting SMI member companies this year. New machines, require less tooling and setup, do more with computers and software. They can produce an intricate, almost individualized spring, with little physical effort and more mental effort. I’ve enjoyed watching these machines with as many as 12 servos to manipulate the metal in fractions of a second.

In short, printing went from a limited number of copies to massive volume production in print shops, to on-demand and personalized printing in our homes and offices, to electronic images with no hard copy.

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It may not be long before I verbally describe a spring with its few parameters to a computer, and the spring is made on demand in my office. It’s not that far-fetched when grade school children are spending their Saturdays at the local science center making plastic parts on 3D additive manufacturing machines that get cheaper and smaller every year. So, take a lesson from the paper printing industry. fiber and other materials that are even easier to form on demand with the help of computers. Over 30 years ago, the automotive industry moved to Direct Computerized Nu merical Cont rol Machines (D-CNC). Today it’s commonplace to use CAD/CAE machines to design a part and download the file to the machine, with little modification to the tooling at times. It may not be long before I verbally describe a spring with its few parameters to a computer, and the spring is made on demand in my office. It’s not that far-fetched when grade school children

are spending their Saturdays at the local science center making plastic parts on 3D additive manufacturing machines that get cheaper and smaller every year. So, take a lesson from the paper printing industry.

Technology affects every part of a company, not just manufacturing. In fact, technology allows us to simultaneously improve cost, quality and performance.

It no longer needs to be a trade-off where you can only optimize one or two of those three measures. To do so, you need to look at your entire business, from start to finish.

At the upcoming SMI Metal eXpo, I’ll be talking about this in a little more detail, but still at a high level. I plan to look not from start to finish, but from “Lead to Repeat.”

I’ll discuss how technology can be used from prospecting for a new customer through, not the end, but through keeping that customer coming back for more products and services from you. I have an interesting and entertaining approach to this in mind. As you think about your own company and its processes from lead to repeat customer, does it look like a Rube Goldberg process? I look forward to seeing you all in Charlotte. n

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38 / SPRINGS / Fall 2015

SMI Members: Consider Hosting a Manufacturing Day Event

©iStockphoto.com/BartCo

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anufacturing Day is an annual national event, executed at the local level, which supports hundreds of manufacturers across the nation as they host students, teachers, parents, job seekers and other local community members at open houses designed to showcase modern manufacturing technology and careers. This year’s designated day is Oct. 2, 2015.

Manufacturing Day addresses common misperceptions about manufacturing by giving manufacturers an opportunity to open their doors and show, in a coordinated effort, what manufacturing is — and what it isn’t.

By working together during and after Manufacturing Day, manufacturers will begin to address the skilled labor shortage they face, connect with future generations, take charge of the public image of manufacturing, and ensure the ongoing prosperity of the whole industry.

Supported by a group of industry sponsors and co-producers, Manufacturing Day is designed to amplify the voice of individual manufacturers

and coordinate a collective chorus of manufacturers with common concerns and challenges. The rallying point for a growing mass movement, Manufacturing Day empowers manufacturers to come together to address their collective challenges so they can help their communities and future generations thrive.

Several SMI members are registered at the Manufacturing Day website at www.mfgday.com as host sites for Manufacturing Day activities October 2. SMI members include: Associated Spring, Barnes Group, Inc.

(Syracuse, New York and Bristol, Connecticut); Betts Company (Fresno, California) Oct. 1; Keats Manufacturing Co. (Wheeling, Illinois); Myers Spring Co., Inc. (Logansport, Indiana); Scandic (San Leandro, California); Spring Dynamics, Inc. (Almont, Michigan); and Wolverine Coil Spring (Grand Rapids, Michigan).

We realize other SMI members may be participating through local community develop-ment groups, community colleges, or were not registered on the Manufacturing Day website as of press time.

We invite any SMI members who participate in manufacturing day 2015 to send us your pictures and thoughts on your event. Send to SMI managing editor, Gary McCoy at gmccoy@ fairwaycommunications.com.

Currently, 1,205 events were registered at the website. The first year the event consisted of 240 registered events and it has grown steadily ever since. Last year had 1,679 registered events and officials expect to exceed that amount once all registered events for 2015 are tallied.

Manufacturing is the backbone of the U.S. economy, and it needs some of the best and brightest to fill its ranks. So make sure you don’t forget to mark Oct. 2, Manufacturing Day, on your calendar this year. n

If you are interested in hosting your own event, visit www.mfgday.com/user/register. You’ll find a treasure trove of resources to help you plan and execute your event. This includes such thing as “Open House Tips,” “Community Planning Guide,” “Media Kit,” and much more.

SPRINGS / Fall 2015 / 39

40 / SPRINGS / Fall 2015

It’s Here.

2015 Show Program Map and Schedule Inside

eXpo Schedule Monday, October 19 2:00 p.m. – 6:00 p.m.

Registration Open

Lobby

6:30 a.m. – 6:30 p.m.

Registration Open

Lobby

10:30 a.m. – 11:00 a.m.

Ribbon Cutting and Exhibit Floor Grand Opening

Exhibit Hall Floor

11:00 a.m. – 6:30 p.m.

Exhibit Hall Open

Exhibit Hall Floor

5:00 p.m. – 6:30 p.m.

Welcome Reception

Exhibit Hall Floor

Tuesday, October 20

Wednesday, October 21 7:00 a.m. – 5:30 p.m.

Registration Open

8:00 a.m. – 8:50 a.m.

Technical Symposia

TRACK: MAnuFACTuRInG TRACK: BuSInESS PRACTICES TRACK: MATERIALS AnD TESTInG TRACK: TECHnOLOGy TRACK: MAnuFACTuRInG TRACK: BuSInESS EnvIROnMEnT

9:00 a.m. – 9:50 a.m.

Repeatability and Reliability…It’s All in the Setup

Lobby 207B/C

Career Technical Education – What are the Options? 207D update: Stainless Steel

208A

Additive Manufacturing (Rapid Prototyping) – Today and in The Future

208B

How to Have It All: Quality, Cost, and Performance

209A/210A

Steel Industry Overview

209B/210B

Technical Symposia

TRACK: BuSInESS PRACTICES

Improve Employee Wellness

207B/C

TRACK: CuLTuRE, LEADERSHIP AnD MOTIvATIOn

How to Hire the Best

207D

update: Coating

208A

TRACK: MATERIALS AnD TESTInG TRACK: TECHnOLOGy

new Technologies to Improve the Production of Compression Springs, Torsion Springs and Wire Forms 208B

TRACK: BuSInESS EnvIROnMEnT

Terms and Conditions of Sales – Pitfalls

9:50 a.m. – 10:30 a.m.

Break

10:30 a.m. – 5:00 p.m.

Exhibit Hall Open

After 5:00 p.m.

Open Supplier night

6:30 p.m. – 9:30 p.m.

Metal Engineering Expo Evening Event with special guest, nASCAR owner and driver Dale Jarrett. (Tickets required) Sponsored by Industrial Steel & Wire

209B/210B

nASCAR Hall of Fame

Repeatability and Reliability...

It’s All in the Setup

Become a Better Leader

Wade Keats, President/CEO, Keats Manufacturing

Gain insights that will help you maximize your leadership potential. Learn to develop your skills, perform better and improve customer service strategy.

Leave with practical tips you can put into practice right away—or use to coach your team members.

Learn best practices in setup for repeatability, speed and accuracy for slide forming machines.

The session will also include an open forum section for those interested with questions and or ideas.

Presented by Keats Mfg. with cooperation of PMA forums on the subject as well.

TRACK: CULTURE, LEADERSHIP & MOTIVATION How to Hire the Best Mark Lee, Owner, Management Solutions, LLC

Selecting the best job applicant isn’t always easy.

In this session, learn best practices in hiring. Leave with a better understanding of how to screen applicants to make sure you end up with the hire who is the best possible match for the job—and for your company.

David Wheatley, Owner/Principal, Humanergy

TRACK: TECHNOLOGY Additive Manufacturing (Rapid Prototyping) – Today and in The Future Todd Grimm, President, T.A. Grimm & Associates, Inc.

Explore the present and future of additive manufacturing (rapid prototyping)—including current materials and applications.

New Technologies to Improve the Production of Compression Springs, Torsion Springs and Wire Forms Dr. Peter Weigmann, Chairman of the Board, WAFIOS AG

For High Performance Wire, Think IWP First.

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Technical Symposia TRACK: BUSINESS PRACTICES The State of HS&E

Improve Employee Wellness Sarah Szul, Wellness Consultant, Kapnick Insurance Group

Dr. Laura Helmrich-Rhodes, Associate Professor/ Consultant, Spring Manufacturers Institute

This presentation will focus on performance-based wellness for small business. Learn what you can do to help reduce your company’s health care costs.

In this interactive presentation, SMI’s new Regulatory Consultant Dr. Laura Helmrich-Rhodes, CSP reviews the top 10 OSHA violations specifically for this industry as well as OSHA’s emphasis on amputation prevention. Get resources to determine if you have combustible dust.

TRACK: MANUFACTURING How to Have It All: Quality, Cost, and Performance Paul Menig, CEO, Tech-I-M

Career Technical Education – What Are the Options?

It is possible! You can have quality, cost and performance without having to make a trade-off.

Delve into examples of advanced manufacturing techniques used in related industries in order to identify improvements in our own industry. Learn integrated and automated solutions for the complex process of “order-entry-to-cash-from-a-satisfiedcustomer” that your people can support.

Al Mangels, President, Lee Spring Company John Dellalana, President, Rowley Spring & Stamping Mike Betts, Chairman & CEO, Betts Company John Bagnuolo, COO, MW Industries

Develop more and better-skilled employees. A panel of executives from four spring companies based in different regions will discuss options and alternatives for achieving this important objective.

Machine Set-Up: Coil & Grind Martin Dorn, CEO, G + M Dorn Drahttechnologie Carl Atwater, President, A.I. Technology, Inc.

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Identify best setup practices for both coiling and grinding machines—then learn tips and ideas on how to automate either or both of these operations with one another. Scrutinize the critical characteristics of coiling setups and learn how to optimize each step to facilitate a defect-free and efficient grinding process. Identify potential efficiencies that can be achieved in the grinding process and get options for automatic feeds and other automation.

Thursday, October 22 7:00 a.m. – 3:30 p.m.

8:00 a.m. – 8:50 a.m.

Registration Open

Lobby

Technical Symposia

TRACK: TECHnOLOGy

update: Residual Stress

207B/C

TRACK: TECHnOLOGy

Software Integration to Manufacturing

208B

TRACK: MAnuFACTuRInG

How to Have It All: Quality, Cost, and Performance

209A/210A

TRACK: MAnuFACTuRInG

Machine Set-up: Coil & Grind

207D

Become a Better Leader

208A

TRACK: BuSInESS EnvIROnMEnT

Economic update

209B/210B

9:00 a.m. – 9:50 a.m.

Technical Symposia

TRACK: CuLTuRE, LEADERSHIP AnD MOTIvATIOn

TRACK: TECHnOLOGy

Additive Manufacturing (Rapid Prototyping) – Today And in The Future

TRACK: TECHnOLOGy

The Effects of Shot Peening Highly Loaded Compression Springs

207B/C

The State of HS&E

207D

TRACK: MATERIALS AnD TESTInG

Metrology: Load vector Analysis

208A

TRACK: BuSInESS EnvIROnMEnT

Steel Industry Overview

209B/210B

9:50 a.m. – 10:30 a.m.

Break

10:30 a.m. – 3:00 p.m.

Exhibit Hall Open

3:00 p.m.

