Executive Outlook

WIRE JOURNAL MARCH 2012

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I N T E R N AT I O N A L www.wirenet.org

Executive Outlook OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

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WIRE JOURNAL

®

I N T E R N A T I O N A L

Editorial . . . . . . . . . . . . . . . . . 6

CONTENTS

Volume 45 | Number 3 | March 2012

F EATURE

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 22 People . . . . . . . . . . . . . . . . . 24 Fiber Watch . . . . . . . . . . . . . 26 Fastener Update . . . . . . . . . . 28 WAI News . . . . . . . . . . . . . . 30 Chapter Corner . . . . . . . . . . . 34 Ops Report/Tech Papers . . 54-69 Products. . . . . . . . . . . . . . . . 70

Executive Outlook . . . . . . . . . . . .36 Key executives share their thoughts on the wire and cable industry, with topics ranging from their approach to investing in unsettled economic periods and the advantages and disadvantages of operating in a global economy to expanding from core activities and what they see as their biggest challenges, and more, including the views of a past company CEO.

Classified . . . . . . . . . . . . . . . 75 Career Opportunities . . . . . . . 75 Advertisers’ Index . . . . . . . . . 79

OPS R EPORTS /T ECHNIC AL PAPERS

Next issue April 2012

• Preview of the WAI Operations Summitt & Wire Expo 2012

The Lean Six Sigma Experience at the Leggett & Platt Wire Group Steve Foust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 The influence of shaft-furnace burner settings on dissolved oxygen in melted cathodes John Hugens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 ANDRITZ Maerz Direct-to-Wire® technology: optimized FRHC copper production Timm Lux, Jörg Köhlhofer and Christine Wenzl . . . . . . .64

Cover: The wire and cable sector has experienced incredible changes in market conditons and demand for new products, but such challenges have always been part of the industry story. The key will continue to be the directions that company leaders take.

MARCH 2012 | 3

INSIDE THIS ISSUE CONTENTS

EHV POWER

CABLE RECORD SET

. . . .10

Sweden’s ABB reports that it has set an industry first with the laying and energizing of a crosslinked polyethylene insulated cable that is 6.5 miles long, a record for EHV cables. The cable is part of the Bayonne Energy Center power generation and transmission project, a new facility that will provide cleaner, more reliable power for Manhattan and the New York City power transmission network.

THE

SIX SIGMA WAY . . . . . . . . . . . . 54

A WAI first is the Ops Report by Rich Parvesse, l, the quality systems and planning manager for the Wire Group of Leggett & Platt, Inc. With him is Jeff Howrey, plant manager of Talbot Industries, a division of Leggett & Platt.

They are before a “brown paper” presentation of a completed Six Sigma project for upper management. This presentation was made at Interwire 2011.

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EDITORIAL WIRE JOURNAL

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EDITORIAL

I N T E R N A T I O N A L

What is an Operations Summit?

I know what you’re thinking.

They changed the name. They tinkered with the schedule. They’re using phrases like “all new” and “first-ever.” But it’s still just the same program in a new package, right?

What if I told you that the all new, first-ever WAI Operations Summit won’t have any technical papers? What if I said the conference will focus entirely on topics like commodities, energy efficiency, regulatory issues, safety and logistics?

Taking the place of the traditional tech program, the Summit will feature sessions focused entirely on timely, practical topics relevant to the day-to-day functioning of a wire business.

Future WAI events like Interwire 2013 and the International Technical Conferences will continue to emphasize the technical side of wire and cable technology. But the Summit offers an opportunity to dedicate more time to the operational side of WAI’s educational mission.

Perhaps no part of the program better exemplifies these changes than “Operational Excellence,” a special new session recognizing the outstanding accomplishments of five top wire and cable manufacturers. We plan to publish some of the Summit presentations in a new, occasional section of WJI called “Ops Report.” Similar presentations from Interwire 2011 are already scheduled to begin appearing in these pages in 2012, and the first one, a preview, starts on p. 54 in this issue.

A pitfall of this new approach is the potential to slow the flow of top technical material WAI has been fortunate to receive from authors around the globe. So we’re aiming to open another avenue for submitting technical articles—namely accepting papers for review and possible publication regardless of whether they have been presented to a live audience. Look for more on that change in future issues.

Special thanks to this year’s Conference Programming Committee, whose dedication and ideas helped us reimagine Wire Expo to include the Operations Summit. Our special hosts and sponsoring organizations have gone out of their way to ensure a memorable Texas-sized experience, including plant tours at Gerdau and Encore Wire that are not to be missed.

It’s a big change, but one I’m sure you’ll welcome. The May 22-23 conference in Dallas should provide a whole new perspective on the state of the industry.

Marc Murray Director of Education & Member Services

Publisher | Steven J. Fetteroll Editor-in-Chief | Mark Marselli Senior Graphic Designer | Bill Branch Director of Sales | Robert Xeller Advertising Sales | Anna Bzowski Director of Marketing & Corporate Communications | Janice E. Swindells Graphic Artist | Adrienne E. Simpson Proofreader | Livia Jacobs Publications Advisory Board Dane G. Armendariz | Henkel Corporation, USA Ferruccio Bellina | TKT Group/President ACIMAF, Italy Peter A. Funk | Talley Metals Technology, USA Malcom Michael | AWIA Australia Don Schollin | Q-S Technologies, USA Ralph Skalleberg | Skaltek USA Dave Stackpole | Nutmeg Wire, USA Giulio Properzi | Continuus Properzi, Italy Robert Wild | Niehoff Endex North America, USA Technical Advisors John Drummond | Scotia Group R. M. Shemenski | RMS Consulting, Inc.

WIRE JOURNAL INTERNATIONAL (ISSN-0277-4275) published monthly by The Wire Journal, Inc., is a wholly owned subsidiary of The Wire Association International, Inc., which is located at 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA, and can be contacted at tel.

203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail mmarselli@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $110 per year, USA; $120 per year, Canada and Mexico; other countries, $140 per year (includes air mail). Back copies: $10 WAI members, $15 non-members. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices.

Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2012 by Wire Journal, Inc. All rights reserved. The Publisher of WJI assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of WJI are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313761-4700.

POSTMASTER: Send address changes to Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA.

6 | WIRE JOURNAL INTERNATIONAL

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New: The gauge heads now have an integrated brilliant LCD display with control panel option. This allows the operator to read the diameter measuring value directly from the gauge head and to control the line.

CALENDAR

CALENDAR March 26-30, 2012: wire Düsseldorf 2012 Düsseldorf, Germany. To be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, info@mdna.com, tel. 312-781-5180.

this event, being put on by American Metal Market and the American Wire Producers Association, is being held in conjunction with WAI’s Wire Operations Summit & Wire Expo 2012. Contact: AWPA, tel. 703-299-4434, www.awpa.org.

April 1-5, 2012: The International Plastics Showcase Orlando, Florida, USA. To be held at the Orange County Convention Center, this event, which is expected to draw as many as 75,000 attendees from 120 countries, is organized by SPI: The Plastics Industry Trade Association.

Contact: U.S. and Canada, tel. 703-259-6132, exhibit@npe.org or go to www.npe.org.

May 22-23, 2012: 2012 WAI Operations Summit & Wire Expo Dallas, Texas, USA. This WAI event, to be held at the Omni Dallas Hotel, includes the trade show and the Association’s 82nd Annual Convention. The new program format will feature an operational excellence focus, with local hosts, Encore Wire Corp. and Gerdau Corp., each providing facility tours. Contact: WAI, sales@wirenet.org, www.wirenet.org.

April 18-19, 2012: Polymers in Cables 2012 Miami, Florida, USA. To be held at the Hyatt Regency Miami. Contact: Applied Market Information LLC (AMI), tel. 610-478-0800, mk@amiplastics-na.com.

May 9-10, 2012: 2012 National Electrical Wire Processing Technology Expo Milwaukee, Wisconsin, USA. To be held at the Frontier Airlines Center. Contact: Expo Productions, Inc., tel. 800367-5520, www.expoproductionsinc.com/wire_home.htm.

May 21-22, 2012: AMM & AWPA 2012 Wire Rod Supply Chain Conference Dallas, Texas, USA. To be held at the Omni Dallas Hotel,

June 11-13, 2012: CRU 6th Wire and Cable Conference Vienna, Austria. To be held at the Vienna Marriott hotel, this forum is for cable manufacturers and their customers.

Contact: CRU Int’l tel. 44-20-7903-2444, conferences@ crugroup.com, www.wireandcableconference.com.

Sept. 25-28, 2012: wire China 2012 Shanghai, China. To be held at the Shanghai New International Expo Centre (SNIEC). Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com.

WIRE A SSOCIATION INTERNATIONAL EVENTS For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; www.wirenet.org.

May 22-23, 2012: 2012 WAI Operations Summit & Wire Expo Dallas, Texas, USA. This WAI event, to be held at the Omni Dallas Hotel, includes the trade show and the Association’s 82nd Annual Convention. The new program format will feature an operational excellence focus, with local hosts, Encore Wire Corp. and Gerdau Corp., each providing facility tours. Contact: WAI, sales@wirenet.org, www.wirenet.org.

Sept. 10, 2012, New England Chapter 18th annual golf tournament Ellington, Connecticut, USA. This event will be held at the Ellington Ridge Country Club.

June 22, 2012: Midwest Chapter 10th annual golf tournament West Chicago, Illinois, USA. This event will be held at the St. Andrews Golf & Country Club.

Oct. 22, 2012: Western Chapter 12th annual “Wild West Shootout” golf outing.

Rancho Palos Verdes, California, USA. This event will be held at the Los Verdes Golf Course.

Aug. 2012: Ohio Valley Chapter 10th annual golf tournament Solon, Ohio, USA. This event will be held at the Grantwood Golf Course.

April 23-25, 2013: Interwire 2013 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center to stage its trade show, technical programs and the Association’s 83rd Annual Convention, Contact: WAI, sales@wirenet.org, www.wirenet.org.

8 | WIRE JOURNAL INTERNATIONAL

Oct. 18, 2012. The Vannais Southeast Chapter 11th annual golf tournament Conover, North Carolina, USA. This event will be held at the Rock Barn Golf & Spa.

Oct. 31-Nov. 1, 2012: Wire & Cable India Mumbai, India. This event is organized by Messe Düsseldorf. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

Nov. 11-14, 2012: 61st IWCS Conference™ Providence, Rhode Island, USA. To be held at the Rhode Island Convention Center. Contact: Pat Hudak, IWCS, www.iwcs.org, phudak@iwcs.org, tel. 732-389-0990.

May 2013: wire Russia 2013 Moscow, Russia. This event is organized by Messe Düsseldorf. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

Sept. 17-19, 2013: wire Southeast Asia Bangkok, Thailand. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

Oct. 8-13, 2013: wire South America 2013 São Paulo, Brazil. Messe Düsseldorf and its partner Grupo Cipa will stage this new fair for the Brazilian market: The new event will be held in parallel with TUBOTECH at the Imigrantes Exposicoes Exhibition Centre in São Paulo. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

April 23-25, 2013: Interwire 2013 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center to stage its trade show, technical programs and the Association’s 83rd Annual Convention.

MARCH 2012 | 9

CALENDAR

Oct. 3-5, 2012: SpringWorld 2012 Rosemont, Illinois, USA. To be held at the Donald E. Stephens Convention Center. Contact: Tom Renk, The Chicago Association of Spring Manufacturers, Inc. (CASMI), tel. 630-369-3466, fax 630-369-3773, info@casmi-springworld.org, www.casmi-springworld.org.

INDUSTRY NEWS

INDUSTRY NEWS Nexans enters agreement to buy AmerCable for US$275 million Nexans announced that it has agreed to acquire AmerCable Holdings, Inc., a U.S.-based company that specializes in cable for mining, marine oil and gas and other industrial cables, including those used for renewable energy, for US$275 million.

A press release said that AmerCable, based in El Dorado, Arkansas, has approximately 400 employees who produce highly engineered and mission critical cables for harsh environments. The company also provides engineering field and support services, and derives more than three quarters of its sales in North America, although it “has growing operations in China, Latin America and Australia,” the release said. For the 2011 fiscal year, its sales revenue were about US$270 million, representing annual growth of more than 30%, it said, adding that the company “has been consistently producing industry bestin-class margins due to its attractive product mix.” The AmerCable product range includes its Tiger line (mining cables) and Gexol line (insulated cables for oil and gas industry).

The release said that AmerCable’s business complements Nexans’ existing operations in resource cables, providing a new strategic and operational platform in North America. Expected synergies include cross-selling of existing Nexans global products into AmerCable’s client base and vice-versa, it said.

“The acquisition of AmerCable fits well with Nexans’ strategy to develop its industry division extending its presence in markets with high-growth prospects and above market profitability,” said Nexans CEO Frédéric Vincent. “The global mining market is expected to benefit from strong global growth, in particular in the coal market in the U.S. and China, and the oil and gas market is expected to benefit from increased drilling activity (both onshore and offshore) and increasing well complexity.