Meeting Concludes

TRACK: BuSInESS PRACTICES

208B

The Global Leader in Wire

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Charlotte Convention Center – Level 2 Map

CONCIERGE F OOD COURT SEATING AREA

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Escalator to Registration & Exhibit Halls

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LEVEL 2 n Symposia Rooms n Restrooms n Escalator n First floor (below)

East Martin Luther King Jr. Blvd.

UPPER GRAND HALL

CONCIERGE

215

Charlotte Convention Center – Level 2 Map

214 213B

211B

212B 213A

211A

212A

SERVICE CORRIDOR

210 209 B B 210 209 A A

206B

208B 208A

207D

206A

207BC 205

203B 201B

202B

201A

202A

SE RV ICE C ORR IDOR

207A 204

203A

SERVICE CORRIDOR

ENTRANCE BEL OW

South College Street

Update: Residual Stress

Economic Update

Dan Sebastian, SMI Technical Consultant, with input from ASW, Gibbs, PAC, Liberty Spring, Associated Spring, Precision Coil Spring and MW Industries

Tim Quinlan, Economist, Wells Fargo Securities, LLC

Explore the preliminary findings of an SMI-sponsored project to identify a more cost-effective means for companies to use basic metallurgical tools to verify that parts have been properly stress relieved. This study’s data will be measured in micro hardness and confirmed with x-ray defraction technology. It will help establish new guidelines governing the temperature and time required for adequate stress relief.

The Effects of Shot Peening Highly Loaded Compression Springs Dave Breuer, Director of Sales, North America, Metal Improvement Company, Curtiss-Wright

Learn the results of a study on the effects of shot peening on highly stressed, low fatigue cycle springs.

Findings will be presented as fatigue life studies and as correlations to Xray Diffraction results on study samples. This study will become the basis for a future SN curve to more accurately predict fatigue for high tensile Chrome Silicon springs with life expectancies of less than 10^5 cycles.

TRACK: BUSINESS ENVIRONMENT Steel Industry Overview John Anton, Director, Steel Service, IHS

Hear an overview of what’s happening in the global steel industry and market. We’ll discuss what to expect in the future and the probable impact on SMI members.

Terms and Conditions of Sales – Pitfalls Gary Carboy, Shareholder, Cowles & Thompson, PC

Terms and Conditions of Sale is an area of potentially high exposure for companies that are not paying close attention. In this forum engage in a discussion regarding some of the most serious pitfalls that all suppliers need to consider when entering into an agreement to supply parts or materials.

What’s next for the global and North American economies? Join us as economist Tim Quinlan shares his thoughts on what’s coming down the pike.

TRACK: MATERIALS & TESTING Update: Stainless Steel Shawn Chaney, Product Manager, Fort Wayne Metals Research Corp.

Medical device designers select stainless for its ideal balance of strength, corrosion resistance, mechanical properties and cost. Discuss the various grades and tempers for medical coil winding applications. Understand the material characteristics that result from the various melting methodologies, inclusion distribution and the resulting fatigue endurance limits.

Update: Coatings Dr. Anthony Chasser, Senior Research Scientist, PPG Industries, Inc. Gary Orosz, Applications Process Manager, PPG Industries, Inc.

Get up-to-date on coatings. We’ll detail the differences between various paint coatings— including a comparison of the strengths and weakness of each as well as outline proper application and processing.

Metrology: Load Vector Analysis Larry Sheiman, Managing Partner, DtechXion Ltd (SAS)

Explore the latest trends in load testing capabilities including load vector analysis. Discuss the benefits of utilizing these capabilities for your company and your customers.

80 years apart.

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Flashback

Value Analysis

By Paul V. Farrell

(Editor’s note: This article originally was published in May 1964 issue of Springs.

Paul V. Farrell, the author of this article, was well known to spring manufacturers.

Farrell was the editor of Purchasing magazine.

His address was one of the highlights of an SMI meeting held in New York, and this article contains excerpts of that talk.)

I

JMicic/Shutterstock.com

t seems to me quite appropriate to be here this morning talking to the spring manufacturers about value analysis.

The very term means elasticity. And elasticity of mind is one of the basic qualities needed in value analysis; the willingness to consider new ideas; the unwillingness to accept status quo simply because “we’ve always done it that way;” the ability to stretch one’s vision beyond narrow concepts, beyond grooved ways of thinking; and the desire always to seek a better way.

Indeed I think it could be said that some obscure spring manufacturer scout i ng a rou nd t he Tig r is a nd Euph r at e s t e r r itor ie s f or mor e business was actually the first value analyst, for it was a primitive form of spring that helped man develop one of his first complex machines.

I would like you to consider this quotation from The Oxford University Press’s “History of Technology.”

“The lever is t he basis of all machines, though for extensive use it must be combined wit h ot her mechanical elements. For long ages men could use it only in its simplest applicat ions. Elaborat ion bega n with one other device-the spring.

Strictly speaking the spring is not a mechanical element, but rather a means of storing energy. Springs also exist everywhere in nature all that was needed was to imitate them.

Bivalve shells may well have been employed as tongs, the two parts acting as levers and the joint as a spring. Most traps made by primitive peoples are mere combinations of levers and springs.”

SPRINGS / Fall 2015 / 41

The very term means elasticity. And elasticity of mind is one of the basic qualities needed in value analysis; the willingness to consider new ideas; the unwillingness to accept status quo simply because “we’ve always done it that way;” the ability to stretch one’s vision beyond narrow concepts, beyond grooved ways of thinking; and the desire always to seek a better way.

There are three elements in that quote, two stated and one implied that I would like you to think about in terms of value analysis.

First, for long ages men could use levers only in the simplest applications. People like habits. They resist changes even when the changes are for their own good.

Value analysis is a means of challenging fixed ways of thought, of questioning accepted ways of doing things that keep us technologically primitive.

Second, all that was needed was to imitate the springs in nature, for the lever was a perfectly good design to begin with. Nobody went around denouncing or embarrassing the primitive engineer who designed it or discovered it.

But somebody did see a way to improve on it, and he spoke up about it, not after the fact as so many of us do, but before.

The third point I wish to make about the quotation is that it anticipates an argument that I hear over and over: value analysis is nothing new, we’ve been doing it for years. Of course we have, we have been doing everything for years for that matter. The Chinese were using rocket propelled weapons centuries ago, but that doesn’t mean that we should drop our efforts to find better and better ways to do the same thing.

American industry has developed an organized approach to finding better ways to do things, to look to nature or anywhere else to improve a basic design. This is what value analysis is, an organized activity that involves everyone in the manufacturing cycle: engineering, production, purchasing, and just as important, you, the supplier, because you are very definitely being considered a member of the value analysis team, and the sooner you realize it, the better off you will be. Management and government have caught on to the idea and are demanding that not only their own people, but their suppliers as well, practice value analysis.

42 / SPRINGS / Fall 2015

Let me brief ly review t he philosophy a nd t he organization of value analysis in industry. These are general outlines. Specific organizations must be suited to particular companies, industries and problems.

Value analysis is the organized study of the relationship of cost, design, and function of a product with the object of reducing its ultimate cost.

Value analysis was first introduced as an independent activity, over and above regular cost reduction programs, when a group of purchasing engineers was designated a value analysis unit in the purchasing department of General Electric in the late ‘40s.

Their job was to value analyze components going into General Electric products.

Today, value analysis organizations often include designers, cost accountants, manufacturing engineers, and always suppliers, whether the suppliers are fully conscious of it or not. Value organizations may vary in size from a one-man department-or a part-time analyst with other duties such as buying -through a small group of value specialists, on up to a plant-wide committee made up of representatives of several departments.

Regardless of how value analysis is organized in the individual plant, the basic approach is the same. All analysts look at a group of parts or components with this definition in mind: “Value is the least cost for an essential function or service at the desired time and place, with the required quality and reliability.”

Keep that word function in mind. It is the key to value analysis.

With that definition of value as a foundation, value analysts begin to ask themselves and their group these basic questions: • What is the part?

• What does it do and what is its function?

• What else will do this and what else will perform the function?

• How much will that cost?

As the analysis proceeds, the questioning becomes more specific: • What substitute materials are there that will do a better job at lower cost?

• Is there a lower cost process to make the item?

• Can a standard item be made to do the same job?

• Will some new product do a better job?

• Is cost proportionate to usefulness?

• Are we making something ourselves that we should be buying at lower cost from a specialty supplier?

• Are tolerances unrealistic?

• Are we paying for features that aren’t needed?

• Are our competitors beating us on this item?

• Can indirect costs (packaging, shipping, storage, etc.) be reduced?

• Can we combine several parts into one and eliminate expensive assemblies?

Actually, many of you have participated and are participating in this type of value project. It is interesting to dig back and find that at least one of the manufacturers represented in the audience today was cited in the first General Electric file on value analysis projects.

Not every value analysis project involves spending less. I remember an early value analysis project that involved switching from steel to phosphor bronze for the manufacture of a small flat spring. The material cost the manufacturer only $1.60 per thousand but plating and heat treating cost him $4.90. By paying more than twice as much for phosphor bronze, $3.50, he eliminated the plating and heat treating cost. In both cases the fabricating costs were $1.00. So, the difference in the total cost was $4.50 against $7.50. This was the case of make rather than buy. I don’t know whether the company still makes it, but I will bet that value analysts have studied the possibility of having specialty suppliers do the job at lower fabricating costs.

Your company may or may not have been considered a supplier in that particular project. But you are being considered in many others whether you realize it or not.

Further, you are expected to consider yourself part of those teams and come up with suggestions of your own.

I can think of no better way to bring this idea home to you than to read the heads and decks of just a sampling of stories from our magazine in the past couple of years: “Suppliers Join Countdown on Cost;” “Get Supplier Help on Cost Reduction;” “Cost Reduction is the Supplier’s Job, Too;” “Purchasing Agent’s Seek More Value Analysis from Suppliers;” “Value Analysis, the Newest Supplier Service.’’

SPRINGS / Fall 2015 / 43

Regardless of how value analysis is organized in the individual plant, the basic approach is the same. All analysts look at a group of parts or components with this definition in mind: “Value is the least cost for an essential function or service at the desired time and place, with the required quality and reliability.”

Well, you may say, people we call on don’t seem interested in this value analysis so we’ll just go along in the same comfortable relationship we’ve had and not rock the boat. There’s small comfort in that attitude, believe me.

Because if you don’t rock the boat, someone will. One or all of your competitors in or out of the industry are just waiting to rock it. Many suppliers have already caught on to the techniques of value analysis and are offering it as a service before they are asked for it. I am sure a number

of you have taken this same approach, but if you have not now is time to prepare. As a first step, we have been proposing that suppliers ask themselves these questions about their own value, attitudes.

1. Do I study my customer’s product?

Don’t just passively accept invitations to quote from buyers. Instead, apply value analysis techniques to a study of your customers’ products and processes with an eye for possible applications of your products and services.

2. Do I help the purchasing agent sell value analysis?

Supplier cooperation is vital to the success of almost any value analysis program. And most of the savings are the product of supplier know-how. By working with the purchasing agent (P.A.), suppliers can benefit from the additional business a successful value program is bound to bring. Ignore value analysis and your competitor will get the order.

3. Am I afraid to say no?

Value conscious suppliers put themselves on the buyer’s team. They know they’ll gain by helping the P.A. boost profits through value analysis. They always take the long term view, even going so far as to turn down business for a product if they know the customer won’t be satisfied with it.

4. Do I have the courage to question every order?

If you get an order for one product and know that another product will do a better job, don’t hesitate to call this to the attention of the buyer. The salesman’s biggest contribution to value analysis is leading the buyer to the product that he can use most profitably.