In particular the growing shift in North America towards unconventional oil and gas development is set to increase demand for AmerCable’s products and services. AmerCable’s presence in Mining and Oil & Gas will double the size of Nexans’ activities in those segments and will be highly complementary to Nexans’ existing operations in offshore and subsea and for total revenues close to 350 million euros.”

ABB sets multiple records with its new power cable in New York Harbor Sweden’s ABB reported that it has completed the delivery and energization of a record-setting cross-linked polyethylene insulated 345 kV AC submarine cable system that is part of the Bayonne Energy Center power generation and transmission project, a new facility that will pro-

10 | WIRE JOURNAL INTERNATIONAL

vide cleaner, more reliable power for Manhattan and the New York City power transmission network.

A press release said that the system includes three single-core XLPE submarine cables, each 6.5 miles (10.4 km) in length, and two XLPE underground cable segments that connect the submarine cables to the power plant in Bayonne and the substation in Brooklyn, respectively. The 6.5-mile submarine cables are the longest extruded extra-high-voltage (EHV) submarine AC power cables ever manufactured, it said. Most extruded submaABB reports that its HV cable was rine AC cables simultaneously laid and trenched have so far been at using a jet-plow that was towed by the 145 kV level or the lay vessel. lower, including the world’s longest submarine AC cable, which ABB is supplying for the Goliat floating oil and gas platform in the Barents Sea (the Goliat cable is 105 km in length and has a voltage rating of 123 kV), it said.

The project, which is designed to provide 512 MW of power generation capacity to the critical wholesale power market in New York City, set two other records as well, the release said. The 6.5 mile extruded cables also represent the longest EHV cables without factory joints. That required exceptional levels of expertise at the cable factory as the extrusion process for the cable took more than 10 days. The second record was related to the New York harbor, which is very busy, so ABB had to bury the cables at a depth of up to 15 ft, which is significantly deeper than the three to six ft required for most other submarine power cables, it said.

ABB was responsible for delivering a turnkey cable system including design, engineering, manufacture, field construction at the landfall sites, laying and installation, and commissioning.

Bekaert restructures in response to weaker solar energy market Citing harsh conditions for the solar energy sector that has in turn affected the company’s sawing wire operations, Bekaert plans to close its plant in Aalter, Belgium, which is largely focused on that production.

A press release said that management felt compelled to undergo the structural measure at Aalter. It added that

Sandvik Materials Technology reports further restructuring for company Sweden’s Sandvik Materials Technology announced that it has initiated negotiations with the unions in Sweden to restructure the company’s wire and resistance strip operations, which it said will enable a shift in the product mix toward more advanced and profitable products in key segments, such as the energy sector.

The restructuring will primarily affect production of wire and resistance strip in Hallstahammar, Sweden, which will be discontinued over the course of the next 18 months, a press release said. “In conjunction with this, efforts will be intensified to phase out wire products that are not sufficiently profitable or do not form part of the core business.”

The manufacturing of the remaining part of the wire product program will primarily be transferred from Hallstahammar to Sandviken, but some of the wire volume will also be moved to wiredrawing plants in India (Hosur) and China (Shanghai), the release said. It noted that in Sandviken, elements of wire production that were destroyed in a fire last April, will be rebuilt and fitted with more efficient technology. Production of resistance strip in Hallstahammar will also be relocated to Sandviken, with the aim of concentrating all strip manufacturing in Sweden to one location.

“As a consequence of the planned changes, the workforce at Sandvik in Hallstahammar will gradually be reduced by 100 employees over the next 18 months. The aim is to man-

age the redundancy process in the best possible way,” the release said. “The restructuring is necessary to focus the product mix toward more advanced and profitable products.

The planned measures also ensure that we conduct cost-efficient manufacturing and strengthen our position in key segments, such as the oil and gas and nuclear power industry,” said Jonas Gustavsson, president of the Sandvik Materials Technology business area.

As part of the restructuring of the strip operations, decisions were also taken during the fourth quarter 2011 to discontinue the production of die cutting products in England (Rugby) and production of springs in China (Qingdao), the release said. The production at these facilities, which in total have about 30 employees, will be consolidated into other strip units within Sandvik, it said.

The measures form part of the Step Change Program announced last September by Sandvik Materials Technology, which noted that it is seeking “to raise the business area’s profitability to a higher and more stable level and to strengthen the position in key segments.”

2 more General Cable plants are named ‘Best Plants’ award winners U.S.-based General Cable continued to add to its legacy of excellence in its manufacturing operations, with two more of the company’s plants being named winners in INDUSTRYWEEK’s 2011 Best Plants Competition.

A press release said that General Cable’s Lawrenceburg, Kentucky, manufacturing facility, which produces communications wire and cable, and its Lincoln, Rhode Island, plant, which manufactures portable cord, ignition wire and renewable products, were selected by Penton Media’s INDUSTRYWEEK magazine as two of the 10 Best Plants in North America. The award program, which started 22 years ago, honors outstanding manufacturing facilities across all industries for achievements in increasing competitiveness, enhancing customer satisfaction, and creating stimulating and rewarding work environments.

“General Cable is once again pleased to receive this award from INDUSTRYWEEK in recognition of our manufacturing excellence,” said Greg Lampert, president and Greg Lampert, president & CEO of CEO of General General Cable North America, conCable North gratulated associates at celebrations held at two company plants that were America. “We use the INDUSnamed to INDUSTRYWEEK’s top ten TRYWEEK comlist of Best Plants in North America.

MARCH 2012 | 11

INDUSTRY NEWS

the production activities of bead wire and half products would be gradually integrated in other entities of the Bekaert Group. “It is the intention to keep the advanced cords end-products department in Aalter and search, together with the social partners, for sustainable solutions,” it said.

As part of its restructuring, Bekaert intends to also adjust its resources and development priorities in the technology center in Deerlijk and in its engineering plant in Ingelmunster, the release said. It also plans to limit the manufacturing activity of the Belgian stainless steel wire platform to products with high added value and to stainless fiber composite for Bekaert’s fiber technology plant in Zwevegem, it said. “These plans and other initiatives to optimize the organizational and cost structure in general, aim at securing Bekaert’s competitiveness as a group and ensuring a necessary alignment of the Belgian operations with the changed business context.”

“Unprecedented changes in market conditions of the solar business force immediate action,” CEO Bert De Graeve said in the release. “Our future lies in continuing to serve our customers worldwide with highly qualitative and innovative products and services. We are all determined, at Bekaert, to safeguard this basis for sustainable growth on a global scale. We do regret the personal consequences of this plan and, together with our social partners, we will do all we can to mitigate the social impact.”

INDUSTRY NEWS

petition as a benchmark for comparing our manufacturing performance against the best in North America in all industries. I would like to commend Mark Thackeray, General Cable’s senior vice president of North American Operations; Heather Stolper and Mike Monti, vice presidents of manufacturing and team leaders; Paul Furtado, Lawrenceburg plant manager; Mike Brown, Lincoln plant manager; and their respective teams, for setting challenging goals and providing the work environment for our associates to achieve them.”

Since 2001, General Cable has had 10 plants selected as finalists in the Best Plants competition, with nine of them making the Top 10 Plants in North America, one of them twice. They are Altoona, Pennsylvania, in 2003 and 2009; Moose Jaw, Saskatchewan, Canada, in 2005; Tetla, Tlaxcala, Mexico, in 2006; Indianapolis, Indiana, in 2007; Manchester, New Hampshire, in 2008; Piedras Negras, Coahuila, Mexico, in 2009; Franklin, Massachusetts, in 2010; and now Lawrenceburg and Lincoln in 2011.

Accurate Wire reports the further expansion of its Connecticut plant U.S.-based Accurate Wire, Inc., founded in 1988 in Branford, Connecticut, as a specialty shaped wire manufacturer by partners Douglas Milheim and Matthew Smith, started out as a very modest 1,000 sq-ft operation.

This year, the company will complete its latest expansion, a project that will see its plant grow from its current size of 47,000 sq ft to more than 70,000 sq ft.

“We knew the potential was there,” said Milheim, whose company two years ago purchased the structure next door and is now building a new section to connect the two structures to make a single plant. It also has added equipment and expanded its in-house processes.

The company, which has 22 employees, focuses on valued added wire products, manufacturing round, flat,

Solon Wire Processing has begun work at former Bluff City Steel plant Solon Wire Processing (SWP), LLC, announced that it has expanded with the establishment of operations at the former Bluff City Steel plant in Memphis, Tennessee, USA. A division of Republic Steel and based in Solon, Ohio, USA, SWP resumed operations at the plant in February, with a staff of under 10 handling pickling, annealing and drawing of wire and rod for the cold heading market (sizes .080 in. through 1.000 in.) in carbon (1008-1065, 10b21) and in alloys (4037, 4140, 8640), a press release said. The expansion will allow SWP to expand its wire and rod product offerings to the midwest and southern markets, it said.

“The addition of the Memphis facility will increase our total capacity to over 6,000 tons per month of coil annealing, in excess of 7,000 tons per month of wire drawing and over 15,000 tons of pickling/coating,” the release said.

“The expansion was driven by development of new product lines, including multi-hole draw machines, that were not currently available in the Solon facility as well as by increased demand and a reaction to overall tightening of capacity in the wire processing market,” said Larry Braun, sales and marketing manager for Solon Wire Processing. Michael Rudd is the plant manager for the Memphis plant, Jim Phillips will serve as general manager of both plants and Braun, at the Solon facility, will handle sales functions.

SWP is an ISO 9001:2008 certified manufacturer of rod and wire for sectors that include the fastener, automotive, hand tools, appliance, off-road heavy equipment and construction industries. For more details, go to www.solonwire.com, which was recently launched.

Accurate Wire Inc. President Douglas Milheim, r, and Vice President Matthew Smith, in front of the company’s plant, which is undergoing expansion. square, and custom shaped wire in copper, brass, bronze, stainless steel, carbon steel, aluminum, and other alloys.

Its customer base includes automotive, electronic, medical, aerospace, industrial and consumer product applications. Milheim said that the company’s specialized capabilities and product quality have enabled Accurate Wire to continue to expand over the years, servicing customers in the U.S., Central America, Europe, Mid-East, and Asia.

For more details, go to www.accuratewire.net.

Noble buys Madsen Wire assets Noble Industries, an Indiana metal fabrication company, has acquired the assets and business of Madsen Wire, a company that had been a wire fabrication partner for many years.

Based in Orland, Indiana, Madsen Wire provides wire forming and wire grid work for shelving, wire guards, wire baskets, cargo barriers, purchase displays and more.

“We are excited about the prospect of adding to our (section continued on p. 18)

12 | WIRE JOURNAL INTERNATIONAL

Sanxin Wire Die & Nano-Diamond America Inc. will exhibit at Wire 2012 - Hall 11 - C24

O P E N

F O R U M

★

E X P R E S S

L E A R N I N G

It takes more than a cactus Stay sharp on smooth wire Not all green plants conserve water. But all wire plants can be green, energy efficient, safe, and sustainable using the latest tips available at WAI’s new summit. This is an express learning opportunity that will change the way you approach material handling challenges and a dozen other in-plant concerns.

Learn more at www.wirenet.org.

9

WAI OPERATIONS SUMMIT wire expo 2012 ~ a wire & cable industry solution center ~

CALLing:

Exhibition: May 22-23, 2012 Omni Dallas Hotel | Dallas, Texas, USA EXHIBITING COMPANIES

All production supervisors, quality control & maintenance personnel, and plant managers.

Ace Metal Inc. • ACM AB • AIM Inc. • Amacoil Inc. • Amaral Automation Associates • Anbao Wire & Mesh Co. Ltd. • AXIS, a Consona ERP Solution • Aztech Lubricants LLC • B & H Tool Co. Inc. • B & Z Galvanized Wire Ind. Inc. • Balloffet Die Corp. • Bartell Machinery Systems LLC • Bekaert Corp. • Beta LaserMike • Bock Maschinenfabrik GmbH & Co. KG • Brookfield Wire Co. • Canterbury Engineering Co. Inc. • Carris Reels Inc. • Cemanco LC • Central Wire Industries Ltd. • Clinton Instrument Co. • Commission Brokers Inc. • Condat • Conneaut Industries Inc. • Continuus-Properzi S.p.A. • Cortinovis Machinery America Inc. • Davis-Standard LLC • Die Quip Corp. • Electron Beam Technologies Inc. • Engineered Machinery Group Inc. • ERA Wire Inc. • Esteves Group • Eurolls Group/Eurolls SpA • George Evans Corp. • Evolution Products • Fabritex Inc. • Filtertech Inc. • Fine International Corp. • FLYMCA & FLYRO • FMS USA Inc. • Foerster Instruments Inc. • Forming Systems Inc. • Fort Wayne Wire Die Inc. • Frontier Composites & Castings Inc. • Gauder America • Gauder Group Inc. • Gem Gravure Co. Inc. • Genca Corp. • W. Gillies Technologies LLC • GMP-Slovakia • Going Well Precision Industry Co. Ltd. • Guill Tool & Engineering Co. • Hall Industries • Heany Industries Inc. • Heatbath Corp. • Heritage Wire Die Inc. • Houghton International Inc. • Howar Equipment Inc. • IAT International Inc. • IDEAL Welding Systems • iiM AG measurement + engineering • Intras Limited • Joe Tools Inc. • KEIR Manufacturing Inc. • King Steel

CORPORATE SPONSORS—Platinum Level: ACIMAF | Gold Level: Carris Reels Inc. • Continuus-Properzi S.p.A. • SIKORA International Inc. | Silver Level: Wire & Plastic Machinery Corp. • Woodburn Diamond Die Inc. | Bronze Level: Gold Metal Recyclers • Red Kite Management (USA) Ltd.