5. Do I sell on profit and value?

With the value analysis approach, the price paid for the item becomes less important. The value of the product in terms of its application by the user is what is really significant.

44 / SPRINGS / Fall 2015

6. Do I work through the purchasing agent?

Management has chosen the purchasing agent to act as a clearinghouse for all value analysis ideas. Pass your value ideas directly to the agent even if you know their execution will also involve other departments. Don’t try to short circuit the system.

7. Do I sell the function, not the product?

Value conscious purchasing agents look at each item in terms of the job it does. Salesmen profit by the same approach. Sell the most efficient power supply, not an electric motor. Sell the most effective fastener, not a cotter pin.

8. Do I get buyers into my plant?

The modern purchasing agent is the company’s eyes and ears for new ideas and purchases. Familiarize them with your plant processes and products and they may well wind up suggesting new applications for your products.

9. Do I encourage product comparisons?

Today most buyers are professionals. If your product offers superior values, don’t be afraid to show the agent scientific evidence. Whenever possible, encourage the use of objective testing methods by the buyer; they may well be your best sales tool.

10. Do I overlook possible waste?

You and the buyer are members of the same value analysis team. Do your best to help the buyer keep costs of packaging, shipping, etc., to a minimum through value analysis and he’s sure to appreciate it.

Did our caveman whom we spoke of at the beginning (perhaps the first president of the Spring Manufacturers Institute) ask himself these questions? Sitting here in comfort in our Hickey-Freeman goatskins we may laugh at the idea. My answer in all seriousness is that he did. He started value analysis in your industry and others have carried it on from there. You cannot afford to ignore it, you must keep re-examining your own thinking and stretch your own minds and creative imaginations in order to stay ahead of competition from any direction.

You’ll find progressive purchasing agents and their counterparts in other departments of your customers’ companies waiting for you. The unprogressive ones won’t be around much longer, I can assure you. Value analysis is not some curious fad you look at from outside. You are now a part of it. n

SPRINGS / Fall 2015 / 45

46 / SPRINGS / Fall 2015

Winning the Talent Wars

By John F. Dini

I

f you haven’t heard the term “Talent Wars” yet, you have now.

They are heating up, and most small businesses aren’t very well equipped to compete in them.

“Talent Wars” refers to a growing shortage in the U.S. labor market for properly trained and educated employees. Starting before the Great Recession, there has been a mismatch between people seeking jobs and those who hire them.

Statistics show that employers are currently advertising to fill 51 million open positions, an all-time record. Many business owners complain bitterly about the lack of talent in the hiring pool—especially in sales, technical jobs and trades.

There are several factors causing this disconnect between employers and prospective employees. You should be aware of them if you intend to compete in the Talent Wars.

The first factor is the shrinking number of people in the prime age group for experienced employees.

Those reaching their 65th birthday outnumber the folks hitting their 45th birthday by 4,000 people a day.

This overlap of the post-WWII baby boom with the baby bust of the late 60s and 70s can’t be changed; and it will continue for the next 10 years.

One strategy to counter the middle-experience gap is to look further up and down the age bracket.

Over the next few years you will find yourself reconsidering fixed ideas about what is an ideal age for these positions. Boomers are generally healthier than preceding generations, and many plan to work much longer.

A “new” hire in her late 50s can be up to speed in far less time, and still be a productive member of the team for 10 or 15 years.

©iStockphoto.com/morkeman

The second major issue with finding qualified people is training.

Our higher education system today is driven more by low-interest government guaranteed loans and far less by the value of a degree.

Employers can no longer look at a college education as de facto evidence of qualifications, but it can still provide some guidance.

How long did it take the applicant to graduate? (Less than 50 percent make it in four years.) What courses did he or she take? Hopefully they were something more substantial than “Bruce Springsteen’s Theology,” (an actual for-credit course at a major university.) A well-rounded liberal arts education still has value, and timely completion still indicates a goal oriented person. Both, however, require more investigation than merely checking the sheepskin.

Finally, business owners have to face increasing competition from Corporate America for talent. After years of downsizing, outsourcing and technology upgrades to replace people, large organizations are now filling the slots left by the wave of

One strategy to counter the middle-experience gap is to look further up and down the age bracket. Over the next few years you will find yourself reconsidering fixed ideas about what is an ideal age for these positions.

SPRINGS / Fall 2015 / 47

©iStockphoto.com/ morkeman

Smaller employers are finally becoming aware of the crisis, and they simply can’t win this battle on the benefits front.

Wages are a much higher percentage of their expenses, and they typically aren’t deep enough at any position to easily swap bodies when one isn’t available. They have to compete in the Talent Wars with the weapons they have always used against giant competitors: speed, creativity and culture.

48 / SPRINGS / Fall 2015

retiring boomers. According to a poll of 587 corporate executives in a study titled “Talent Wars – The Struggle for Tomorrow’s Workforce” published in The Economist, the top five concerns were: 1. Aging population 2. Shift of personal values (e.g., stronger focus on work/life balance) 3. Lack of investment by organizations in training and developing employees 4. Increasing gaps between what universities provide and what industries need 5. Low or declining standards of education The issues they identified aren’t surprising. What the owners of small and midsized businesses need to realize, however, is that this study was done eight years ago. In that time corporations have already reacted. Job offerings for desirable hire now include signing bonuses, guaranteed wage increases and creative benefits packages.

Smaller employers are finally becoming aware of the crisis, and they simply can’t win this battle on the benefits front. Wages are a much higher percentage of their expenses, and they typically aren’t deep enough at any position to easily swap bodies when one isn’t available. They have to compete in the Talent Wars with the weapons they have always used against giant competitors: speed, creativity and culture.

There are tactics available to smaller employers that cost little beyond some time and energy, and may actually reduce your employment expenses.

Treat employees as real people: Most small companies say things like “We are proud of our family atmosphere.” The culture of your business is still your biggest advantage. Employee satisfaction surveys consistently rate the importance of social interaction in the workplace far higher than wages.

Tailor jobs and benefits to individual employees: Use behavioral tools to show that you are truly concerned about an employee’s job satisfaction. Some companies have a flexible selfimprovement benefit; a few hundred dollars annually for each employee to use as he or she chooses for education, hobby lessons or a gym membership. Consider carefully whether it is really a problem if an employee schedules around family needs, like dropping children off at school in the morning.

Maintain current technology: Most of us get frustrated if a website doesn’t load in less than five seconds.

Don’t make your employees deal with outdated equipment or software.

The cost of a second monitor or upgraded workstation is less than most employees’ weekly salaries.

Consider outsourcing: Many smaller companies hire a skilled person, and then “fill in” his or her 40 hour week with lower-level tasks.

Is your controller entering invoices?

Does your sales manager produce the customer newsletter? The luxury of “We do that ourselves” is impractical when you are overpaying for the function, and you can’t afford to pay for full-time talent if it is really only a part-time job.

Invest in skills: Owners often worry that they are training people to get better jobs elsewhere. Let employees know that you are investing in them as recognition for their ability, and have them sign agreements that forgive training costs over time. Once they are more qualified, adjust wages to reflect their new value. Gratitude is a shortlived motivation for staying in a job.

Pay market rates: Everyone has lost an employee to “an offer we just couldn’t match,” but if it is happening regularly you may be out of touch

with the wage scale. Remember, there are 2.5 jobs being advertised for every person who is looking for one. Those with ability don’t have a problem finding work. You may not match the top of the market, but you need to be in the ballpark.

Market internally: Employees can develop a “grass is greener” attitude when they take for granted all the good things that their current employer offers. Make a list of all the tangible and intangible benefits that your company provides, and schedule regular reminders of them for your workers.

The Talent Wars are here, and they will intensify in the years to come. Finding and retaining the right people will depend on your ability to fight back with the inherent advantages of a small business: speed, creativity and culture. n

John F. Dini is a coach, consultant, speaker and author of “Hunting in a Farmer’s World,” “Celebrating the Mind of an Entrepreneur” (winner of the New York Book Festival’s “Best Business Book”), “11 Things You Absolutely Need to Know About Selling Your Business,” and “Beating the Boomer Bust.” Recognized as one of the nation’s leading experts on business ownership, Dini has delivered over 10,000 hours of face-to-face, personal advice to entrepreneurs. For more information, visit www. johnfdini.com.

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.

SPRINGS / Fall 2015 / 49

Diamond Wire Helps Make Grass Springs for Children’s Museum of Pittsburgh Display

50 / SPRINGS / Fall 2015

L

ike most companies in the spring industry, Diamond Wire Spring Co. has gotten some unusual requests over the years. The company recently produced springs to be used as blades of grass for a traveling exhibit produced by the Children’s Museum of Pittsburgh. The springs hold giant blades of grass to their mounts, and make them bounce back to standing when bumped or stepped upon.

According to a recent article on the display in the Pittsburgh Tribune-Review, The “grass” is part of the “The Very Clumsy Click Beetle” portion of its “Very Eric Carle” exhibit that opened June 13, 2015.

To demonstrate how the springs work, Lisa Carvajal, exhibit design manager at the Children’s Museum came out to the Diamond Wire Spring Co. plant earlier this year. Carvajal dove on top of a small rectangular section of “grass” and rolled around.

“I don’t think we had ever seen anyone rolling on the ground like that,” said Chris Fazio, Diamond Wire Spring Company general manager in the newspaper article. “We’re still talking about it.”

The Children’s Museum needed something that would stand up to thousands of children playing very roughly on its new exhibit—which is centered on the idea of bringing to life the “Very” books authored

by Carle. His books include: “The Very Hungry Caterpillar,” “The Very Lonely Firefly,” “The Very Clumsy Click Beetle,” “The Very Busy Spider” and “The Very Quiet Cricket.”

The plan for the exhibit was for children to be the very hungry caterpillar, busy spider and the rest to experience the world through those eyes and the eyes of Eric Carle.

“Normally, when we get design requests, we need a spring to meet some kind of mathematical parameters,” says Diamond Wire Spring Co. engineer Terence Sahr.

“Instead, it was, ‘We need this to look like grass.’

“It was a more intuitive project (than we’re used to).

It needed to flex like grass, but still be rigid enough to spring back up.”

The grass is made of foam, wrapped in a mottled green sleeve patterned on the distinctive look of Carle’s hand-painted paper collage-based artwork. It took weeks of meetings to settle on the material and the look. There will be 100 square feet of grass, and 450 individual blades, with some backup blades.

The plan for the Carle exhibit was for it to be at the Children’s Museum of Pittsburgh for three months during the summer of 2015, and then move to the Magic House in St. Louis. Currently, the exhibit is on track for a 30-city, 10-year tour. Watch for it at a children’s museum near you. n

SPRINGS / Fall 2015 / 51

52 / SPRINGS / Fall 2015

Exhibitor Preview

molaruso/Shutterstock.com

SPRINGS / Fall 2015 / 53

SMI Metal Engineering eXpo Show Preview

Alloy Wire International

AIM Inc. A&D Trading LLC Booth #1009 A&D Trading is the premier Taiwanese spring and wire forming machinery distributor. We specialize in full servo controlled CNC compression spring machinery, and both cam-driven and camless wire forming machinery with capabilities up to 16 axis and beyond.

We feature the best warranty and service in the business; training is included in every purchase.

Booth #818 Automated Industrial Machinery, Inc. (AIM Inc.) manufactures 2-dimensional and 3-dimensional CNC bending machinery. The company is an active machinery exporter via its two manufacturing facilities in North America and Europe. Founded in 1992 by Constantine Grapsas, AIM Inc. has grown to become the premier CNC bending machine supplier serving customers worldwide.