★

P L A N T

T O U R S

★

E X H I B I T S

in the lobby to have a green plant. operations at WAI’s new summit.

Manufacturing innovations.

Hiring & training.

Risk mitigation.

Commodities.

Safety.

Regulations, patents, & standards.

Material handling.

Accolades to WAI award winners.

Group luncheon & networking.

Work-related fun, southern style.

Corp. • Kyocera Industrial Ceramics • Lamnea Bruk AB • LaserLinc Inc. • Leggett & Platt Wire Group • LEONI Wire Inc. • Lesmo Machinery America Inc. • Lloyd & Bouvier Inc. • Magnetic Technologies Ltd. • Mathiasen Machinery Inc. • MAXCESS/MAGPOWR • Metavan NV • The MGS Group • MGS Manufacturing Inc. • Micro Products Co. • Morgan-Koch Corp. • Mossberg Associates Inc. • Niagara Composites International Inc. • Niehoff Endex North America Inc. • North American Steel & Wire Inc. • Northampton Machinery Co. (USA) • NUMALLIANCE • Ohio Rod Products • Oklahoma Steel & Wire • OM Frigerio • P&R Specialty Inc. • Paramount Die Co. • Parkway-Kew Corp. • Phifer Wire Inc. • Pittsfield Plastics Engineering Inc. • Plasmait GmbH • Plymouth Wire Reels & Dies Inc. • Polyfab Plastics & Supply Inc. • Polytec Inc. • Power Sonics LLC • PPI Wire & Cable LLC • Precision Die Technologies Inc. • Premier Wire Die • PrintSafe • Properzi International Inc. • Queins Machines GmbH • Radyne Corp. • Rainbow Rubber & Plastics • Reel Options by Vandor Corp. • Reel-O-Matic Inc. • Refractron Technologies Corp. • RichardsApex Inc. • Rockford Manufacturing Group Inc. • Rosendahl Nextrom Technologies • Roteq Machinery Inc. • RTD Manufacturing Inc. • SAMP USA Inc. • Sealeze, A Unit of Jason • SIKORA International Corp. • SIMPACKS • Sivaco Wire Group • Joe Snee Associates • Sonoco Reels • Starrett-Bytewise • Stolberger Inc. dba Wardwell Braiding • T & T Marketing Inc. • Talladega Machinery & Supply • Taubensee Steel & Wire Co. • Teknikor • Thermoplastics Engineering • Tri Star Metals • Tubular Products Co. • Ultimate Automation Ltd. • Untied Wire Co. Inc. • Unitek Crossheads • US Synthetic Wire Die • Vollmer America Inc • Wafios Machinery Corp.

• Weber & Scher Mfg. Co. Inc. • Windak Inc. • Wire & Cable Industry Suppliers Association (WCISA) • Wire & Cable Technology International • Wire & Plastic Machinery Corp. • The Wire Association International, Inc. • Wire Forming Technology International • Wire Journal International • Wire Lab Co. • Wire Machine Systems Inc. • WireWorld Internet • Witels Albert USA Ltd. • Woodburn Diamond Die Inc. • Worth Steel and Machinery Inc. • WTM - Wire Technology Machinery • Yield Management Corp. • Zumbach Electronics Corp.

The Wire Association International, Inc. ONSITE SPONSORS—Amacoil Inc. • Baum’s Castorine Co. Inc. • Carris Reels Inc. • Commission Brokers Inc. • Davis-Standard LLC • Lloyd & Bouvier Inc. • SIKORA International Inc. • Woodburn Diamond Die Inc.

A D VA N C E R E G I S T R AT I O N F O R M 1. COMPLETE & MAIL OR FAX THIS FORM TODAY Note: Please print neatly and complete all information to ensure accurate registration.

If you choose to mail this form, make sure you keep a photocopy.

INTERNAL USE

Omni Dallas Hotel | Dallas, Texas, USA | May 22-23, 2012 3. EVENT REGISTRATION (This section must be completed for proper processing.)

DT RCD *advanced (on or before APRIL 30, 2012) *on-site (after APRIL 30, 2012) AMT PD

Please Print Your WAI Member Number ________________________________

PYMT

*advance Includes WAI Operations Summit program & online conference proceedings, Wire Expo exhibits, Production Solutions, Welcome Reception, and one year WAI Membership.

LAST NAME FIRST NAME

*on-site

FULL REGISTRATION PLUS NEW WAI MEMBERSHIP (BL/AEM)

MIDDLE

New Member

$395 ❏

$495 ❏

❏ Yes, I wish to receive a free subscription to Wire Journal International.

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TITLE

DATE

FULL REGISTRATION (BL/AE) COMPANY

Includes WAI Operations Summit program & online conference proceedings, Wire Expo exhibits, Production Solutions, and Welcome Reception.

STREET/MAILING ADDRESS

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$295 ❏

$395 ❏

Non Member

$395 ❏

$495 ❏

FULL REGISTRATION ADDITIONAL COMPANY PERSONNEL (ADA/ADL) Includes WAI Operations Summit program & online conference proceedings, Wire Expo exhibits, Production Solutions, and Welcome Reception.

2ND ADDRESS LINE IF NEEDED CITY

STATE/PROV.

POSTAL CODE

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$195 ❏

$295 ❏

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$395 ❏

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EXHIBITS ONLY (GD/CE) Tuesday-Wednesday, May 22-23 Includes Wire Expo exhibits and Production Solutions.

COUNTRY COUNTRY CODE TELEPHONE (include area code)

WELCOME RECEPTION ONLY (IE)

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E-MAIL (REQUIRED) [

Tuesday, May 22 Note: Welcome Reception is already included in full registration fees.

]

FUNDAMENTALS OF WIRE MANUFACTURING (INCLUDES EXHIBITS) (GDS)

2. BUSINESS INFORMATION (These two questions must be completed for proper processing.)

A. Which ONE of the following best describes your company’s type of business?

PLEASE CHECK ONLY ONE.

Member

$250 ❏

$350 ❏

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$325 ❏

$425 ❏

Member with Full Registration

$100 ❏

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$120 ❏

$220 ❏

$50 ❏

N/A

$75 ❏

N/A

$50 ❏

N/A

$75 ❏

N/A

Monday, May 21 Includes program handouts, Monday lunch, and access to the Wire Expo exhibits, and Production Solutions.

ENCORE WIRE PLANT TOUR (PTN)

WIRE MANUFACTURING 10 ❏ Aluminum & Al. Alloys (Rod/Bar, Bare Wire) 20 ❏ Copper & Copper Alloys (Rod/Bar, Bare Wire) 30 ❏ Steel & Steel Alloys (Rod/Bar, Bare Wire) 40 ❏ Other Metal (Rod/Bar, Bare Wire) 50 ❏ Electrical (Insulated Wire) 53 ❏ Communication (Insulated Wire) 55 ❏ Fiber Optics

Member Wednesday, May 23 Note: Space is limited and preference will be given to full conference Non Member registrants. Individual registrations subject to approval.

GERDAU PLANT TOUR (PTF) Member Wednesday, May 23 Note: Space is limited and preference will be given to full conference Non Member registrants. Individual registrations subject to approval.

FASTENERS, WIRE FORMING, FABRICATING 61 ❏ Fastener Manufacture 62 ❏ Four-Slide Forming 64 ❏ Hot and/or Cold Forming and Heading 66 ❏ Spring Manufacture 68 ❏ Wire Cloth Mesh Screening 69 ❏ Other Forming and Fabricating Please Specify ____________________________________________________________

4. TOTAL REGISTRATION FEES, U.S. $ 5. REGISTRATION FEE IS PAID BY: ❏ Check enclosed payable to THE WIRE ASSOCIATION INTERNATIONAL, INC. (Checks must be in U.S. dollars drawn on U.S. bank)

SUPPLIERS TO THE WIRE INDUSTRY 72 ❏ Machinery 74 ❏ Process, Accessories, Materials

Credit Card ❏ Visa ❏ MasterCard ❏ American Express ❏ Discover

WIRE END-USER 11 ❏ Appliance 12 ❏ Communications (Voice/Data) 13 ❏ Computer 14 ❏ Construction/Building 15 ❏ Electrical (Equip./Components/Power) 16 ❏ Transportation/Vehicular 17 ❏ Wire Formed Durable Goods

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OTHER 80 ❏ Service Cntrs, Distrib. & Warehouses 90 ❏ Consultants 92 ❏ Govt., Library, Others Allied to Field

Fax Registrations must use Credit Cards for payments of ALL meeting fees. Fax No. (001) 203-453-8384

B. Which ONE of the following best describes your primary job function? CHECK ONLY ONE. 10 ❏ General & Administrative Management 20 ❏ Engineering and/or Operations and/or Production 30 ❏ Technical and/or Research & Development and/or Quality Control 40 ❏ Purchasing 50 ❏ Sales & Marketing 90 ❏ Other Please Specify _____________________________________________________________

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The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 USA | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org

H O T E L I N F O R M AT I O N Omni Dallas Hotel | Dallas, Texas, USA | May 22-23, 2012

Omni Dallas Hotel 555 S. Lamar, Dallas, Texas 75202

Contact the Omni Dallas Hotel directly to reserve your room(s) today.

Call in Reservations: 1-888-444-OMNI (6664) or Online Reservations: http://www.wirenet.org/events/wireexpo/chklodging.cfm

Accommodations

Room Rates

The newly opened Omni Dallas Hotel, in the center of the revitalized downtown Dallas, is the site for the 2012 WAI Operations Summit & Wire Expo and the AWPA Wire Rod Supply Chain Conference.

DEADLINE: Book by April 23, 2012 to receive special rates.

The hotel features 1,001 guest rooms, including 67 luxury suites and three presidential suites; it also includes a full-service Mokara Spa, rooftop terrace pool deck, and a spacious fitness center with stunning views of downtown.

Omni Dallas Hotel is built to meet the U.S. Green Building Council LEED Silver Certification standards, placing it on the forefront of environmental awareness and conservation in the city.

Choices for dining at the hotel include: Bob’s Steak & Chop House, the innovative farm-to-market 3-meal-a-day restaurant Texas Spice, the Owner’s Box, a state-of-the-art interactive sports bar and Omni’s gourmet coffee shop, Morsel’s.

Singles Doubles Suites

$179 per night + tax $189 per night + tax Please call hotel for availability and price

Rates do not include sales tax (currently 15% per room per night, subject to change). Room availability is on a first-come, first-served basis. Please contact the hotel directly for information and availability on suites.

NOTE: Hotels will not accept faxed or mailed requests. A one night room and tax deposit by credit card guarantee is required. Credit cards must be valid through June 2012. Your credit card is a guarantee and will be charged at the discretion of the hotel holding your reservation. The hotels will not accept cash, wire transfers, or purchase orders.

Confirmations Confirmations will be provided immediately for both online and telephone reservations. Please review your confirmations for accuracy.

For changes or cancellations, please contact the hotel directly.

Cancellation Policy Cancellations made prior to 72 hours before the day of arrival will not be penalized. Cancellations within 72 hours of arrival date will be charged one night’s room and tax.

Parking There is a charge for both self and valet parking. The current self-parking rate is $10 plus tax per vehicle, per night, and the current overnight valet rate is $18 plus tax. Parking rates are subject to change.

The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 USA | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org

INDUSTRY NEWS

(section continued from p. 12) presence in the tube fabrication and wire forming capabilities along with giving Madsen Wire the ability to offer full-service metal fabrication with services offered here at Noble Industries,” said Brenda Snyder, vice president of sales for Noble Industries. “We look forward to adding new employees to our company as our consumer base expands.” Madsen Wire will greatly remain a separate entity and remain in Orland, Indiana.

Swiss-based ABB to buy Thomas & Betts to expand low-voltage presence Swiss engineering group ABB has agreed to buy U.S.based electrical components maker Thomas & Betts for $3.9 billion, a move that greatly expands its presence in low-voltage products.

Thomas & Betts supplies the construction, communications and power industries with connectors for cables, steel masts and heating and ventilation products. ABB Chief Executive Joe Hogan said that the acquisition would open up a potential U.S. market for low-voltage products of about $24 billion for ABB’s most profitable product range. Last January, ABB paid $3.1 billion for Baldor Electric Co.

Submarine cable communications project has linked Italy and Israel Bezeq International, an Israel internet and international telecom provider, and Alcatel-Lucent report that they have commercially launched a new superfast submarine cable link between Israel and Italy.

A press release said that the high-speed optical fiber system, named JONAH, “covers 2,300 km across the Mediterranean, and is intended to address the growing demands of the highly dynamic Israeli telecom market, which shows one of the highest household broadband and mobile penetration rates in the world.” The link, which leverages Alcatel-Lucent’s most advanced submarine communications networking technology, is the first highspeed submarine cable system fully owned by an Israeli operator, it said, noting that it is designed to operate at 100 gigabits-per-second data transmissions to enable data capacity of 7.6 Terabits-per-second (Tbps) between Tel Aviv and Bari, Italy.