American Spring Wire

Alex Industries, Inc.

A.I. Technology, Inc. Booth #1001 A.I. Technology is the agent for: The Itaya Engineering Ltd CNC Machinery, www.itaya.co.jp; GM Dorn Spring End Grinders, www.gmdorn.de, MicroStudio Testing and Optical Measuring Instruments, www.microstudiotec.it; Spring Tooling Ltd., www.spring-tooling. co.uk; Gasden Ro Ovens, www.gasdenro.co.jp

54 / SPRINGS / Fall 2015

Booth #611 Manufacturing spring wire and shaped wire from .001" to .827", Alloy Wire is the springmakers’ manufacturer. From over 50 alloys: Inconel, Hastelloy, Monel, Phynox, we manufacture to your specification, provide technical support and deliver in just two weeks. With approvals including AS 9100, ISO 9001 and DFARS compliance, quality is a guarantee.

Booth #601 Alex Industries is the exclusive North American sales representative for Fortuna Federn GMBH (www.fortunafedern. com). We specialize in large wire diameter spring coiling machinery for hot or cold wire forming. We can customize any of our standard machine models to meet your specific needs. Send a sample or blueprint and we can recommend the best solution.

All Wire Forming Machinery, Inc. Booth #814 All Wire Forming Machinery, Inc. has over 20 years’ experience serving the wire forming industry with new wire forming machinery. We offer: 2D & 3D CNC wire benders, CNC spring coilers, CNC wire formers, Power Payoff dereelers, custom built machines, and automation systems. New Diacro benders & cutters.

Visit: www.allwireforming.com.

Booth #919 American Spring Wire Corporation (www.americanspringwire.com) manufactures valve spring and commercial quality spring wire in carbon and alloy steel grades. Capabilities include round and shaped wires from .120” to .625”.

Manufacturing processes include: chemical pickling, surface removal, die drawing, cold rolling and oil tempering.

ASW is registered to ISO 9001:2008 standards.

Amstek Metal Booth #714 Amstek Metal provides high quality engineered stainless and carbon wire and coil products, including precision stampers, spring makers and a variety of products from domestic and overseas sources. We are both a supplier of precision coil and wire from mill sources and stock. Our suppliers consist of producers with complementary capabilities, which can be "tailored" to your specific material needs.

Anchor Abrasives Co. Booth #914 Anchor Abrasives Co. specializes in the design and manufacture of resin, epoxy and oxychloride bonded nut-

SMI Metal Engineering eXpo Show Preview inserted discs and cylinders, recently adding resin bonded centerless and roll wheels. We are a highly skilled team that devotes maximum effort in the development, manufacture and application of these specialized products.

Bekaert Corporation Booth #713 Bekaert has over 135 years of experience in drawing steel wires and applying wire coatings for a wide range of applications and industries. Through co-creation, we provide customized wire solutions that combine varied basic materials, coatings and shapes. Customers leverage our global presence and local support to their benefit.

Bennett Mahler / NIMSCO Booth #419 On display will be several machines including a large wire diameter spring coiling lathe and a single end spring grinding machine. Bennett offers a wide line of spring making production machinery for both small and large volume work.

Dell Marking Systems, Inc. Booth #725 Founded in 1973, Dell Marking Systems, has been serving the spring and wire industries for over forty years. Combining both chemistry and engineering providing innovative identification products, systems and services, assisting our customers in improving quality, manufacturing processes and reducing costs.

A company small enough to be flexible and large enough to be global.

ERA Wire, Inc. Booth #709 ERA Wire Inc. since 1988, wire straightening and cutting specialist. Diameter range from .005-1.00" ferrous and nonferrous alloys cutting rounds. flats, and shaped materials, from under an inch to over 200 ft. Tight tolerances for medical, aerospace, automotive and spring industries. In-house centerless grinding capabilities. Used or rebuilt wire straightening machinery, replacement parts and tooling for wire straightening machines. ISO 9001 certified.

FENN Booth #801 FENN, a leader in metalforming machinery for over 100 years, proudly continues to produce its Torin line of CNC spring coilers in Connecticut. On display are: the refreshed 2016 model FZ 11 with a wire diameter range of .015” to .080”; and the FZ 12, with a wire diameter range of .047”-.177”. Torin spring coilers can produce a wide variety of springs and wire forms on a single machine.

F.A.R. SPA Central Wire Industries, Ltd Booth #911 CWI has the largest specialty wire drawer in North America and the UK, producing a wide range of wire products in stainless, nickel, copper and others upon request. We stock stainless spring wire in grades 302, 316, 17-7, X750, MP35N, NI600 and others. Custom sizes, shapes, coatings, and spring wire stocking programs, and spring passivation services available. Proudly made in the USA.

Deacero Booth #705 Deacero is a steel producer with more than 60 years of market experience.

Company manufactures various industrial steel wires as well as merchant bars, beams and structural shapes. Hot rolled rod, cold drawn wire, bright wire, galvanized wire, pc wire, annealed wire, cold heading quality and more.

Booth #915 F.A.R. SPA is an Italian company producing tempered steel wire in a wide diameter range, shaped according to customer specification. We offer high resistance tempered steel wire for the automotive and aerospace industries, or anywhere there is a use for elastic components in critical conditions with strong mechanical stresses, such as suspensions, clutch, valve springs, etc.

Certified ISO 9001:2008 and ISO TS 16949:2009.

Fenix, LLC Booth #511

Forming Systems Inc. Booth #401 Forming Systems Inc. will be exhibiting in booth 401, and key personnel will be there to answer questions about HSI spring making accessory equipment, HTC spring and wire forming machines, SAS spring testers and vision systems, TBE automated wire forming machines, OMD spring grinders, and Jaykase programmable tabletop benders.

FROHN North America, Inc. Booth #908 Frohn is one of the world’s leading manufacturers of cut wire peening media and blast cleaning media. Carbon & stainless steel, aluminum or zinc whatever your requirements, we have the media for you. Our media meets or exceeds all manufacturing specs.

SPRINGS / Fall 2015 / 55

SMI Metal Engineering eXpo Show Preview

Furnace Fixers, Inc. Booth #804 We manufacture: stress relief furnaces; Catch N Count (parts counter); Simple Coat Coating System (automatic paint system); conveyors (incline, horizontal, z, low riders, etc.); Monorail Paint Drying System with curing furnace; wire dereelers or payout; scissors lifts; platform carts; heating elements (distributor); stainless steel belts, flat, turned up edge, chain driven, and flat wire belts (distributor); Custom projects to customer specifications.

Gator Stamping Int'l. Inc. Booth #723 Gator Stamping specializes in low cost, short to medium run metal stamping, sheet metal fabrication, weldments, assemblies and laser cut components We are ISO 9000-2008 registered company.

Gator Stamping is capable of producing parts from .002 to ½ thick on our punch presses that range from 20 to 545 tons.

Gibbs Wire Booth #719 Gibbs is a leading distributor of metals in North America. We have a strong reputation for superior service and quality metals. We supply both wire and flat-rolled precision strip products. We pride ourselves on having a company of engaged, diverse individuals of high integrity who are very focused on the customer.

automation. Daewon for automated high output wet spring grinders. Pyromaitre, designers and builders of compact energy efficient furnaces.

Granite Falls Furnace Booth #1014 Granite Falls Furnace manufactures drawn steel wire and annealed wire products for a wide variety of industrial markets. Our continued focus is to deliver cost effective quality wire products and superb customer service.

We employ state-of-the-art equipment and processes coupled with a highly experienced staff to produce the highest quality drawn steel wire in the industry.

HTC Booth #401 HTC will be exhibiting in booth 401.

HTC manufactures spring coilers and spring formers with wire ranges up to 16mm. They are exhibiting new spring coilers and spring formers that include the HTC-60CL spring coiler and the HTC-20XU spring machine.

Industrial Steel & Wire

HSI Booth #401 HSI will be exhibiting in booth 401 and will have many of their products on display used for the production of springs and wire forms, which include box ovens, conveyor ovens, parts collectors, parts washers, payoff reels, spring length gages, part conveyors, vision gage systems, and electrostatic air cleaners.

Booth #710 Industrial Steel & Wire is one of the largest stocking distributors of round, flat, and shaped wire products in the world.

Count on ISW for • A complete inventory of competitively priced carbon, stainless and nonferrous wire.

• More than 400,000 square feet of warehousing, strategically located throughout North America.

Your trusted source for spring and wire form manufacturing solutions.

HSM Solutions

Gibraltar Corp.

Booth #310 Gibraltar Corp specializes in sales for spring and wire forming equipment.

Simco Spring Machinery for spring coiling .006 -2.00” wire/bar and forming machinery; grinding and other special purpose machinery. Morita and Company specializing in hot winding, leaf spring, and stabilizer bar machinery and

56 / SPRINGS / Fall 2015

Booth #622 HSM Wire Technology produces low carbon, high carbon and induction tempered wire. We also produce 2D and 3D wire forms, tubing in 22-11 gage, and metal stamping. In addition, we have in-house capabilities to paint and powder coat our products. Our manufacturing plants are ISO 9001 certified and TS 16949 certified.

Interwire Products Booth #819 Wire distributor of specialty spring wire, both round and shaped including music wire, Bezinal music wire, galvanized music wire, oil tempered, chrome silicon, phosphor bronze, brass, beryllium copper, 302, 316, 17-7 Inconel, Monel, nickel, nitinol, titanium, aluminum and recently other medical grade wires. Also offering straight and cut wire.

SMI Metal Engineering eXpo Show Preview

Jaykase Booth #401 Jaykase will be exhibiting in booth 401.

The Jaykase line of programmable tabletop bending machines are available in two sizes, the JK-250 has a maximum mild steel wire size of .250” and the JK625 has a maximum mild steel wire size of .625” inches.

Keystone Steel & Wire

Moyer Companies

Booth #523 Keystone Steel & Wire Co. is an EAF steel mill producing 800,000 tons per year of rod, rebar and wire. Product capabilities include low to high carbon rod sizes from 7/32" to 3/4", wire sizes from .062" to .625" / Direct drawn industrial & plating qualities, Lime Brite, borax coated, galvanized, brite & black annealed, borax substitute, zinc phosphate. HDMB & large diameter HDMB.

Booth #815 Moyer Manufacturing supplies the spring industry with 12", 18", 30", 36" and Tandem 36" grinders, refurbished grinders, automation, and set removal equipment. Moyer Process & Control introduced digital freelength gauges.

They continue with the 100 percent Spring Load Tester, CNC controls, repair gauges, and service testers.

Kiswire Trading, Inc. Booth #831 World's leading manufacturer of high carbon steel wire products.

Larson Systems Inc. Booth #806 Manufacturer of spring testing equipment.

We offer manual and automatic testers for compression, extension and torsion testing. Gauging and sorting equipment.

Racing products, service and calibration.

JN Machinery Corp Booth #901 Designer and manufacturer of electric conveyor ovens of all sizes under the brand "JN.” Custom oven designs are possible, too. Other brands are TRC Painting Machinery, Aqua-TRC Coating Material, and FTS Garage door Spring Paint System. Examples of all our brands and machines will be on display.

Jowitt & Rodgers Co. Booth #809 Jowitt & Rodgers Co. is a manufacturer of abrasive products employing conventional, ceramic and super abrasive materials. We manufacture grinding wheels suitable for grinding spring ends on virtually any spring grinding machine.

Our latest development is a bonded super abrasive that can provide extremely long life, will hold tight tolerances and is suitable for a wide variety of spring materials.

Keyence Corporation of America

Link Engineering Company Booth #627 Link Engineering Company is a premier designer and manufacturer of customized, precision test systems, and provides comprehensive vehicle and laboratory test services for the global transportation industry. Established in Detroit, Michigan, LINK now operates facilities around the world and specializes in the areas of brake, transmission, driveline, steering, wheel, hub, tire, bearing, electric motor, and resilient material applications.

Mount Joy Wire Corporation Booth #727 We are a made-to-order facility engineering products to our customers' exact specifications, whether it's AmeriCoat Music Wire or any other wire, including carbon steel from C1005 to C1095, chrome silicone, spherodize annealing, oil tempering, tin plating, and electro-galvanizing with full capabilities for sizes from .005 to .162.

Nitrex 707 Heat treating services in the automotive, aerospace, springs, aluminum extrusion, pneumatic/hydraulic, gears, machinery, plastics, tool and die, industrial and commercial sectors.

OMD Booth #401 OMD will be exhibiting in booth 401. OMD spring grinders have all the features that springmakers require such as continuous pass grinding, down feed grinding, single and double loading plates, special ventilation systems, automatic grinding wheel compensation, automatic grinding wheel dressing and automated grinding systems.

Oriimec Corporation of America (MEC) Booth #428 Oriimec is the solutions leader in the spring and wire forming industry offering coiling, extension, torsion, and wire forming machines. We are also a supplier for Coilmaster Reels.

Booth #800 Advanced sensing & measuring solutions for factory automation.

SPRINGS / Fall 2015 / 57

SMI Metal Engineering eXpo Show Preview

Precision Metalforming Association Booth #921 With more than 850 member companies spanning the globe, the Precision Metalforming Association (PMA) is dedicated to providing a platform for its members to make valuable connections, access training and educational resources, receive relevant news and learn about emerging industry technologies. Visit www.pma.org to find out how PMA can work for you and your company.

Radcliff Wire, Inc. Booth #701 A world leader in the manufacturing of quality precision shaped wire. Specializing in stainless steel, copper, beryllium copper, brass, phosphor bronze, nickelsilver, carbon steel, and nickel alloy wire. 50 years ago the company began by servicing the spring industry. Today Radcliff Wire, Inc. provides wire for applications in the aerospace, medical, electronics, telecommunications, automotive, computer hardware, and consumer products industries.

Precision Steel Warehouse Booth #711 Precision Steel Warehouse, Inc. in Franklin Park, Illinois specializes in custom slitting of flat rolled steel from .002 to 0.187 in. thick. Products include stainless steel in many grades and tempers, CR low carbon strip and sheet, high carbon tempered and annealed, tin plate, electro-galvanized 4130 alloy, and brass. Custom processing includes slitting, edging, oscillated coils cut- tolength EDI and bar coding.

Pyromaitre, Inc. Booth #410 Pyromaitre Inc. manufactures high quality ovens for stress relieving and tempering applications. Pyro technology allows reducing cycle time, which gives many savings such as labors, footprint, energy, uniformity and much more. Visit us and find out how we can offer you a competitive edge.

Raajratna Stainless Wire (USA) Inc. Booth #726 Raajratna Metal Industries Limited is an ISO 9001 : 2008 accredited stainless steel wire manufacturer, and one of the most reliable source of stainless steel wires, S.S bright bars, stainless steel welding wire, stainless steel spring wire and cold heading wires. Our wire includes industrial stainless steel wire, SS Tig-Mig wires, Redrawing wires, SS Spring wires, nail wires and spoke wires.

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RK Trading Company Booth #501 Since 1996 RK Trading has been supplying the spring industry with Herdon CNC formers, coilers, and grinders. RK offers a complete line of parts tooling for all the Herdon machines. RK also provides second-to-none service on all machines we sell from our Chicago, Illinois facility.

Rolled Metal Products, Inc. Booth #615 Stainless steel flatroll service center.

SAS Testers Booth #401 SAS Testers will be exhibiting in booth 401. SAS spring testing equipment includes compression, tension, torsion, life cycle, fatigue testers and the latest line of vision inspection equipment for both axi-symmetrical parts and for 2 and 3 D wire forms.

Shinko Machine Tool Co., Ltd Booth #418 Shinko Machine Tool Co., Ltd. Is a coiling machine manufacturer from Japan.

We were founded in 1985 and beloved by many spring manufacturers all over the world. We provide machines for compression, extension, wire forming and torsions.

Simplex Rapid / NIMSCO Booth #425 Simplex Rapid will have several two point coiling machines on display. Simplex Rapid is an industry leader in state-ofthe-art technology and construction quality. Also known for innovative ideas, they are constantly introducing revolutionary solutions to increase productivity and machine user-friendliness.

Sivaco Wire Group Booth #631 Sivaco is a leading North American supplier of customized steel and wire and a vital component of Ivaco/Heico inc, a leading North American producer of steel and wire rod.

Spectral Systems Booth #415 Industrial machinery manufacturing.

Sumiden Wire Products Booth #515 Sumiden Wire Products is a domestic manufacturer of high quality stainless steel wire. Nickel coated, soap coated and medical grade options are produced at our Dickson, Tennessee mill. Our engineering staff is available to design custom specifications for special applications.

SMI Metal Engineering eXpo Show Preview

Suzuki Garphyttan Corp

Toyo Seiko North America Inc.

Booth #628 Suzuki Garphyttan develops and manufactures advanced spring wire from various alloys for applications where the quality and performance requirements are extremely strict. The main applications are valve springs, transmission springs, piston rings, wave springs, die springs, linear guides and springs for injection systems.

We have operations in China, England, Japan, Sweden and USA.

Booth #632 Manufacturer of highest quality cut wire shot peening media. Highest hardness shot available. Long life high durability cut wire. Manufacturer of Toyo Seiko Coverage checker. Warehoused and distributed from centrally located South Bend, Indiana.

Taubensee Steel and Wire Company Booth #811 Taubensee Steel & Wire is a leader in the steel wire and cold drawn bar industry, built on family values and exceeding customer expectations for more than 70 years. Our quality, service, reliability, and trust puts us ahead of the pack as your go-to manufacturer for all low and high carbon wire, straightened and cut wire, and cold drawn bar needs.

Ulbrich Stainless Steels & Special Metals, Inc. Booth #802 Ulbrich Stainless Steels & Special Metals, Inc., is a global precision re-roller and distributor of stainless steel strip, special metals strip, foil, shaped wire, fine wire, sheet, plate, bar and PV ribbon products. Ulbrich’s product line includes, but is not limited to: stainless steels, PH grades, nickel and nickel alloys, cobalt, niobium, zirconium, titanium and titanium alloys.

Unidex Group, Inc.

TBE (T. Butler Engineering, Ltd.) Booth #401 T. Butler Engineering, Ltd. (TBE) is represented in booth 401. TBE is the leader in high volume, precision wire forming and spring making equipment. TBE has solutions for complex 3D shapes, fast changeover times, and integrating secondary operations for automated production of complex wire forms and assemblies.

quality product at competitive prices while offering superior customer service. VINSTON is constantly striving to improve its products through valued customer feedback and a constant drive to innovate.

Booth #703 Unidex Group specializes in manufacturing fine carbide spring-forming tools.

With more than 20 years of experience, we offer highest quality, custom tooling capabilities, convenient customer service to all of our customers at below competitive market price. *Special tooling for all domestic and foreign machines *Tool duplication and custom fabrication *Highest quality *On time delivery

United Wire Co., Inc. Booth #610 Manufacturers of flat, square, and shaped wire in stainless steels, carbon steels, nickel alloys, and copper alloys.

WAFIOS Machinery Corp.

Booth #201 WAFIOS was established in 1914 in Reutlingen Germany, and today is the leading global supplier of precision wire and tube working machinery.

Continuously committed to remain on the forefront of quality and innovation, WAFIOS currently manufactures over 120 models of wire and tube working machinery, with locations in all major manufacturing economies worldwide.

Wire Forming Technology International Booth #513 Wire Forming Technology International is a quarterly publication covering the manufacture of springs, wire formed parts, wire mesh and rebar products and the materials, tooling, machinery and control systems for making those parts. Subscriptions are free to industry professionals at www.wireformingtech. com. Readers are located in over 70 countries.

Zapp Precision Strip, Inc. Tong Lu SanLi Furnace Co.,Ltd Booth #614 The biggest manufacturer of continuous conveyor tempering and quenching furnaces in China (70 percent of the total Chinese market), mainly used for the heat treatment of spring and other hardwares. We also manufacture spring end grinding machines, grinding wheels, chamfering machines, and industrial dust aspirators.

Vinston US Corp Booth #109 VINSTON’s mission is to provide total custom satisfaction by providing a

Booth #624 Material customization-providing solutions.

Quality from the start: • Partnership-in-process – customized specifications • State-of-the-art rolling mills in Dartmouth, Massachusetts and Unna, Germany • Just-in time Service Centers providing slitting, edging, and winding Call us at our East Coast service center to see what we can do for your business: Toll free 866-578-9277 n

SPRINGS / Fall 2015 / 59

booth 501

EliminatE SEcondary opErationS HaX 3d turrEt SEriES FormErS With the same trusted quality you’ve experienced in smaller Herdon Hybrid formers now you can handle larger wire ranges. The 16-axis all servo former comes with touch screen programming, moveable slides, rotary wire, 3 standard servo spinners along with an optional double servo spinner or looping station you can take on the large wire jobs without those costly secondary operations. Now is the time to move to the ne xt le ve l.

www.rktradingusa.com 60 / SPRINGS / Fall 2015

847-640-9771

©iStockphoto.com/Björn Meyer

visit us at

©iStockphoto.com/Björn Meyer

Springmaker Spotlight

On The Move: A Profile of Phil Jones and Industrial Spring Corporation of Kansas City

By Gary McCoy, Managing Editor

Just like its hometown baseball team, the Kansas City Royals, Industrial Spring Corporation of Kansas City (ISCKC) is enjoying a “season” of success as the company recently celebrated its move to a new location that nearly doubles its space. The company, founded in 1967, relocated in August 2015 from its longtime home in Riverside, Missouri, to nearby North Kansas City, Missouri. They’ve gone from 23,000 sq. ft. to 45,000 sq. ft.

Phil Jones, who started working at ISCKC right out of high school in 1977, has filled many different roles at the company during his 38-year tenure. He started out running a hand coiler and later became production manager and head of sales.

Jones became president Jan. 1, 2014.

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He said the move to North Kansas City was long overdue because its location in Riverside was landlocked, making expansion impossible.

“We moved to a great area, and not far from our old location,” explained Jones. “It has a lot of good highway access.”

He said the area was coveted by many companies, so finding buildings available for purchase was challenging.

Jones said ISCKC has always been a cash company, so the idea of leasing was out of the question. He had realtors watching for buildings to buy, but previous properties they had looked at didn’t fit their needs.

“When this building (the new location) came up for sale, I looked at it and I could picture right off the bat how our production would flow through it.”

With a grin Jones said, “I couldn’t pass it up.”

Two Full-Time Jobs Preparing the new building and coordinating the move was like having two full-time jobs for Jones, for more than three months.

The company’s new headquarters in North Kansas City was previously a steel distribution warehouse, so it needed a lot of upgrades, especially with the electrical system. In addition, Jones said their previous location in Riverside was air conditioned, so it was essential to add that as well. “Our employees are used to that (A/C), plus it’s better on the equipment, especially for CNC machines.”

Jones has a very positive outlook on the future. “I wouldn’t make a move like this if I didn’t think we’ve got a lot of market share we can pick up.”