EU renews tariffs on steel ropes and cables from China and Ukraine The European Union (EU) has renewed 13-year-old tariffs on steel ropes and cables from China and Ukraine to curb competition for EU manufacturers, while allowing tariffs against South Africa to expire.

Bloomberg reports that the EU re-imposed the import duties for another five years because Chinese and Ukrainian exporters were selling the ropes and cables in

18 | WIRE JOURNAL INTERNATIONAL

Europe below cost. The rates are 60.4% for China and 51.8% for Ukraine. The article said that the decision from the 27-nation bloc found that Chinese and Ukrainian exporters continue to undercut EU producers and have significant spare capacity that could pose an additional threat. It added that the expiring duty on South Africa, 38.6%, was allowed to end as its industry stopped undercutting European competitors and has limited spare capacity.

The EU report said that the combined Chinese and Ukrainian share of the EU market for steel ropes and cables fell to 2.2% in the 12 months through September 2010 from 3.8%, while South Africa’s share dropped to 0.1% from 0.5% over the period.

The actions were the outcome of an almost 15-month probe that had prevented the levies against the three countries from expiring as previously scheduled in November 2010.

New representative company formed Joe Snee announced the formation of Joe Snee Associates, Inc., which he said will serve as the exclusive North American distributor for the Pressure Welding Machine (PWM) line of cold pressure welders, dies and spares.

A press release said that Snee has nearly 20 years of experience in the wire and cable industry, and that he has sold cold welding products since 1992. He has been affiliated with PWM in various capacities since 2000.

The U.S. company will be located in Seekonk, Massachusetts. Snee can be contacted at tel. 774-9910504 or joe@jsnee.com.

El Sewedy Electric wins Kuwait contract for high-voltage cables Egypt’s El Sewedy Electric reports that it has been awarded a contract worth approximately US$59 million to supply high-voltage cables and accessories on a turnkey basis to the Ministry of Electricity and WaterState of Kuwait.

The award, a press release said, “is a strong vote of confidence in El Sewedy Electric in the Gulf region.” It noted that the company has a total backlog for high-voltage power cables to be supplied over the next 20 months on a turnkey basis in Kuwait that represents about US$160 million of business. “We are extremely optimistic regarding strong growth in spending for transmission and distribution projects in Kuwait, and El Sewedy Electric should stand to benefit from this growth given our solid standing and approvals in the State of Kuwait.”

Moving plans set this year for TPC Wire & Cable Operations TPC Wire & Cable Corp., a supplier of high performance industrial wire and cable, reports that it is moving

media converters, software (proprietary embedded software and application software) and professional services.

Reuters reported that the deal was the largest for Siemens since it took over Israeli solar thermal fields maker Solel for $418 million in 2009. ... U.S.-based CommScope, Inc., exceeded industry standards by successfully enabling a 100 Gigabit Ethernet (GE) data transmission over off-the-shelf multimode fiber optic cabling at a

News briefs Germany’s Siemens AG said that it will buy Canada’s RuggedCom, Inc., in a deal valued at about $381.41 million, topping an offer from U.S. manufacturer Belden Inc. RuggedCom provides communications networking solutions designed for mission-critical applications in harsh environments, with products including Ethernet switches, network routers, wireless devices, serial servers,

Dave Tanis, EMEA Technical Director, CommScope, in front of the CommScope stand at Cisco Live!

MARCH 2012 | 19

INDUSTRY NEWS

its corporate headquarters in Ohio from Independence to Macedonia. The move, which will include the company’s warehouse locations in Mentor, Ohio, and Fraser, Michigan, was prompted by steady growth and a need for more room, it said. The move is scheduled to take place this year from April through June, starting with the warehouses.

“TPC has seen continual steady growth for the past two years, which has forced us to look at consolidating our operations to one location,” said company President Steve Michalski. “Future projections show our growth continuing which necessitated our need for more space.”

TPC was acquired by Pfingsten Partners LLC, a Chicago-based private equity firm, in January 2011 from Premier Farnell plc, a U.K.-based corporation.

INDUSTRY NEWS

length of 430 meters. In collaboration with Ixia and Reflex Photonics Inc., the demonstration took place at Cisco Live! in London using SYSTIMAX® InstaPATCH® 360 fiber cable assemblies using LazrSPEED® 550 OM4 fiber. “This demonstration shows a future-proof path from 10G through 40G and onto 100G with error-free operation,” said Peter Marsh, the U.K. technical manager for CommScope. “It also demonstrates that our customers will not have to re-engineer their networks or deploy new cable when they eventually evolve to 100G. CommScope’s solutions are engineered to exceed industry standards, but this demonstration, exceeding last year’s mark by almost 100 meters, proves the value high-performance cabling infrastructure can bring.” ... Last December 2011, a delegation of some 40 most influential members of the Intercable Association visited the Gauder Group facilities in Liège together with President Prof. Peshkov.

Pourtier had invited customers to see complete rigid

stranding lines and drum twister lines for the production of HV power cables, as well as a multiwire continuous concentric stranding line, type COS 1200, while Setic demonstrated a new generation buncher, model TD 630 i.

Visitors from Russia, Ukraine, Belarus and Greece also inspected the wide range of second-hand machines available in stock at Gauder warehouses. The event included a walking dinner that was held in the workshop. ... The 2012 WCMA Distinguished Career Award Banquet will be held on Saturday, April 21, 2012, at the Connecticut Convention Center in Hartford, Conncticut, USA. For information about the honorees as well as for registration and sponsorships (the deadline is April 6), contact Deb Mathiasen, WCMA Executive Director, at tel. 860-873-2311 or by email at mrcdm@snet.net. The registration form can also be accessed at the WCMA website at www.wcmainc.org. Overnight accommodations, at a group rate, are available at the Hartford Marriott Downtown Hotel, which is located near the center. Call 877-513-6305 or go online to https://resweb.passkey.com/go/wireandcable.

20 | WIRE JOURNAL INTERNATIONAL

ASIAN FOCUS

ASIAN FOCUS Bekaert reports that it has acquired interest in Chinese steel wire producer Bekaert and Xinyu Steel announced that they have successful closed a partnership deal in Xinyu, Jiangxi Province, China, for approximately US$17 million.

Bekaert, a worldwide technological and market leader in drawn wire products and applications, and Xinyu Iron & Steel Co., Ltd. (Xinsteel), a Xinyu-based (Jiangxi, China) iron and steel company, reported the successful closing of their partnership transaction, by which Bekaert acquires 50% of the spring wire and Aluclad activities of Xinsteel in Xinyu.

The activities, a press release said, represent an annual turnover of approximately CNY 500 million. The partnership includes two manufacturing plants in Xinyu that produce high carbon steel wires, mainly spring wires for the automotive, motorcycle and engineering sectors. The portfolio, it said, complements Bekaert’s existing product range manufactured in its wire plant in Jiangyin, Jiangsu Province. The partnership also includes the Aluclad (aluminum clad) wire and strand production unit, serving markets for overhead conductor networks and data communication, it said. Manufacturing, it noted, will be concentrated in one production plant in Xinyu.

The companies herewith formally enter a partnership aimed at combining complementary technologies and applications to open up new opportunities in the respective target markets.

Based in Belgium, Bekaert notes that it has been active in China since the early nineties and now operates 21 sites within 18 legal entities at 10 locations (Shenyang, Weihai, Jiangyin, Wuxi, Shanghai, Suzhou, Chongqing, Huizhou, Qingdao, Xinyu) that collectively employ more than 11,000 people. Xinyu Steel, located in the Jiangxi Province, is a state-owned enterprise whose activities include steel, mining, equipment and construction. It employs 28,000 people.

Kobe Steel esablishes steel wire processing company in China Japan’s Kobe Steel, Ltd., announced that it has established a company in the Guangdong Province of China in Foshan, to make steel wire for use in high-quality springs.

The new company, called Kobelco Spring Wire Co., Ltd., will begin operations in the first half of 2013, and have

monthly production capacity of 600 metric tons, a press release said. To shorten construction time and reduce investment costs and overhead, KSW will be located within the premises of sister company Kobe Wire Products Co., Ltd., it said.

KSW will receive technical assistance from Shinko Wire Company, Ltd., and Suncall Corporation for the secondary processing of steel wire rod, the release said. Established in January 2012 and capitalized at 650 million yen, KSW is a

wholly owned subsidiary of Kobelco Holding Co., Ltd., which is based in Shanghai.

The release observed that in recent years, automakers in China have been rapidly increasing production. In addition, the automobile industry along with current exhaust gas regulations is being pressed to reduce carbon-dioxide emissions. In the future, automakers will be required to make smaller and lighter cars while improving engine combustion efficiency.

China’s major spring manufacturers have been actively adding new production lines and increasing capacity to make engine valve springs and other high quality springs.

Kobe Steel anticipates that demand for high grade steel wire for springs made from its wire rod, highly evaluated by automakers in Japan, the United States and Europe, will increasingly grow.

When KSW begins operating, plans call for steel wire which is exported to shift to local production to meet market demand for automotive springs in China. Through the establishment of KSW, Kobe Steel aims to meet the growing demand for high quality steel wire in China. It plans to build a local supply network that can meet the market in terms of quality, competitiveness and flexibility.

Report expects further growth for India’s electric wire and cable market “Electric Wires and Cables Market in India 2012,” a new report from Netscribes (India) Pvt. Ltd., a consulting solutions company, predicts a strong focus in infrastructure “that will cause electric wires and cable demand to rise even further.”

The report, which shows the distribution of the global cable and wire industry and a market overview section of the Indian electrical equipment industry, highlights the market size, growth and segmentation, a press release said.

Have news that belongs here? If so, e-mail it to editorial@wirenet.org.

22 | WIRE JOURNAL INTERNATIONAL

ASIAN FOCUS

The focus is on providing a better understanding of prevailing structure of the electric wires and cable market, it said, including the classification and a comparison between polyethylene (PE) and polyvinylchloride (PVC) cables for various parameters.

The report shows import and export volume with respect to electric wires and cables over the last four years, including the major countries of import and export.

Drivers of the expected growth include the huge investments made by various private companies in power sector as well as the increasing budget allocation by the government on the power sector, the release said. It noted that the power sector is the largest consumer of cables in India while another important driver “is the rollout of 3G and broadband on a pan-India basis which will boost the market as demand will increase as players look to enhance broadband penetration levels.” Other drivers, it said, include government impetus in refineries, power and fertilizers as almost all manufacturing companies need cables, while robust industrialization and growing urbanization will also be significant contributors. The auto sector and railways, it said, remain important sectors for wire and cable, while further urbanization will require much wire and cable for buildings and offices.

The release said that some of the challenges the industry faces are price increases and competition from Chinese imports. Further, as the price of copper continues to increase, profit margins are squeezed and they become uncompetitive in the international market, it said. Another section in the report covers “government initiatives where the credit lending subsidiary scheme is explained.” It also highlights the rules and regulations to which the wire manufacturers need to adhere, it said.

A section on competition includes a bubble chart that shows the relative positions of the players depicted with respect to their revenue, net profit and market capitalization, the release said. It also includes profiles of the major players in the market, along with their financials as well as key ratios and a list of important contact persons, it said. The report identifies key developments that have taken place in the market and it also includes strategic recommendations “where the critical success factors important to this industry have been depicted,” it said.

Figures in the report include: market segmentation for electrical wires and cables in India (unorganized vs. organized); the export and import levels in value terms (2007-08 – 2010-11); the increase in budget for the power sector; expenditure on the power sector and for cables (2012-17); growth in telecom subscribers (2010-2012e); consumption of cable (India vs. China); growth of Indian urban population (2001-2021e); net absorption of office space in India (2009-2011), and more. Contact: Netscribes (India) Pvt. Ltd., www.netscribes.com.

Visit us at Wire Düsseldorf – stand - 9C-71

MARCH 2012 | 23

PEOPLE

PEOPLE Mid-South Wire Company (MSW) announced that Todd Plate has joined the company as vice president of sales and development. He will be responsible for identifying current and future marketing and sales opportunities for its manufacturing facilities, with a focus on expanding market share in the galvanized and carbon steel wire industry. He has 21 Todd Plate years of experience, most recently working as general manager for Siskin Steel and Supply. He holds a B.S. degree from the University of Michigan and an MBA from Northwestern University. Based in Nashville, Tennessee, USA, MidSouth Wire manufactures low- to medium-carbon bright wire as well as industrial quality galvanized wire.

Lloyd & Bouvier, Inc., has named Jim Miller, principal, Jemco Industries, Westmont, Illinois, as its midwest sales representative. He has more than 25 years of experience in the wire and cable industry, including extensive machinery knowledge. Prior to starting Jemco, he was vp operations and general manager of Isotec, Inc./Gepco International, Inc., and he also worked for Coleman Cable. He will cover the states of Iowa, Wisconsin, Illinois, Indiana, Kentucky and Ohio. Based in Clinton, Massachusetts, USA, Lloyd & Bouvier provides new, used and rebuilt wire and cable machinery.

Taubensee Steel & Wire Company announced that it has replaced its previous inside sales service department with a new customer relations department. The six team members collectively have more than 77 years of experience in the steel industry, with extensive sales and customer

OBITUARIES Richard Nash Jr., 82, a longtime leader of Maryland Specialty Wire Co., died of pneumonia and heart failure on Wednesday, January 11, 2012, at his winter home in Naples, Florida. A native of Baltimore, Maryland, he graduated in 1951 from Princeton University. During the Korean War, he enlisted in the Navy and served as a flight deck officer aboard two carriers. He returned to Baltimore and became superintendent of a paint manufacturing plant before going to Maryland Specialty Wire Co., where he worked for 27 years. The company became part of Handy & Harman, and he headed its wire group, which also included Willing B Wire, Strandflex and Rigby-Maryland Stainless Wire. During his tenure, he became a highly respected leader in the stainless wire industry. Nash retired in 1996.

He is survived by his wife of 56 years, Sherrill Gray Nash; daughters Abigail Nash Keller and Lydia Nash Weiss; a sister, Kate Nash Chittenden; three grandchildren; and many nieces and nephews.

Luigi Maggi, the owner and founder of OMCG Srl, died Jan. 27, 2012, at age 66 at St Raphael Hospital in New Haven, Connecticut, USA. He started the company, based in Olginate, Italy, in 1965, and sold machines in more than 40 countries. The company specializes in vertical slide forming machines, and in 1985 Maggi introduced the first all-servo-driven wire forming feed and form machine. He was known for his passion for helping customers and will be missed by the industry. The company has two offices in the U.S., one in Bridgeport,

Connecticut, and the other in Bensenville, Illinois. His body will be shipped back to his home town of Olginate.

He is survived by a sister, Lia Maggi Gnecchi.

Edgar Edmund Konrad, the founder of Konrad Machinery Corporation in Shelton, Connecticut, USA, died Jan. 17, 2012, in West Palm Beach, Florida, USA, at age 75. A native of Medenbach-Breitscheid, Germany, in 1952 he started as an apprentice with Berkenhoff & Drebes, a wire die company in Herborn, Germany.

He then went to Maschinenfabrik Herborn, a leading wiredrawing machinery supplier, where he worked for 15 years. In 1967, he immigrated with his wife and two children to the U.S., and joined Wafios-Herborn Machinery Corporation in Hackensack, New Edgar Edmund Jersey. In 1978, he founded Konrad Konrad Machinery Corporation, which specialized in new and used wire and cable equipment. In 1979, he moved his family and business back to New Jersey. He had many friends in the wire industry that helped him persevere through the hard times. He joined the WAI in 1969 and became a lifetime member in 1998.

He is survived by his wife of 50 years, Margret Konrad; son, Mario Konrad; two daughters, Sabine Cohen-Konrad and Regina Aretz-Konrad; and 10 grandchildren.

Send People items to editorial@wirenet.org. You are welcome to include a photo (jpg, 175kB to 1-2MB).

24 | WIRE JOURNAL INTERNATIONAL

includes April Smith, an 11-year employee, senior customer relations executives; Nicole Silvers and Hollie Calow, customer relations executives; and Andrew Winter, customer relations specialist. They will work with the company’s outside sales force. Based in Wheeling, Illinois, USA, Taubensee Steel & Wire Company manufactures steel wire and cold-drawn bar.

As part of an expansion at Solon Wire Processing, LLC (see p. 12), the company has expanded its sales force.

Added were Bob Brofman, sales representative; Tom Tubaugh, inside sales, rod and wire, and Chris Andrews, inside sales, customer conversion. A division of Republic Steel based in Solon, Ohio, USA, Solon Wire Processing, LLC, manufactures rod and wire for a range of sectors, from fasteners to construction.

From l-r, back row: Lee Ann Brooks, April Smith, Hollie Calow and Andrew Winter; front row: Kris Mikkelson and Nicole Silvers.

The Elgin Fastener Group recently named Ian McKenna as its CFO. He has 20 years of experience in various financial director and alliance management roles.

Based in Versailles, Indiana, USA, the Elgin Fastener Group includes Ohio Rod Products, Leland Powell Fasteners, Chandler Products, Silo Fasteners and Landreth Fastener, among others.

Inosym Inos sym R eellss

Visit us at wire DĂźsseldorf - stand 11 D58

Inosym Ltd. Ph: +64 21 353 634 Fax: +64 3 341 6668 Email: inosym@inosym.com Web: www.inosym.com

MARCH 2012 | 25

PEOPLE

service competencies. The department is led by Kris Mikkelson, customer relations manager, a 19-year employee; Lee Ann Brooks, a 36-year employee, and

FIBER WATCH

FIBER WATCH Corning reports that its global sales of multimode fiber tops 1 million km U.S.-Corning reports that the company has sold more than one 1 million km of its ClearCurve® multimode optical fiber to more than 90 cablers in 20 countries around the world.

“With more than six million terminations globally deployed, the broad market acceptance of ClearCurve multimode optical fiber is apparent,” a press release said.

“Passing 1 million kilometers sold is an exciting achievement that validates continued customer acceptance of Corning ClearCurve multimode fiber in the market,” said Barry Linchuck, division vice president and director, worldwide marketing, Corning Optical Fiber.

“ClearCurve multimode fiber remains our standard 50micron multimode product offering, providing assurance against tight bends and challenging cable installations with up to 10 times less signal loss than traditional multimode fibers.”

The release notes that ClearCurve multimode fiber is the world’s first laser-optimized, high-bandwidth, fully standards-compliant, multimode fiber to withstand tight bends down to 7.5 mm radius with substantially less signal loss than traditional multimode fibers. It added that the product’s superior bend performance enables efficient optical cable routing and installation and additionally provides spare operating margin. Traditionally, when an optical cable experiences tight bends, some of the light can escape from the fiber core and part of the signal can be lost, but the ClearCurve multimode fiber is designed to keep the light within the fiber core even under tight bends, better maintaining the integrity of the optical fiber signal, it said.

Corning ClearCurve multimode fiber is fully compatible with the installed base of 50-micron multimode fiber and meets or exceeds the ISO/IEC 11801 OM2, OM3, and OM4 product standards for high-bandwidth, laser-optimized, multimode fiber, the release said.

Prysmian Group launches telecom brand strategy at FTTH conference At the FTTH Council Conference held in February, in Germany, the Prysmian Group launched its new telecoms brand strategy following the integration of Prysmian and Draka.

A press release said that Prysmian presented its new xsNet portfolio that includes bend-insensitive fiber technologies, cables and connectivity, all targeted specifically at the Fiber-To-The-Home (FTTH) market. “The Group’s xsNet brand will also be launched at the event as the defining system of products targeted specifically at the FTTH market. Bringing this combined portfolio together into a clear structure under the xsNet brand is the defined

26 | WIRE JOURNAL INTERNATIONAL

product brand strategy of the Group,” it said.

Phil Edwards, executive vice president of telecoms at Prysmian Group, made a presentation at the conference looking at trends in the market and how the industry is constantly innovating to keep ahead of the levels of demand. “We fully support the European Digital Agenda 2020 and as a company are convinced that a fiber-based, open-access infrastructure is fundamental to providing the future-proof networks that this requires. Prysmian Group will maintain its strong commitment to innovation in order to develop the products and systems which will enable these networks to be created and sustained,” he said in a press released prior to the event.

“The FTTH Council is a fantastic opportunity for us to show our credentials as the new Prysmian Group,” Edwards said in the release. “As a combined company, with our collective knowledge and cohesive message, we have become the leading global player in the energy and telecom cable industry. The integration process is proceeding quickly and the Group has already presented its new organizational model, brand strategy and product range for both our businesses.”

Verizon’s 2011 investment made in Pennsylvania topped $500 million Verizon, one of the world’s largest installers of optical fiber technology, reports that the company invested more than $512 million in its wireline communications network and IT infrastructure throughout Pennsylvania.

“No other company is as interwoven with daily life in Pennsylvania as Verizon is, providing an engine for economic growth through our aggressive wireline network and IT deployment,” said Tim Smith, Verizon region president of consumer and mass business for Pennsylvania/ Delaware. “Our significant infrastructure investment is removing traditional technological boundaries, empowering people and businesses to connect however, whenever and wherever they want.”

The investment, a press release said, included major wireline infrastructure programs last year that saw its 100-percent fiber-optic FiOS TV and FiOS Internet services made available to more than 1.5 million homes and businesses at year’s end. The company also continued accelerated deployment of fiber-optic links to wireless carriers’ cell sites throughout Pennsylvania, with some 1,100 such sites connected in 2011, it said.

The release said that the company has continued to improve its copper infrastructure investment program, which includes key upgrades to copper-based facilities and at central office locations across Pennsylvania to enhance the overall reliability and dependability of the network.

If you’re serious about a career in wire and cable all signs point to WAI membership.

Q: Why did you join WAI? A: For the networking, education, and information.

Q: Why have you renewed your membership over the years?

A: To stay on top of industry happenings, maintain relationships and friendships, and to help promote educational experiences.

Q: How did you get involved in the wire industry?

A: By accident. During college I had a brief part-time job at Phalo, as an extrusion line operator. Years later I worked for the Entwistle Co., followed by work with several plastics-related companies and two wire manufacturing companies, until I permanently landed in wire and cable machinery sales.

Q: What would you be doing if you hadn’t gotten involved in the wire industry?

A: I would be in, as Mr. McGuire says in The Graduate, “PLASTICS.”

Erik A. Macs VP Sales | Fine International Corp.

Member Since: 1990

Meet Erik A. Macs.

One of WAI’s worldwide members.

One compelling story.

Erik is a wire industry ambassador who seeks camaraderie and fosters it, notably within WAI’s largest chapter.

Q: What can you help people learn more about?

A: Braiding, cabling, and extruding (especially foam).

Q: If you were to nominate yourself for an award what would it be for?

A: The Eternal Optimist/Pessimist (depending on the day).

Q: What is something almost nobody knows about you?

A: My sometimes irrational affection for the Firesign Theatre.

Q: What is your lifelong ambition?

A: To be a professional photographer.

An Ambassador | A Human Pendulum | A Picture Snapping, Free-wheeling, Pedaling Peddler | A Charmer He’s tickled by Firesigns but true to the zodiac he’s a Libra who’s drawn to scales. Maybe that’s why this charmer has an appetite for serpentine sustenance. In numerological terms and beverage choice he’s a 7.

Q: What do you do for leisure?

A: When in Florida, biking by the St. Petersburg shore parks.

We’re not sure what influenced his career most: the symmetrical motion of wire braiding or his admitted tendency to oscillate between extremes.

He appreciates international culture and has an affinity for iconic Americana: Rock ‘n’ roll and baseball. He’s probably fond of apple pie.

Q: What is your best industry related travel story?

A: It involves the night I had snake soup in China and my favorite

Social, informed, and astute, his ideas are completely baked. Ask him for career advice and he’ll give you three choice words: “WIRE and PLASTICS.”

MNEMONIC TIP: ERIK MACS. THIS MAC IS PC.

Q: Where would you most like to visit?

A: Any country in Central or South America.

beverage, Jack Daniel’s Old No. 7.

Q: What is your favorite memory from Interwire or Wire Expo?

A: The Opening Receptions at the Henry Ford Museum, Churchill Downs, The Rock and Roll Hall of Fame, and Fenway Park.

Q: What is your greatest accomplishment?

A: Putting on the Fundamentals of Insulated Wire Manufacturing presentation for the New England Chapter (twice).

Meet your peers. Achieve your goals. Join WAI’s community at www.wirenet.org.

The Wire Association International, Inc.

1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 USA | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org

FASTENER UPDATE

FASTENER UPDATE WinWholesale reports acquisition of Midwest Industrial Sales U.S.-based WinWholesale reports that it has acquired Midwest Industrial Sales, which is based in Kansas City, Kansas, and has reopened as Kansas City Winfastener Co. The announcement said that Richard S. (Shane) Garrison, co-owner of Midwest Industrial Sales, was named president of Kansas City Winfastener. The company provides industrial joiners, tensioners, fastening systems and tools to the Kansas City metropolitan area encompassing 15 counties in Kansas and Missouri. To expand the company’s capability to serve customers, it said, the tool repair division of KC Windustrial Co. in Kansas City, Missouri, has been moved to the newly acquired company. In addition, the company will add product lines. The current lines include Gripple joiners and tensioners, and Metabo, Milwaukee, RIGID and LENOX tools.

In an article in TheWholesaler.com, WinWholesale COO Monte Salsman described Kansas City Winfastener as “a great addition to the Win Group of companies in the Kansas City metro area. Our team members there have 100 years of experience. We believe putting that together with expanded services and inventory is a huge advantage for customers.”

Novaria Group acquires Fitz U.S.-based Novaria Group announced that it has acquired Fitz Manufacturing Industries, a Texas supplier of precision aerospace components.