And he doesn’t rule out the possibility of growing through acquisitions.

“It could be smaller spring companies to help with our growth. It’s not all going to be organic, I don’t think,” Jones said. “We have explored acquisitions in the past, but our size limitations deterred that.”

With more space at its new location, Jones sees expansion for ISCKC more feasible than in the past.

Overall, he sees bright skies ahead for the company.

“I know a lot of people have been fairly stagnant, especially since 2008, but we’ve had good growth year after year.”

Where They’ve Been Glenn Tehel was the original founder of Industrial Spring in 1967. Tehel, a World War II Navy veteran, started doing tool and die work for Kansas City area companies after the war. One of those companies, Farris-Burns, made springs. “He worked for them for many years, before he ventured out to work on his own,” explained Jones.

Industrial Spring was started by Tehel, his best friend Jerry Doyle and a group of investors. Doyle later started a division in St. Louis, so the company had two locations for many years.

“When Glenn started to think about retirement around 1990, he looked into forming an ESOP (Employee Stock Ownership Plan),” explained Jones. “He found there were

62 / SPRINGS / Fall 2015

lots of tax advantages and a way for him to get his money out of the company, while still establishing a succession plan.”

In 1991 the company became a partial ESOP. “We did a leveraged bank loan to finance the purchase back of all the stock (from the stock holders) and a company loan also. It was two separate loans. As those got paid down through the years, stock was distributed to all the current employees.”

“The folks at the St. Louis facility didn’t want to go that direction, so at that point they bought out their portion of the company,” said Jones.

ISCKC is unique among SMI members because of its organizational structure as an ESOP. The National Center for Employee Ownership (NCEO) estimates that as of 2015 there are roughly 7,000 employee stock ownership plans (ESOPs) covering about 13.5 million employees.

ISCKC employees outside the company's new headquarters in North Kansas City, Missouri.

“Every employee, from the person that quotes your requirement, to the person that ships your completed order and everyone in between, is an owner and has a direct stake in your satisfaction as a customer. We feel that this gives our customers an added benefit not found with many of our competitors.�

SPRINGS / Fall 2015 / 63

Jones admits that communicating the benefits of an ESOP structure to ISCKC employees has been a struggle at times, “because it is more of a retirement plan and everybody would prefer some immediate gratification.”

He points out that it’s rare for employees to own stock in a company where they have a direct involvement in its performance.

“We’ve got some employees that have been in it (ESOP) for a long time and they’re seeing strong, six digit balances,” said Jones. Some of them are getting old enough (55) to receive diversification distributions. They’re seeing pretty strong diversification distributions and they’re starting to say, ‘Well, this was a pretty good idea, I think.’”

The company’s workforce numbers around 17 and as ISCKC says on their website, “Every employee, from the person that quotes your requirement to the person that ships your completed order and everyone in between, is an owner and has a direct stake in your satisfaction as a customer. We feel that this gives our customers an added benefit not found with many of our competitors.”

Jones says he enjoys making employees appreciate and enjoy what they’re doing as much as possible.

He feels the ESOP structure contributes to having an enjoyable work environment. The company also takes time out to celebrate milestones.

Jones said when ISCKC broke it sales record in January 2015, the company celebrated by going to a place called

64 / SPRINGS / Fall 2015

“Power Play” which he describes as a “Chuck E. Cheese for adults.” The team building competition included go kart racing.

“It’s good to keep the fun stuff like that going, to keep everybody motivated and enjoying what they’re doing,” said Jones.

Products and Services The company attempts to live up to its mission statement, which says, “Industrial Spring Corporation of Kansas City is dedicated to building long term partnerships with our customers, owners and suppliers by exceeding their expectations of quality and services.”

The company manufacturers compression, extension, flat and torsion springs, along with wire forms. The company’s biggest market segment is in commercial lawn equipment, followed closely by agriculture which includes veterinary supply type products. They are also involved in making parts for many other industries, but manufacture little for the automotive industry by choice.

“We felt like if we started getting into too much automotive that it would end up being our only focus,” explained Jones. “And all our other customers would suffer because of it.”

They do some automotive aftermarket product work and for some tier 3 suppliers.

Though an overused phrase, and with different meanings for various spring companies, for Jones “customer service” is an area where ISCKC can stand out from the crowd.

“There used to be three things that everybody concentrated on: price, quality and on time delivery.

All three of those now are just expected,” related Jones.

“In my opinion, your advantage in the marketplace is in customer service.”

Though the company has voice mail at its new location, Jones emphasizes that it is not used during business hours.

“When you call Industrial Spring of Kansas City, you get to talk to somebody every time,” Jones said. “Everybody in the shop knows that...and they get tired of me or my sales manager going out and saying, ‘So and so called, they need these tomorrow.’”

Jones says that sometimes ISCKC can’t do tomorrow, but for a good customer “we’ll bend over backward to try and accommodate what they need.”

He goes on to say, “They say real estate’s ‘location, location, location.’ For me, it’s ‘customer service, customer service, customer service.’ That’s what we concentrate on.”

Jones partially attributes the company’s recent growth to its focus on customer service.

He says they’ve won a few customers back recently that they lost to price, “but not usually due to China.”

“We lost a very large customer in 2010 to price and got them back about a year and a half ago because of quality and delivery issues,” stated Jones. “So price isn’t always the only factor.”

“It’s become increasingly difficult with each passing year to find qualified people that are interested in this kind of work,” lamented Jones. “Most of our people have been here a long time. Some as long as me, some longer than me, and several people with over 20 years of service.”

Family Focus Jones is not one to judge his success based on business.

“I’m much more of a family-oriented kind of person.”

Jones got married straight out of high school to Sherry.

They have two daughters and a son. His oldest daughter, Ginny, is married and has two sons.

His 20-year old son, Patrick, is an entertainer in “multiple ways.” He teaches dance, drums and is a worship leader at a church. “And he’s a working magician,” explained Jones.

His youngest daughter, Lena, works at McDonald’s and is a high school senior.

“She recently became a manager at McDonald’s after working there for one year,” said Jones. “I am very proud of all of my kids.”

Jones said his whole family is very musical. “I played guitar when I was younger,” said Jones. In fact, during

the ‘70s he was part of a local Christian rock band called “Sacred Heart.”

“Music with my family is a hobby still,” said Jones.

“Like I said, I don’t play much anymore, but my brothers are musical and all our Thanksgivings are nothing but sitting around the piano with guitars and having a blast with that kind of stuff.”

Church is a big part of Jones’ life. He’s a member of a very large Baptist church where he volunteers his time doing lighting. “We go to what most people would call a megachurch.”

Jones said none of his children have shown an interest in working at ISCKC and he said as a company they’ve discouraged hiring relatives.

“I know a lot of spring companies are family owned,” said Jones. “That’s a great thing, but it was never right for us.”

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“I’m always concerned with productivity,” said Jones. When we conducted the interview, Jones had just received his copy of the 2015 SMI annual market survey and said, “We’ve always had a well above average employee to sales ratio, according to the survey.

It just confirms that we have really productive employees.”

Next Generation Challenge For someone who joined the spring industry straight out of high school in 1977, Jones has witnessed significant changes during that time.

He said two of the biggest changes is in technology with the changeover to CNC equipment, and in higher customer expectations on a constant basis.

Like many spring companies finding qualified workers is a change that’s turned into a challenge.

“It’s become increasingly difficult with each passing year to find qualified people that are interested in this kind of work,” lamented Jones. “Most of our people have been here a long time. Some as long as me, some longer than me, and several people with over 20 years of service.”

After a pause, Jones said, “I’d say that’s been the biggest change, trying to find qualified people that want to work in a manufacturing environment.”

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With the company expanding, Jones said it is not so much about ISCKC buying more machines, it’s having more run time on the equipment it already owns.

“That’s a struggle because of the challenge of finding good employees,” he said.

Recently, ISCKC has looked to recruit employees from a machine tool training program at a metro Kansas City community college.

“There’s a little bit of a crossover between machine tool type work, as far as CNC programming and springmaking,” he said with an emphasis on “a little bit.”

Jones explained further, “At least you get some good, basic knowledge on blueprint reading and using calipers and micrometers and that kind of stuff. We’ve gotten a couple of good people from there that I’m hoping will pan out to be long term employees. This could help us down the road to add a second shift, which we currently don’t have.”

In addition to the challenge of finding good employees, Jones said he’s been personally challenged in making the transition to president of the company following Bob Thill, who took the position after Tehel retired.

“I had a good working knowledge of what Bob was doing,” explained Jones, “but it’s not the same until you’re actually doing it yourself.”

Jones is hoping to get more involved in SMI, like his predecessors Tehel and Thill, who attended many SMI meetings. He’s planning to come to the SMI Metal Engineering eXpo in October with his sales manager, John Tvrdy.

Though not as active as some other spring companies in SMI, Jones said ISCKC has taken advantage of the many services the association offers, including the spring design software, safety audits and the annual market survey.

“I’m always concerned with productivity,” said Jones.

When we conducted the interview, Jones had just received his copy of the 2015 SMI annual market survey and said, “We’ve always had a well above average employee to sales ratio, according to the survey. It just confirms that we have really productive employees.”

Though he doesn’t have the opportunity to attend many professional sporting events, Jones enjoys being a fan of the Chiefs and Royals.

With the recent success of the Royals, Jones said “it’s been fun to watch.”

Though not the same as following a sports team, ISCKC’s recent success through expansion and increased sales has also been enjoyable for Jones to watch — but probably not so much through the eyes of its competitors. n

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Rust: The Longest War

C

orrosion is a major issue for springmakers, stampers and their suppliers. We all recognize that it is often a prime consideration in the selection of materials, so it is not surprising to find a book on corrosion of interest.

But in “Rust: The Longest War,” Jonathan Waldman has written a wonderful book that will appeal to a very broad group. In fact, I was led to this book by reviews in The New York Times and Wall Street Journal.

Waldman wastes no time in framing the importance and breadth of rust-related problems: deaths related to bridge collapses, reactor meltdowns, nuclear warheads rendered powerless, leaky oil pipelines, water heaters sent skyward, rusting ships and jets, house fires, washing machines, national treasures and historical artifacts like the Statue of Liberty. By page 7 we have learned that there is rust in outer space. Corrosion is a major issue for the U.S. Navy, in fact, its biggest issue. (The author points out that the term “rust” concerns iron and corrosion applies to other metals, but he uses the terms interchangeably.)

Rust is a big worry for soda can makers, and those who must keep municipal water mains working. Firestone had a problem with the tire cord in steel belted tires. All in all, rust is costlier than all other natural disasters combined and averages out to “about $1,500 per person per year.”

It will be no surprise to readers of this magazine that corrosion doesn’t get the focus it deserves because it lacks sex appeal. But the beauty of this book is that Waldman writes so well and has picked his topics with such breadth that he makes corrosion a very interesting topic and makes it, if not sexy, at least fascinating.

One of the greatest features of this fine book is the way the author glides from topic to topic. Chapter 2 is a very interesting discussion about the issues with corrosion at the Statue of Liberty. Chapter 3 provides an excellent historical overview. Pliny the Elder, Robert Boyle, Sir Humphry Davy, Michael Faraday, and Marcel Pourbaix all spent major time on issues relating to corrosion. A chapter on Harry Brearley is a very interesting perspective on the man and his single-minded devotion to metal.

Waldman has a chapter on the complexity of cans and corrosion, which may make you change your drinking habits. There then follow chapters on such diverse subjects

as gover n ment ef for ts regarding corrosion and a photographer, Alyssha Eve Csük, who takes wonderful pictures of rusty objects, mostly at the old Bethlehem Steel Works in Bethlehem, Pennsylvania. I strongly recommend visiting this photographer’s website at www.alysshaevecsuk.com.