A press release said that Novaria “will pursue strategic growth and expansion of Fitz’s capabilities while also delivering enduring value to customers, employees, and the aerospace industry.” It noted that Fitz’s manufacturing capabilities are focused on three primary product categories: aerospace bushings, aerospace fasteners and precision-machined components. These products, it said, are incorporated into most subsystems of both commercial and military airframe applications. The company also operates a metal finishing facility, allowing it to vertically integrate processes and more comprehensively serve its customers, it said.

“There is significant opportunity for Fitz to accelerate its growth plans by joining forces with Novaria,” said Earl Larkin, managing partner of Novaria Group. “The current Fitz management team, combined with our financial support, deep industry relationships, and strategic expertise, will better serve customers while preserving the culture and reputation for high quality that Fitz has built over the last 16 years.”

Fitz’s customers include major tier 1 and tier 2 original equipment manufacturers (OEMs), and major distributors, including B/E Aerospace, Boeing, Bombardier, GE, Goodrich, Spirit, and Wesco. Greg Fitzgerald, founder of Fitz Manufacturing, will remain an equity partner and CEO of the company, the release said. Fitz will maintain

28 | WIRE JOURNAL INTERNATIONAL

its current 132,000-sq ft location in North Richland Hills, just north of Fort Worth, Texas. The company, with approximately 150 employees, was founded in 1995 “under the vision and entrepreneurial spirit of the Fitzgerald family, including Greg’s parents, Barry and Bonnie Fitzgerald and longtime friend Steve Huey,” it said.

“To better serve our customers during this critical time in the aerospace market, I needed a true partner who understood the industry, had experience operating successful organizations, and provided value-add well beyond capital support,” Fitzgerald said.

The release said that Novaria “is currently pursuing additional growth opportunities, capitalizing on the expanding aerospace market by acquiring majority interests in smallto mid-market companies looking for a long-term oriented, well-aligned, financial and operational partner.”

The Novaria Group is the aerospace investment platform for Satori Capital, a middle-market growth capital and buyout firm based in Dallas, Texas.

Zipper manufacturer goes solar Southern Energy Management (SEM) reports that it is helping the world’s second largest zipper manufacturer with sustainability efforts by installing its first solar array.

A press release said that IDEAL Fastener Corporation (IFC) has hired SEM to design and build a 198.24 kW solar photovoltaic system on the roof of the company’s factory in Oxford, North Carolina. The project, it noted, includes 826 of LG’s 240-watt solar modules. IFC, which has operations in more than 20 countries, offers zippers for any application including apparel, automotive, furniture, luggage, military and specialty, it said, adding that its client lists includes virtually every known apparel brand and retailer in the United States and Europe, the U.S. armed forces, and numerous Fortune 500 and international manufacturers across a range of industries.

Crews from SEM, based in Morrisville, North Carolina, started building the system in October and completed work by mid-December. The installation will generate an estimated 261,280-kilowatt hours of electricity per year, enough to power more than 20 average homes. With help from federal and state incentives, the project has just a four-year payback at current energy rates.

“Southern Energy Management made the entire process easy, especially since this was our first solar installation,” said IDEAL Fastener Vice President Steven Gut. “This project was a perfect way to reduce our carbon footprint and make a smart business decision. It’s a win-win for everyone involved.” He added that the plan to harness solar power was something they had examined for several years, and the company is already considering adding more solar arrays to the same site or some of its overseas plants.

WAI

NEWS

WAI NEWS

Cox to be keynote speaker at Dallas W. Michael Cox, director of the O’Neil Center for Global Markets and Freedom, a research institute within Southern Methodist University’s Cox School of Business, will be the keynote speaker on Tuesday, May 22, the second day of WAI's Operations Summit & Wire Expo 2012, to be held at the Omni Dallas Hotel in Dallas, Texas, USA. An accomplished public speaker, Dr. Cox may be bestknown for celebrating capitalism’s capacity to deliver economic progress and raise living standards. His recent work focuses on the new businesses models arising from the globalization of the labor force and the emerging power of India and China.

Dr. Cox is former chief economist and senior vice president of the Federal Reserve Bank of Dallas, where he served for 25 years advising the bank’s presidents on

monetary and other economic policies. He holds the distinction of being the Federal Reserve System’s only Chief Economist in history. In 2009, he retired and became director of the O’Neil Center, which focuses on the study and teaching of how competitive market forces impact freedom and prosperity in the global economy.

W. Michael Cox Dr. Cox earned his doctorate at Tulane University and his 35 years of college teaching experience includes stints at Virginia Tech, the University of Rochester and SMU. He

WAI Q&A WJI Reference Guide & Virtual Trade Show Share Data, Promote Awareness This occasional section covers a topic of general interest involving WAI. This one is with WAI Marketing and Corporate Communcations Director Janice Swindells.

Q: What is the procedure to submit a company profile in the WJI Reference Guide?

Swindells: New listings should be created and submitted online at the following link: http://www.wirenet.org/vts/admin/newlist.cfm.

The individual who creates the listing becomes the company’s main contact person who will have access to update the data throughout the year. Most organizations appoint someone from their sales, marketing, or communications departments.

Q: When are new profiles accepted?

Swindells: New listings can submitted anytime.

Profiles received by November 30 of each year are included in the subsequent publication, which is released annually in mid-February.

Q: What does a listing cost?

Swindells: Basic listings are free. Black boldface and red boldface listing upgrades are also available at $125 and $225, respectively.

Q: Should a company submit a new listing every year?

Swindells: No. WJI requests updates to existing listings in the late August time frame by sending a reminder to the main contact. New submissions are not necessary

30 | WIRE JOURNAL INTERNATIONAL

each year and are a potential cause of duplication in the database, which is something we aim to avoid.

Q: How does WAI use the information supplied in the Reference Guide?

Swindells: Company profiles are added to a database that is updated as changes are submitted. That database runs the Virtual Trade Show (VTS) portion of WAI’s website, which acts as a companion medium to the printed publication. Visitors to the VTS can sort by various criteria—such as product type, location, or type of business—to fine-tune a search for global wire and cable companies. Profiles online provide direct links to company websites and e-mail addresses. The VTS also extends the value of the annual publication by offering a real-time view of the database, and it enlarges the number of products that can be listed for each company from 10 (in print) to 20 (online), helping potential customers pinpoint suppliers and wire manufacturers.

The data is also used to promote WAI-related events and membership initiatives.

Q: What is new about the 2012 Reference Guide?

Swindells: About 100 new company listings were added to the 2012 publication. Some, you’ll note, show additional plant locations for large wire manufacturing companies.

Also the guide includes 117 companies from India, a jump due in large part to new contacts made through WJI’s sister publication in India, WIRE BULLETIN.

Silver • Wire & Plastic Machinery Corp.

• Woodburn Diamond Die Inc.

13 companies are sponsors for WAI’s Operations Summit & Wire Expo 2012

The Onsite Sponsors include: • Amacoil, Inc. (coffee break) • Baum’s Castorine Co., Inc. (coffee break) • Carris Reels, Inc. (lanyards) • Commission Brokers, Inc. (juice bar) • Davis-Standard, LLC (Cyber Cafe #1) • Lloyd & Bouvier, Inc. (Cyber Cafe #2) • SIKORA International, Inc. (directional signs) • Woodburn Diamond Die, Inc. (tour transportation)

As of press time, a total of 13 companies have become sponsors for WAI’s Operations Summit & Wire Expo 2012, to be held May 22-23 at the Omni Dallas Hotel in Dallas, Texas, USA. The Corporate Sponsors include: Platinum • ACIMAF Gold • Carris Reels, Inc. • Continuus-Properzi SpA • SIKORA International, Inc.

Bronze • Gold Metal Recyclers • Red Kite Managdment (USA) Ltd.

For more information about sponsorships, contact WAI’s sales staff at sales@wirenet.org. (section continued)

MARCH 2012 | 31

WAI NEWS

is the author of Myths of Rich and Poor, a book nominated for a Pulitzer Prize. He has written a series of 17 “annual report” essays that explain the inner workings of American capitalism and has written numerous articles for The Wall Street Journal, The New York Times, USA Today, Financial Times, Investor’s Business Daily, Leadership Excellence magazine and more.

WAI NEWS

Dallas session to highlight the success stories of 5 companies

quality and increased capacity, especially critical given the tightness of the current transportation marketplace.

Five wire and cable companies will get to tell their unique stories during a special session at the upcoming WAI Operations Summit & Wire Expo May 22-23 in Dallas. The new “Operational Excellence” session will highlight outstanding achievements in manufacturing excellence within the wire and cable industry. The twohour program will feature five back-to-back case studies beginning at 1:30 pm, Tuesday, May 22. Each presentation will be followed by a brief Q&A. “There are so many great stories going on in the industry every day that people might not hear about,” said WAI’s Director of Education & Member Services Marc Murray. “This session will be a perfect platform to share the kind of good news and extraordinary accomplishments that can make everyone in the industry proud.”

Development of a 230 kV System, Cable, and Accessories Presenter: Patricio G. Murga, Director of Technology & Development, Viakable SA de CV, Mexico This presentation describes the development of the 230 kV System, made by Viakable from 2008 to 2011. This project included the development of an insulated power cable, for 230 kV, 2,000 mm2 – copper, and a system using ABB-Kabeldon accessories. The presentation includes the technology development, the cable and process design, the extrahigh voltage (EHV) testing area design and construction, and alliances with well-known international laboratories for the witnessing process. The 230 kV system was tested for more than a year in Viakable’s state-of-the-art EHV laboratory, and met the proper international specifications.

Feature Presentation: The Encore Success Story Presenter: Daniel L. Jones, President/CEO, Encore Wire Corporation, USA Jones will share the amazing story of Encore’s growth which is based on their continuous reinvestment in the company, and their collaborative approach with suppliers and customers, as well as their ability to maintain a highquality team of employees. Encore Wire, which was formed in 1989, operates from a single 192-acre campus in McKinney, Texas, that includes a new R&D center, as well as stateof-the-art manufacturing, an expansive warehouse, and rod mill. Encore manufactures commercial and residential building wire as well as metal-clad and armor-clad cable.

Expanding Supplier Integration to Logistics Presenters: Paul Kasinski, Director of Logistics, General Cable, and Ken Gray, Branch General Manager, C.H. Robinson Worldwide Inc., USA For decades, General Cable sourced transportation services based largely on lowest initial cost and had at best a transactional relationship with carriers. Entering the recession, the company challenged its core carriers to become integrated business partners, and embraced their expertise and resources to maximize overall relationship value. The integration model with C.H. Robinson is an excellent example as it has evolved into a highly effective transportation and load planning management process. This integration has resulted in lower cost per unit, improved

32 | WIRE JOURNAL INTERNATIONAL

Interconnecting Operations and the Environment Presenter: Bruno Lioi, Regional Director of Operations, Gerdau – Wire Products, and Thomas Sondgeroth, Sales Manager, Gerdau – Carrollton Wire Products, USA In 2011, Gerdau’s Carrollton wire operation received the Environmental Distinction Award from the City of Carrollton (Texas). This presentation will discuss the various factors that have positioned this specific facility for excellence, including steadfastly applying Kaizen, the installation of an oil recovery system, and other environmentally friendly facility modifications.

Marlin Wire’s Engineered Solutions Presenter: Drew Greenblatt, President, Marlin Steel Wire Products, USA Marlin Wire has a growingly diverse and demanding customer base for their wire fabricated products.

This presentation illustrates their keys to success when working with such industries as aerospace, medical, and the military.

CHAPTER CORNER

CHAPTER CORNER

Economist Brian Hirt finally got to speak to a full house.

No snow job: New England Chapter’s annual meeting was back-to-business With nary a snowflake reported on Jan. 26 within a hundred miles, the New England Chapter once again saw attendance top 120 members and guests at its annual dinner meeting at the Mohegan Sun Resort Conference Center. The event saw both the introduction of news officers and board members as well as a full house for the returning speaker, whose presentation the prior year had been made to an audience whose numbers had been blizzard-reduced.

Outgoing Chapter President Marie Geary welcomed attendees to the event, which began with a reception featuring comedian/magician Charlie Hayden, who did a superb job entertaining. He was followed by a speech by economist Brian Hirt, marketing manager for IEWC. Hirt said that the nationwide unemployment rate was still high, but definitely started to move in the right direction last year. The unemployment rate, he observed, “goes up fast and down slow.” Conditions are still not great, but it’s get-

John Rivers, the 2012 chapter president, with Marie Geary, the outgoing president.

ting better, he said. Housing continues to be a drag, but based on the shrunken size of the industry, the ongoing negative impact of the sector is almost non-existent in headline growth figures for the country. The auto industry should continue to improve as the data indicate there are a lot of very old cars that need replacing. One positive in a negative, he said, was that a decline in inventories in the third quarter of 2011 should translate to more growth in the future as businesses restock.

There are no long-term guarantees, but 2012 should be a good year, Hirt said. He noted that consumer spending, which accounts for about 70% of spending, has seen strong growth. One reason is that the savings rate, which grew from nearly 2% to 6% headed into the recession, has since dropped off to about 4%, which means that consumers are spending more. That’s also a plus because it is an indicator of confidence, he said, noting that potential concerns going forward include government austerity cuts and European government debt default.

Following dinner, Geary introduced the 2012 officers.