One of the final chapters describes the issues involved with detecting possible corrosion in the Alaskan pipeline.

Waldman does an excellent job of describing issues we face with a pipeline that is filled with less oil and thus more moisture. It is disconcerting, but many of the employees who work on this problem are outstanding in their diligence.

The best books entertain but also make us think.

Waldman has done this very well. He got me thinking about our industry and NACE (the National Association of Corrosion Engineers). Should we be looking to do more with them? Is this an opportunity to help advance this topic for the benefit of all parties in North America?

This book also made me think about attracting the next generation to our industry. Waldman makes the science interesting. He makes topics that might seem dull very interesting. He shows us the importance of his topic.

He writes well. Rust can ignite an interest in science or awaken in humanities majors the desire to learn more science. We need to think about these lessons for our industry so we can attract the best candidates. We have a good story to tell and if we tell it well, we can attract very strong candidates to our industry.

Waldman has done a terrific job with “Rust.” I eagerly await his next book.

(Reviewer’s note: If you mistakenly pick up the book “American Rust” by Phillip Meyer you will be reading a novel about some great characters, a decaying mill town, and an accidental death. While not the book described above, it is a very well-written novel by a wonderful author.) n Reviewed by William J. Torres, CEO and president of Gibbs

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

SPRINGS / Fall 2015 / 69

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Global CTE News Highlights MiCareerQuest is a Big Hit in West Michigan

W

ithin the cavernous space of 27,000 square feet in the DeVos Place in Grand Rapids, Michigan, more than 6,000 high school and some middle school students from West Michigan gathered for MiCareerQuest 2015.

The event was held for the first time in April 2015 and designed to provide students with an interactive, hands-on, informational and inspiring career and college readiness event. Employers from four industry sectors – advanced manufacturing, construction, healthcare and information technology – had a half-hour each to provide students with activities and an overview of what a career is like in that sector.

Helping represent advanced manufacturing was Jay Dunwell, president of Wolverine Coil Spring in Grand Rapids. To help support the event was Dan Bagwell, manager of technical sales for Forming Systems, Inc. who arranged for an HTC machine to be at the event for students to see manufacturing technology in action, firsthand.

“The students’ faces said it all as they stared mystified by the HTC machine bending and coiling wire,” said

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Dunwell. “The ‘wow’ factor was (Editor’s note: in high gear.”

In this issue of To help the students see the Springs we present action close-up, a camera was a new department mounted near the machine and devoted to news projected on to a 65-inch TV about Career & display so students could get a better look.

Technical Education Wit h on ly 30 m i nutes i n (CTE). Please keep the manufacturing quadrant, us posted about any Dunwell said the program was efforts in your area broken up into t h ree phases to attract students with an overarching theme of to careers in the “manufacturing impacts.” The spring and wire idea they were trying to impart forming industry.) was, if you want to impact the world, come explore careers in manufacturing. Phase 1 helped students understand the creative side of manufacturing in terms of how parts are designed, along with role of new materials and prototypes.

“Students don’t always think of manufacturing as a career choice for the creative and artsy types, but it truly is,” explained Dunwell.

Phase 2 focused on the production side of the business, with metal forming, plastics and robots taking center stage.

Phase 3 was the final part of the advanced manufacturing segment, where students could see how the pieces and parts from the production phase come together as finished products from various West Michigan manufacturers.

Dunwell said they learned a lot from the first event, and were pleased with the results. “The construction segment made a big hit, pun intended, with students, simply by letting them swing a mallet and attempt to break a Plexiglas window,” said Dunwell. “So we hope to make the advanced manufacturing segment more interactive in 2016.”

With a huge need within the spring and wire forming industry to attract new talent, Dunwell sees MiCareerQuest as something that could be duplicated across the country.

“The concept of busing students in for an event like this could be easily copied by other springmakers in their area,” said Dunwell. “To see 6,000 students come through, get exposed to new careers, and make a big splash was very inspiring. It’s the sort of thing that will help recruit new talent to manufacturing.”

To learn more and watch a short video, visit www. micareerquest.org. n

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Strong Speaker Lineup Planned for 2016 SMI Annual Meeting

S

MI has assembled a strong roster of speakers for the 2016 Annual Meeting that will be held April 15-19 at the St. Regis Monarch Beach in Dana Point, California.

Dr. Rajita Sinha, director of the Yale Stress Center and a professor at Yale University in New Haven, Connecticut, will hold a special session Sunday morning, April 16. She will conduct exercises on mindfulness, yogic breath, and psychobiology on how to be effective and optimize function.

On Monday, April 17, Dr. Sinha will address: “Stress and the Brain: Introduction to Stress Management and Optimizing Function.” During this 90-minute session, Dr. Sinha will discuss the science of the brain and how stress can damage brain cells.

As we all know, health care costs are rising at an alarming rate nationally.

Dr. Sinha will provide SMI members with common sense approaches on how to improve wellness in the workplace.

Dr. Sinha is the founding director of the Yale Stress Center, a universitywide center that focuses on understanding the effects of stress on emotions, mood and behavior, in order to improve health outcomes relating to choices and maladaptive behaviors.

She has also served as the director of addiction services at the Connecticut Mental Health Center. She is internationally known for her pioneering research on the mechanisms linking stress, emotions to addictive behaviors and health outcomes.

A second session Monday will begin the first of a two part presentation by Dr. Paul Stoltz, the author of the national best-seller “GRIT: The New Science of What it Takes to Persevere, Flourish,

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Succeed.” GRIT is a compelling introspective on how much GRIT you have as an individual and how you can use GRIT to your advantage in all aspects of your personal and business life.

Dr. Stoltz will conduct the second part of his presentation Tuesday, April 18, at 10 a.m. During that session he will review the individual GRIT Gauge survey results that SMI members have the opportunity to participate in before the convention. He will present each member with their results in an envelope. In addition, he will hold audience discussions on what it takes to maximize your GRIT, and how you can grow your GRIT and take it even higher.

Dr. Stoltz is considered the world’s leading authority on the integration and application of grit and resilience. He is the founder and chief executive officer of PEAK Learning, Inc., as well as the originator of the AQ® (Adversity Quotient®) and GRIT™ theories and methods, used at Harvard Business School, MIT and Fortune 100 companies worldwide. He resides with his extended family in the coastal mountains of San Luis Obispo, California.

Before Dr. Stoltz’s Tuesday presentation, the day will kick off with a presentation by Paul Menig, CEO

Paul Menig

of Tech I-M. Menig, who will be conducting a presentation at the SMI Metal Engineering eXpo in October, will present the results of his in-depth investigation of the spring industry for nearly two years. His presentation will be a compilation of over 40 private discussions he’s held with SMI members, associate members and a few nonmembers. He will speak about what the future of our spring industry will look like for small, medium and large companies. Menig will look at how to move the needle and grow your business into a more successful enterprise, depending on the size of your company.

Each SMI member in attendance will receive a copy of Menig’s study in the form of a white paper.

Menig has spent his career leading teams to develop, introduce and support new products for diverse industries including automotive, trucking, factories, hospitals and the military. While working at General Electric, Eaton and Daimler, he was part of new business startups and financial turnarounds. He worked with global research groups to conceive new products, has been in front of customers to help make the sale, and in the field solving problems.

For more information and to register for the SMI Annual Convention, phone SMI at 630-495-8588. n

SPRINGS / Fall 2015 / 73

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The Work is Almost Finished

A

s the need has arisen, SMI has formed new committees to help meet the needs of its members.

That’s how the SMI Trade Show Committee was formed in 2014.

It all started in 2013 when the SMI board ratified a new strategic plan that called for expanded technical training and a new North American trade show.

Dan Sceli, president and CEO of Peterson Spring, was tapped to serve as the chairman of SMI’s trade show committee. The committee consists of SMI member springmakers, associate member suppliers, honorary members and SMI staff. The committee includes: Mike Betts, Betts Company Jim Callaghan, Lee Spring Lynne Carr, SMI Mark DiVenere, Gemco Manufacturing

Simon Fleury, Liberty Spring Bert Goering, Precision Coil Spring Co. Gene Huber Jr., Winamac Coil Spring Steve Kempf, Lee Spring Company Gary McCoy, SMI Rob Myers, RK Trading Company Daniel Pierre III, JN Machinery Hap Porter, SEI MetalTek Dina Sanchez, SMI Dan Sebastian, Honorary Member Bill Torres, Gibbs Wire and Steel The committee held its first in-person meeting last year on April 24, 2014 in Chicago. This year, the committee has met regularly through monthly conference calls to track the progress of the show.

On Aug. 7, 2015, the committee held its last face-to-face meeting in

Chicago to review final plans for the event and to work with the team from Tradeshow Logic of Atlanta, Ga. that was hired by SMI to organize and administer the show.

“The work is almost finished,” said Sceli. “As the chairperson of the show, I’ve had the privilege of working with an incredible team of volunteers to help bring together all the pieces to make the trade show and technical education sessions a reality. I thank each member of the committee for their hard work and dedication.”

For more information or to provide feedback about SMI’s committees, contact SMI’s executive director Lynne Carr at lynne@smihq.org or 630-4958588. n

The SMI trade show committee met with leaders from Tradeshow Logic to go over final plans for the Metal Engineering eXpo, including Chris Price (above right), Bobby Bergeron (lower right), and Donna Karl (not pictured).

SPRINGS / Fall 2015 / 75

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See the Shape of Things to Come.

Introducing SMI Metal Engineering Expo, a tradeshow for the entire spring, wire and metal forming industry. Conduct business, make new connections with suppliers and expand your professional expertise at an event like none other in North America.

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See the complete symposia schedule, learn more about networking events and register at

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New Products

SAS Testers ALT-2000 High Speed Compression Spring Tester SAS Testers introduces the new ALT-2000 series of high speed automatic compression spring testers for high volume production.

The ALT-2000 can be used in various configurations: • Auto-feeding, setting, testing and sorting (5 ways, 3 ways or 2 ways).

• Auto-feeding, testing and sorting (5 ways, 3 ways or 2 ways).

• Manual feeding, setting, testing and sorting (5 ways, 3 ways or 2 ways).

• Manual feeding, testing and sorting (5 ways, 3 ways or 2 ways).

The ALT-2000 crosshead can move at speeds from 0.0004”/s (0.01mm/s) to 4.92”/s (125mm/s) fully programmable using all the functions of a regular motorized spring tester. The software includes SPC functions for displaying reports of data saved while testing. Programs of spring setups are stored making setup of different spring tests easy and intuitive.

Production rates up to 2500 parts per hour (pph) are possible when setting and testing one force at height and using a small stroke (note that production rate will be reduced with multiple test points and large strokes, and/or light springs where vibration stabilization is needed). Setting is achieved in parallel to testing (using up 1, 2 or 3 setting actions) with no reduction in throughput.

The ALT-2000 is capable of testing compression springs up to 450lbf (2000N) and free lengths up to 8” (200mm).

For additional information, contact Forming Systems, Inc. at 269-679-3557.

You can also see the new ALT-2000 Test System at the SMI Metal Engineering eXpo, Booth 401.

Larson Electronics Reveals a 150-Watt Portable Explosion Proof LED Light on Base Stand Larson Electronics has announced the release of a Class 1 & 2 Division 1 & 2 portable explosion proof LED light mounted on a base stand fabricated from non-sparking aluminum.