Those include: President John Rivers, Delaware Marketing Services; Vice President Kevin Buchanan, Fluoropolymer Resources Inc.; Treasurer Bob Srubas, Times Microwave Systems; and Secretary Ken Strandberg, T &T Marketing.

Geary is the Immediate Past President.

The full board also includes Rick Amaral, Amaral Automation Associates; Grant Campbell, Multi/Cable Corporation; Jim Stocking, Hitachi Cable; David Fisher, James Monroe Wire & Cable Corporation; Brian Holden, Carris Reels, Inc.; Mark Long, Quirk Wire Company; Rene Mayer, Mossberg Reel LLC/Boxy Group; Mike McKee, Lloyd & Bouvier; Derek Olson, Gem Gravure; Roy St. Andre, EIS Wire & Cable Company; and Maria Neclerio, Q-S Technologies. Neclerio and Stocking are new board

The 2012 board of directors for WAI’s New England Chapter.

34 | WIRE JOURNAL INTERNATIONAL

Automation Associates and MultiCable; and (Bronze Sponsors) Beta LaserMike, Nutmeg Wire, Mathiasen Machinery, Inc., Mossberg Reel, Chromatics and W. Gillies Technologies LLC.

Last call for scholarship applications Time is running short to apply for a scholarship from three WAI chapters that—in conjunction with the Wire Foundation—are seeking applications from the children of chapter members in good standing for their 2012 scholarship awards.

Applications from members of the New England, Midwest and Southeast chapters must be postmarked no later than Friday, March 30, 2012. They should be sent to Wire Association International, 1570 Boston Post Rd., Guilford, CT, 06437, to the attention of Livia Jacobs.

For both the New England and Midwest chapters, eligible candidates for the awards are graduating high school seniors who will be continuing their education in college. The Southeast Chapter also allows continuing college students to apply. Non-members of WAI who have students who would be eligible to apply for the scholarships are welcome to join WAI and their respective chapter. For more information about the scholarship programs or WAI membership, contact Steve Fetteroll at tel. 203-453-1777, ext. 115, or at sfetteroll@wirenet.org.

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MARCH 2012 | 35

CHAPTER CORNER

members while Geary and Denise Coyle, Chromatics, Inc., completed their terms.

Rivers shared his thoughts about the organization. â&#x20AC;&#x153;The chapter is not about making money,â&#x20AC;? he observed. Itâ&#x20AC;&#x2122;s about providing a place for colleagues to socialize and network while doing some good, such as by putting on educational programs and offering scholarships, he said.

Another highlight was the raffle for four tickets to a Boston Red Sox/New York Yankees game at Fenway Park, which was won by Grant Campbell, whose popularity rating immediately soared as questions arose about who he would be taking. Rivers thanked Gem Gravure President Dave Gemelli for donating the tickets, noting the raffle raised $1,400, all of which will go to the chapterâ&#x20AC;&#x2122;s scholarship fund. The chapterâ&#x20AC;&#x2122;s board had earlier voted to transfer $10,000 to the scholarship fund. He also noted that the chapter plans to hold an educational program this summer.

The meeting chairman, Kevin Buchanan, thanked all the sponsors for their support. Those included (Gold Sponsors) Delaware Marketing Services, T&T Marketing Inc., Commission Brokers, Gem Gravure Co., Inc., James Monroe Wire & Cable Corp., S&E Specialty Polymers and Du Pont; (Silver Sponsors) Carris Reels, WAFIOS Corp., Leoni Wire, Inc., Breen Color Concentrates, Quabbin Wire & Cable Co., Inc., Lloyd & Bouvier, Fluoropolymer Resources, Inc., Wire & Plastic Machinery, Amaral

FEATURE

Executive Outlook T

he view from the top in any business requires

a person who can assess the field’s direction and

potential and choose a path from the myriad possible directions, that leads to continued success. This feature presents observations from a dozen wire and cable manufacturers (and one equipment supplier) as well as the perspective from a former company president.

WJI: Is bigger inherently better for a wire and cable company?

We tend to believe that generally, bigger is inherently better for a wire and cable company. Given that this is a very competitive industry with margins being extremely tight, the larger the production base the better cost savings you will be able to achieve. From the purchasing of the raw materials to the actual efficiency of the plant we believe that there is a true benefit of scale resulting from distributing the overheads on a larger base, ultimately reducing your cost/ton of production. In addition to scale, it is important to have a wide product range and Ahmed El Sewedy the ability to produce El Sewedy under different standards such as IEC, BS (British standard), NF (France), VDE and others. Finally, the diversification of your product portfolio by market is also a key decision to be considered when increasing capacity. El Sewedy Electric currently serves Egypt, Europe, GCC, Middle East, North Africa and Sub Saharan Africa. Ahmed El Sewedy, CEO, El Sewedy Electric, Egypt.

36 | WIRE JOURNAL INTERNATIONAL

The bigger a cable company is, the more difficulties the company’s management has, and the lower its efficiency.

Shi Aiwei, vice president, Beijing Force Automotive Wire Co., China.

There are many benefits created by the size of the company. Synergy effects are enticing and stimulate acquisition and merger behavior. In my opinion, bigger does not necessarily mean better. Large companies, more often than not, lose focus on the customers and their special needs. Additionally, companies tend to shift their focus from market activity into internal organization struggles.

TELE-FONIKA Kable has no ambition to be the largest cable company in the world, but certainly, we will work to ensure our business partners that our products are the most reliable available on the market. Marcin Szymański, CEO, TELE-FONIKA Kable Sp. z o.o.

S.K.A., Poland.

The answer depends. Bigger is important when you need the ability to scale in order to offer consistent product worldwide. Cable is heavy and thus much of the ecosystem is influenced by transportation costs. Bigger is also better when demand is not consistent for all customers. Flexibility to scale and fill orders will benefit those with a well-structured capacity. On the other hand, scale requires consistent demand or underutilization of capacity will limit profitability. As such, important niches are often ignored by scale players, and niches tend to grow into mainstream markets. This common phenomenon is something all large companies need to be cognizant of.

Morgan Kurk, senior vice president of Intelligent Buildings, CommScope, U.S.

Feature contributors American Wire and Cable (AMC). Based in the U.S., AMC produces lead-wire and hookup wire for customers throughout North America.

Beijing Force Automotive Wire Co. Based in China, Beijing Force Automotive Wire Co. is one of country’s largest producers of automotive wire and cable.

CommScope. Based in the U.S., CommScope’s end-toend solutions for wired and wireless networks are used in virtually all the world’s best communication networks.

Conductix-Wampfler/Delachaux Group. Based in France, Conductix-Wampfler offers equipment for production of bare fiber optic, fiber optic cable and copper.

EIS Wire & Cable. Based in the U.S., EIS is a lean enterprise that specializes in solving problems for the OEM, military, industrial and specialty product markets.

El Sewedy Electric. Based in Egypt, El Sewedy Electric is a leading integrated cables and electrical products manufacturer in the Middle East.

Institute of Non-Ferrous Metals. Based in Poland, the Institute is an R&D organization that also is a wire producer through its units, which include INMET.

Hayrettin Cayci, Sarkuysan A.S.

Large-scale requirements and tenders may include cable products with different specifications and volumes (in which case a small or medium size company may not meet the specific demand). Mergers and consolidations may make it possible for the new entities to meet such demand to a greater extent, thereby increasing their competitive edge. Also, major players seeking growth in the cable sector, prefer downstream integration, thus attaining higher value added products rather than upstream integration, which is another potential success factor as cable products are in great demand for today’s rapidly advancing technologies that require quick response to changing specifications. Hayrettin Cayci, president and chairman of the board, Sarkuysan A.S., Turkey.

In India, products and services become commodities very quickly, and so it is for the wire industry. Hence, volume is the game. Big volumes not only reduce the cost of production but also increase bargaining power with your suppliers. Predominantly, in the wire industry, the raw material is the biggest input cost, so it’s important that your purchasing power is really good. Vinit Lohiya, Samrat Wires Pvt., Ltd.

Minnesota Wire. Based in the U.S., Minnesota Wire is a custom manufacturer for wire, cable and interconnect assemblies to the medical, defense and industrial markets.

Samrat Wires Pvt., Ltd. Based in India, SWPL, part of the GITA Group, produces CHQ and steel alloy wires at its wiredrawing plant at Khopoli, Maharashtra.

Sarkuysan A.S. The first successful publicly held corporation in Turkey, Sararkuysan’s electrolytic copper products can be found in nearly half the vehicles in Europe, Seminole Wire & Cable Co. Based in the U.S., Seminole is a family owned and operated specialty manufacturer that specializes in low-volume, customer specific wires.

Taubensee Steel & Wire Co. Based in the U.S., Taubensee produces steel wire and cold finished bar at its plants in Wheeling, Illinois, and Henderson, Kentucky.

TELE-FONIKA Kable Sp. z o.o. S.K.A. Based in Poland, TELE-FONIKA’s copper, aluminum and optical fiber wire and cable products are sold in 80+ countries.

MARCH 2012 | 37

FEATURE

While answering this question, it will be useful to look back to the last 15 to 20 years of the cable industry and remember the experiences over the time. Firstly, it will be suitable to divide the industry into two sectors, namely as wire and cable. Excessive growth in the wire sector does not contribute considerably; on the contrary, rapid increase and volatility in commodity prices bring about a rise in the operating stock costs, thus causing a financial pressure on the operation. Particularly, during the recent economic crisis, this issue put the big manufacturers in serious problems. For this reason, plans for excessive growth by overriding optimum scales have given way to focusing in core operations, or in some instances it forced manufacturers to exit from the market. Some wire manufacturing plants were closed or sold. As for the cable sector, intensive merger and consolidation transactions have been observed with positive financial performance outcomes.

FEATURE

Perspective: the view of a former company president George Graeber, who attained industry icon status from his 14 years at Belden/Cable Design Technologies (CDT), and is still active today in acquisitions as a consultant, acknowledges that the wire and cable industry has changed over the years. At the same time, he notes that the industry has always undergone change, and that if anything there is more opportunity today than ever. Only one has to know how to grab it.

“What mattered years ago still matters today,” said Graeber, who started out in the engineering department at Brand Rex in 1969 and rose through the ranks to key executive positions where he was instrumental in launching new products and in making key company acquisitions.

New wire and cable technology is being driven by demands for specific product demands, bolstered by environmental concerns, but fundamentally, he observed, the industry hasn’t changed. Opportunity inherently exists in the wire and cable industry as demands always change, he said. In the 1960s and 1970s, one could be very successful producing telephone wire. In the 1980s, network cable would sell out. In the 1990s and 2000s, it was fiber optics and category cables. The key to success then, now and the years to come, he insists, is focus. From when he first joined Brand Rex, he recalled that the pay was low but there were opportunities for management, travel and introducing new products. “As simple as the business is, it’s one of the most exciting industries,” he said, noting that one week he could be visiting a plant making radios and the next week be in a nuclear power plant. The key to success, he said, has always been simple, but it carries a demanding price: time, and lots of it.

“I never stopped learning about the industry,” Graeber said. “That was my only interest. I didn’t read books or follow sports. If I was on a plane, I’d be reading financial records or technical data or marketing while others were reading novels. I was a straight A college student and I was a straight A wire and cable student. I also hung around a lot with the older veterans. I listened to them talk about technology, sales and marketing and new products.”

During his career, he had three mentors (Paul Olsen at CDT, Bob Wilson at Anixter Brothers and Pete Petrucik at Brand-Rex) who he said taught him the industry subtleties, most notably the value of understanding customers.

“Know their requirements and when you provide product, make sure it’s right,” he declared. That may sound obvious, but in any era that takes industry knowledge, he said.

Any company can provide equipment; what separates them is the ability to hire and maintain people who know how to work together to manufacture quality products, how to sell them and how to establish relationships, all the while taking pride in the process, he said.

Today’s global economy is both a challenge and a bonanza, Graeber said. Whether a region’s fiscal outlook today is gloomy or not, opportunities still exist. Developing

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countries, such as the BRIC members, are going through the heady growth stages, and while not simple to serve they offer much potential. To tap into the global market, size does matter, but smaller companies can still do this if they can offer a differentiated product, he said.

One of the downsides of being with a large publicly traded company is that there is a lot pressure to show quarterly profits, Graeber said. The reality is that the industry has cycles, and a company is better off maintaining good employees than trying to raise share prices by layoffs, “but 35-year George Graeber olds with MBAs who represent investors don’t want to hear that,” he said.

As a consultant today, Graeber advises potential investors on a range of matters, focusing mostly on acquisitions. He focuses on industry basics, and while size does matter, it’s more important for a company to be profitable than it is to be large. The focus inevitably has to be on the numbers, but even there the going is not always so clear. “For instance, a company could have 20% of its value tied up in inventory, but how much of that could be obsolete?”

There are other concerns as well, Graeber said. Could a company’s value-added product margins be well on the way to commodity pricing? And how do you really know that a company is what the sellers claims it to be? One cannot afford to make assumptions, he said, noting that he discovered that one company, a potential acquisition with revenues of $2 million to $3 million, was not a legal entity. It had just set up shop and was doing business.