The EPL-16BS-1X150LED-X24I-50 portable explosion proof LED light from Larson Electronics provides operators an easy to maneuver LED work light for use within hazardous locations. This portable fixture is comprised of a 150 watt LED light head that is mounted atop a base stand fabricated from non-sparking aluminum and operates on 120-277 volts AC stepped down to 24 volts DC via an inline transformer. The LED light head

produces a brilliant flood pattern of light that is ideal for illuminating enclosed areas and hazardous locations where flammable vapors, gases and dusts may be present. The LED lamp head is T5 temperature rated and retains 80 percent of its lumen output after 60,000 hours of use. The lamp can be easily adjusted up or down 90° and locked into position by loosening the two hand screws located on the side of the light head. Once the light is in the desired position, the operator then tightens the screws back to set the position. The light frame assembly features a carrying handle on the top for easy transport and a hand screw at the

base allowing operators to pivot the top frame assembly on the four leg base stand. Included with this portable LED light is 50 feet of chemical and abrasion resistant SOOW cord leading up to the encapsulated step down transformer.

Five feet of 16/3 SOOW cable is on the input side of the transformer and is fitted with an industrial grade cord cap for easy connection to common wall outlets.

You can view Larson Electronics’ full line of industrial grade lighting at Larsonelectronics.com, or by phone at 800-369-6671 or 214-616-6180 for international inquiries.

SPRINGS / Fall 2015 / 77

New Products

New Catalog Describes Benefits of Canted Coil Springs for EMI/RFI Shielding A new technical catalog published

by Bal Seal Engineering, Inc. provides engineers and designers with detailed information about how canted coil springs can be used to address electromagnetic interference/radio-frequency interference (EMI/RFI) shielding challenges.

The 10-page catalog, titled “Bal

Spring™ canted coil spring: Solutions for EMI/RFI Applications,” describes how the company’s compact, precisionengineered spring protects sensitive electronics from the harmful effects of EMI/RFI, particularly in high-frequency, small-package applications.

The catalog presents data on the spring’s EMI/RFI shielding properties, including transfer impedance and shielding effectiveness, as well as graphics illustrating attenuation versus frequency at 1–10 GHz and 100 MHz–1 GHz. Summary testing data show that the spring exhibits much lower transfer impedance than finger stock, helical flat springs, or wire mesh over elastomer technologies.

Shielding performance data in the catalog were compiled from transfer impedance (SAE ARP 1705) measurements taken from over 150 different configurations. Bar graphs present data in terms of specific parameters, including materials and platings, groove types and forces.

A force deflection chart depicts the spring’s mechanical properties, examples of typical groove configurations illustrate optimized spring performance in various user geometries, and the most common assembly orientations are shown along with typical examples.

Bal Spring canted coil springs have been tested and proven to provide effective shielding in the packaging of electronics enclosures.

As interface components, the springs offer a simple, economical design that greatly reduces radiated and conducted interference. Unlike

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filled elastomers, the springs also resist compression set and offer improved durability and reliability.

Available in a broad range of coil heights, wire materials and plating types, the Bal Spring canted coil spring maintains a nearly constant force over a broad compression range, compensating for angular misalignment, surface irregularities, and even temperature changes without significant deviation from its initial force. Each coil works independently, maintaining contact with the mating surface and ensuring maximum conductivity. The versatile component’s locking, latching, and holding properties also allow designers to meet very specific insertion and breakaway force requirements.

Download the new catalog free of charge at www.balseal.com/technical-library. Request a free printed copy at sales@balseal.com.

HMI 485H Temperature Recorder for HSI Ovens HSI Ovens has just introduced the new 485H Temperature Recorder providing real time temperature charting and recording of the temperature. The 485H can chart up to seven channels.

When accompanied by the DEM Digital Error Meter and DSMI Digital Speed Meter Interface, the system can also record alarms and conveyor speed. The new system can provide the chart in BMP format and temperature readings in text format for utilization in Excel.

Data can be stored on a USB device and read on a PC. Sampling intervals can be set between 10 seconds and 10 minutes. The 485H can also be used to set temperature and belt speed via the user-friendly touch screen interface. The available magnetic base allows for easy and convenient placement on the oven.

For additional information, please contact Forming Systems, Inc. at info@ formingsystemsinc.com or visit www. formingsystemsinc.com

New Products

Dialight’s Stand-Alone Wireless Occupancy Sensors for Smart LED Lighting Systems Dialight, the innovative global leader in LED lighting technology for industrial applications, unveiled its new wireless occupancy sensor, a unique battery-powered plug-and-play sensor that speeds and simplifies installation to provide maximum lighting control flexibility and energy savings in industrial applications.

Designed to integrate seamlessly with any Dialight smart lighting system, the new wireless sensor can be placed virtually anywhere within a facility, without the need to install or move cabling, for nearly unlimited lighting control options. A single sensor can be programmed to control multiple lights and groups of lights, eliminating the need to install a sensor on every light.

Using Pyroelectric InfraRed (PIR) technology, each sensor can

instantly switch a single light or a group of lights from off to on or from a dimmed state to on when motion is detected for full visibility and brightness only when needed, greatly reducing on-time and power consumption. Multiple sensors can be linked to a single Dialight gateway to manage several (or up to 100) nodes (sensors and lights) from a single wall controller.

Programmable dimming and customizable timeout options allow facilities to configure fixture on-time for each sensor at one-minute intervals. Lights can be programmed to remain on for up to 30 minutes once motion is no longer detected and then dim or turn off instantly.

The new wireless occupancy sensors are available in two lens types.

A wide-angle lens detects motion up to 30 feet at a 120-degree angle, ideal for ceiling mount applications to cover a larger footprint for general area lighting. The long-range lens detects motion up to 100 feet away at a narrow 10-degree angle, best suited for wall mounting and aisle coverage.

For more information, visit www. dialight.com. n

Advertiser's Index A & D Trading (440) 563-5227. . . . . . . . . . . . . . 14 Admiral Steel (800) 323-7055. . . . . . . . . . . . . . 35 Alex Industries (847) 298-1860. . . . . . . . . . . . . . 52 Alloy Wire International (866) 482-5569. . . . . . . . . . . . . . 70 CASMI (630) 369-3466. . . . . . . . . . . . . . 17 Central Wire (800) 435-8317. . . . . . . . . . . . . . 45 Century Spring, Division of MW Industries (800) 237-5225. . . . . . . . . . . . . . 32 Diamond Wire Spring Co. (800) 424-0500. . . . . . . . . . . . . . 49 Dispense Works (815) 363-3524. . . . . . . . . . . . . . 27 Elgiloy Specialty Metals (847) 695-1900. . . . . . . . . . . . . . 36 Fenn/Torin (860) 594-4300. . . . . . . . . . . . . . 21 Forming Systems Inc. (877) 594-4300. . inside front cover, back cover Gibbs Wire (800) 800-4422. . . inside back cover Gibraltar Corporation (847) 769-2099. . . . . . . . . . . . . . 18

Industrial Steel & Wire (800) 767-0408. . . . . . . . . . . . . . . 3 InterWire Products Inc. (914) 273-6633. . . . . . . . . . . . . . . 1 JN Machinery (224) 699-9161. . . . . . . . . . . . . . 10 John Evans’ Sons (215) 368-7700. . . . . . . . . . . . . . 44 Kiswire (201) 461-8895. . . . . . . . . . . . . . 37 Larson Systems (763)780-2131. . . . . . . . . . . . . . 65 Link Engineering (734) 453-0800. . . . . . . . . . . . . . 71 Mapes Piano String Co. (423) 543-3195. . . . . . . . . . . . . . 66 Mount Joy Wire (717) 653-1461. . . . . . . . . . . . . . 20 NIMSCO (563) 391-0400 . . . . . . . . . . . . . 16 North American Spring Tool (860) 583-1693 . . . . . . . . . . . . . 49 Orimec (859) 746-3318. . . . . . . . . . . . . . 67 Proto Manufacturing (800) 965-8378. . . . . . . . . . . . . . 64 Radcliff Wire (860) 583-1305. . . . . . . . . . . . . . 31 RK Trading (847) 640-9371. . . . . . . . . . . . 5, 60

Rolled Metal Products 800) 638-3544 . . . . . . . . . . . . . . 28 Shinko 81-6-6794-6610. . . . . . . . . . . . . 40 Simplex Rapid (563) 391-0400. . . . . . . . . . . . . . . 6 Spring Manufacturers Institute (630) 495-8588 . . . . . . . . . . . . . . 76 Suzuki Garphyttan (574) 232-8800. . . . . . . . . . . . . . 72 Tool King (800) 338-1318. . . . . . . . . . . . . . . 8 Ulbrich Stainless Steels (203) 239-4481. . . . . . . . . . . . . . 74 Unidex Group Machinery (630) 735-7132. . . . . . . . . . . . . . 43 United Wire Co. (800) 840-9481. . . . . . . . . . . . . . 46 Vinston (847) 972-1098. . . . . . . . . . . . . . . 9 Vulcan Spring & Manufacturing Co. (215) 721-1721. . . . . . . . . . . . . . 10 WAFIOS (203) 481-5555. . . . . . . . . . . . . . 68 wire Düsseldorf (312) 781-5180. . . . . . . . . . . . . . 11 Zapp Precision Strip (203) 386-0038. . . . . . . . . . . . . . 38

SPRINGS / Fall 2015 / 79

Snapshot ©iStockphoto.com/Tryfonov Ievgenii, nicholas belton

Nina Fazio-Williams

Diamond Wire Company Name: Nina Fazio-Williams Nickname: Nina “Rose” and “the Cookie Lady.”

Company name, city and country: Diamond Wire Spring located in Pittsburgh, Pa., South Carolina, and Tyler, Texas.

Brief history of your company: Founded in 1939 by Alphonse J. Fazio as a manufacturer of precision springs.

Job title: Southwestern sales manager.

Birthplace: Pittsburgh, Pa. Current home: Houston, Texas.

Family: Two sons, Eric and Marc. Five grandchildren, Sofia, Aminah, Olivia, Finn, and Lana.

What I like most about being a springmaker: Meeting and greeting customers at trade shows.

Favorite food: Chocolate.

Favorite books/authors: Suze Orman, “The Courage to be Rich.”

Nina Fazio-Williams with her grandchil dren from bottom left (counterclockw ise): Olivia, Aminah, Sofia and Finn. Not pictured: Lana, who was not born at the time of the photo.

Favorite song/musician: Barbra Streisand.

My most outstanding quality is: Thoughtfulness.

Hobbies: Travel, reading, baking, and gardening.

People who knew me in school thought I was: Happy-go-lucky.

Favorite places: No place like home.

I knew I was an “adult” when: I had to pay the mortgage myself.

Best times of my life: Present.

A really great evening to me is: Spending time with my grandchildren exploring new places.

The one thing I can’t stand is: Lack of initiative.

80 / SPRINGS / Fall 2015 80 / SPRINGS / Fall 2015

If I weren’t working at Diamond Wire, I would like to: Be a tour director.

The most difficult business decision I ever had to make was: Having to let go of a “difficult” customer.

I wonder what would have happened if: My mother, Jane Good-Fazio, would have sold the business in 1959 after my father died at the age of 49.

Role model: My mother, who was chairperson of Diamond Wire Spring until her death in 1993 and the mother of seven children.

I would like to be remembered in the spring industry for: Going the extra mile for customers and employees.

But people will probably remember me for: My chocolate chip cookies.

Internal memo to Gibbs’ Sales Department:

Photo courtesy of Abigail Keenan / Unsplash

When planning our next gathering of customers who told us they love our service, please remember to budget for crowd control.

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