Graeber said that he continues to work today because he still finds the industry exciting. “It never gets old,” he said.

“I’m not a philosopher. I’m a guy who has been in the engine room for 40 plus years and understands what makes things work. This is what I do.”

George Graeber has spent 37 years in the wire and cable industry, serving as president of Brand Rex E&I division, CEO of Manhattan W&C, v.p. and general manager of energy products for Anixter and president and CEO of Cable Design Technologies, which merged with Belden in 2005. He is a recipient of the Wire Industry Distinguished Career Award and was the first winner of the Wire Industry Leadership Award in 2006. Since 2005, he has been involved in consultant and M&A activities in the wire industry. He holds a MSEE degree from the University of Connecticut. He can can be reached at georgegraeber@yahoo.com.

Absolutely not. We have been in business since 1962, and we have had a slow steady growth in revenues over

the past 20 years from $1,000,000 to $8,000,000, and our customers are always satisfied. Customer service is key. I believe that the larger the company, the less the customer service. Owner operators will always give better service than a hired sales team because there is more skin in the game. I am the president of our company and I still, occasionally, call on customers who spend less than $1,000 a year with us. Our biggest issue is being able to afford the best and brightest talent. Larger companies do have the edge over us in their ability to pay higher salaries. Michael Genzel, general manager, Seminole Wire & Cable, Co. WJI: What single element represents the biggest challenge your company faces?

The biggest challenge is the daily work on the organizational and technological improvements that allow us to offer our customers the most attractive prices and a top quality products. We are seeing increased competitive pressure in all market segments served by our company.

At present, there is a huge production capacity surplus, while technological and investment entry barriers into cable industry sector have significantly decreased over the last 20 years. Competition against smaller firms, with low-cost profiles, forces introduction of effective organizational changes within our company and the adoption of continuous efforts leading to significant production costs reduction. Marcin Szymański, CEO, TELE-FONIKA Kable Sp. z o.o. S.K.A., Poland.

I think the biggest challenge for EIS is to not allow ourselves to become complacent and to not let up on developing our culture of Lean Continuous Improvement. We’ve found a real void within the wire and cable industry that demands a much higher level of customer service that wasn’t being filled adequately so we’re aggressively developing our capabilities in order to satisfy those needs.

Roy St. Andre, executive vice president, EIS Wire & Cable, U.S.

MARCH 2012 | 39

FEATURE

Bigger does not necessarily mean better. American Wire and Cable is a medium-sized company that has chosen to remain focused on manufacturing leadwire and hook-up wire for the appliance industry. By focusing on this one key segment of the industry we are able to offer the high levels of Kim McClain service and quality American Wire and Cable that our customers demand. Our production of 60 to 70 million feet of hook-up wire each month allows us to offer a broad range of products at competitive prices while still focusing on a relatively small segment of the industry.

Most users of hook-up wire need a wide variety of different products including different UL styles, conductors, gauges, colors, etc. This large variety of products makes it very hard for our customers to predict demand, so they usually require short lead-times and often need to expedite orders. Our focus on this segment allows us to react to those needs in a much more timely and efficient manner than we could if we were also producing other types of wire and cable. This approach has allowed us to add new customers on a consistent basis while building loyalty with existing customers. To paraphrase Ralph Waldo Emerson, “Do one thing well and the customers will beat a path to your door.” Kim McClain, vice president, American Wire and Cable, U.S.

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Without question, our biggest challenge remains the barriers that exist in the marketplace for small, fast-moving high technology firms like ours, including federal and state tax policies, the trade imbalance, and of course the sluggish economy itself. All of this represents a drag on the entrepreneurial spirit that has been the hallmark of Minnesota Wire’s success for years. Our approach, however, is to attack the market aggressively in the niche—but critical—areas where others are reluctant to do so, despite these barriers. There is hopefully a growing realization by government to address these barriers, and we believe we will be uniquely poised to capitalize on our investments when things improve. Eric Wagner, president, Minnesota Wire, U.S. New product development. Finding process engineering personnel. Michael Genzel, president, Seminole Wire, U.S. The biggest challenge we face is attracting the right people at the right time and creating an environment for the employees to develop their skills. For our kind of industry, human resources become the most important asset as capital investments in newer and better technologies involves understanding various available technologies, evaluating them and successfully implementing them. To remain competitive we have to control costs and hence it is important to motivate our employees to run the plant as efficiently as possible because inefficiency is one of the major cost for small industries. Vinit Lohiya, director, Samrat Wires Pvt., Ltd., India.

At present, I think funding and human resources are the biggest challenge. Shi Aiwei, Beijing Force Automotive Wire Co. I believe the biggest challenge our organization faces is making sure we have the best people in the correct positions so that we can sustain longterm growth. This ranges from the maintenance technicians to key leadership roles.

Granted, we are faced with multiple economic, political and global challenges, but if we have the right people in the correct positions, our collective wisdom will resolve the most difficult challenges. Vern Abel, president, Taubensee Steel & Wire Co., USA. WJI: How far out do you plan for future investments, and are you willing to commit during a period of uncertainty?

The supremacy of TELE-FONIKA Kable lies, among other things, in the courage to invest in state-of-the-art and modern production lines. We are constantly developing new projects. We analyze our competitors development and the global market situation. In addition to large development plans to increase production capacity, we focus on the modernization of our machinery. We

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believe that in order to survive in this competitive environment, constant investments in quality and production economics are crucial. We intend to continue the philosophy of development within the most technologically advanced cable structures. Our company slogan, “We Deliver Reliability,” means that we want to offer our customers products manufactured using thestate-of-the-art production lines.

There is a natural Marcin Szymański, fear of investing TELE-FONIKA Kable. in a period of great macroeconomic uncertainty, but if the financial resources permit, we want to complete several ambitious projects that would prepare us for a period of prosperity. Marcin Szymański, TELEFONIKA Kable.

Investments plan are usually made to take care of three years. In India, the growth story is still intact and hence, the cyclical uncertainty usually does not matter much.

Vinit Lohiya, director, Samrat Wires Pvt., Ltd., India We do not have a set timetable to plan investments.

However, we are constantly looking for ways to improve our customer relations, add value and diversify in offerings that are consistent with our long-term goals. To that point, it is usually in the periods of uncertainty where we identify such opportunities. We will make investments at these times in order to position our organization for when the markets recover, allowing us to maximize growth opportunities. Vern Abel, Taubensee Steel & Wire Co. As a medium-sized, family owned business, American Wire and Cable does not really need a formal long-range planning process. Senior managers discuss issues on an ongoing basis and decisions can be made very quickly.

Finances are managed in a very conservative manner and nearly all investments are funded with internally generated funds. We are willing to make investments at any time when there are opportunities to improve our efficiency and our ability to service our customers. In late 2009, during the depth of the recession, we committed to a 25,000 ft expansion of our facility in Ohio. We saw the need to upgrade and expand our wiredrawing and bunching operation. The recently completed expansion has resulted in a significant improvement in our business. Our planning process is focused much more on our specific

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FEATURE

business than on any macro-economic trends in the industry or the economy in general.

We believe that by understanding our business and staying close to our customers we will know when to make the necessary financial commitments and avoid any significant mistakes. Kim McClain, American Wire and Cable.

The Institute of Non-Ferrous Metals in Gliwice has a unique position as it is both an R&D organization and, through its units and through the company, INMET, it produces nonferrous products that include silver- and copper-brazing wire, solders and more. The time horizon for the investments certainly depends on the assumed priorities of the company and the investment value. In case of major undertakings, decisions are preceded by detailed market analysis and a feasibility study made with an account of technological and logistical aspects. When results of such analyses are positive on the scale of the market analyzed, the decision on realization of specific project is made. The time horizon for such projects should be at least five years. Prof. Zbigniew Smieszek, PhD, managing director, Institute of Non-Ferrous Metals, Poland.

I believe it is necessary to plan for future investment, simultaneously including the investment of industry and real estate. In terms of the needs of the wire market, we will invest in the future just as now. At the moment, I think there is more opportunity to invest during this period of uncertainty than ever.

Shi Aiwei, Beijing Force Automobile Wire Co.

Uncertainty is exactly what we’re counting on. Our company’s strategy over the past nine years has remained the same: to become an agile manufacturer that can turn on a dime and quickly respond to changing market conditions without skipping a beat. Our plan has really come together over the past past years. EIS just secured a large capital expenditure line of credit for our 2012–2013

Visit us at wire Düsseldorf - stand 10 D37

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Shi Aiwei, Beijing Force Automobile Wire Co.

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growth plans that include double-digit growth in each of the next three years. Roy St. Andre, EIS Wire & Cable.

Because of the tough economy, Minnesota Wire has become very good at resource allocation both in the short term and while projecting out over a two- to three-year period. While we canâ&#x20AC;&#x2122;t foresee all of the market trends that are coming our way, our investments are becoming highly focused in the areas where our core strengths reside: namely R&D for the future of electrical interconnects and uniquely tailored labor and equipment for our areas of excellence in complex and custom finished cable assemblies, particularly for medical and defense. Eric Wagner, Minnesota Wire.

We plan our investments at least one year in advance.

Yes, we are willing to commit in a period of uncertainty if it will give us a competitive edge over the competition.

Michael Genzel, Seminole Wire.

WJI: Has globalization made it more difficult to predict market trends?

Yes, I think so. Shi Aiwei, Beijing Force Automotive Wire Co. Visit us at wire DĂźsseldorf stand 10 E76

44 | WIRE JOURNAL INTERNATIONAL

We deal mainly with NAFTA companies, so globalization has not affected us so much. Possibly our customers, but we have not had to do any more or less research than normal research. However globalization has added to the amount of information being shared electronically within the industries. Michael Genzel, Seminole Wire.

For us, globalization means the emerging of an enormous world market, and predicting any trends for this market is extremely difficult. However, when reliable information on global market demand and supply sources is available, it is used to efficiently plan development and modernization of production of specific goods. Prof.

Zbigniew Smieszek, Institute of NonFerrous Metals.

Prof. Zbigniew Smieszek, Inst. of Non-Ferrous Metals

Globalization makes it easier to predict market trends.

Trends that happen in one region usually occur in another region but at a later time. Variations exist in some part due to regional development stage, but more often than not the same problems exist the world over, thus the solution differs only by the impact of differences in labor and materials. Morgan Kurk, CommScope.

Yes. Most of the developing countries, such as India, Brazil, China, etc., have huge internal markets and hence predicting the trends should not be difficult. But due to opening of markets and seamless trades, it has become difficult because the developed countries are more dependent on developing countries, and any changes in the system now affect the whole world. Vinit Lohiya, Samrat Wires Pvt., Ltd.

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The ambiguity in the market trends caused by the globalization makes it harder to determine the future strategies. Formerly, the influence of an economic changeâ&#x20AC;&#x201D; whether positive or negativeâ&#x20AC;&#x201D;taking place in a region outside our area of interest as a manufacturer would remain confined to a great extent. Today, this impact is reflected in the global markets in a rather short period of time. The copper industry is a perfect example of this fact. In the past, while making future sales or raw material purchase plans and strategies, an economic activity taking place in China or a measure or decision by the Chinese would have no impact on the global markets.

Now, news of a likely tightening in the bank loans in China will instantly affect the global markets and commodity prices. Making predictions about market trends has become rather difficult, particularly if you consider the increased number of market variations. Hayrettin Cayci, Sarkuysan A.S.

Vinit Lohiya Samrat Wires Pvt., Ltd.

Absolutely! Probably the only trends I can predict in the global marketplace are that inventories will be watched closely due to volatile copper cost; unpredictability for market demand will cause customers to hold off on ordering until they definitely know they need to; and when there is demand in the market, quick delivery and better service will be critical factors in getting the order. Roy St. Andre, EIS Wire & Cable.

MARCH 2012 | 45

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The greatest difficulty in predicting market trends comes from the uncertainty about economic conditions in all world regions. Globalization, as a process leading to countries's greater economic integration, improves global stability by increasing economic interdependence. Long-term market trends are very apparent and only a serious financial crisis may influence its paths. In my view, globalization doesn’t affect the development predictability of the cable industry. Marcin Szymański, TELE-FONIKA Kable.

The greatest difficulty in predicting market trends comes from the uncertainty about economic conditions in all world regions. Globalization, as a process leading to countries’s greater economic integration, improves global stability by increasing economic interdependence. Longterm market trends are very apparent and only a serious financial crisis may influence its paths. In my view, globalization doesn’t affect the development predictability of the cable industry. Marcin Szymański, TELE-FONIKA Kable.

I do not believe globalization has made it more difficult to predict trends, but the compression of our business cycle has. Going back to the early 2000s, the typical business cycle would last a year or more. This provided adequate time to align resources like people, equipment and inventories. However, over the past couple years, we have seen multiple cycles in the same year. This has become a new challenge in that the same resources are more difficult to adjust in the short term without the potential of incurring excess cost. Vern Abel, Taubensee Steel & Wire Co.

WJI: Will the day come when there is a universal global standard for cable products? Would you welcome one?

In my view, (some) cable products will have universal global standard, and I expect that the day will be coming.

Shi Aiwei, Beijing Force Automotive Wire Co.

Vern Abel, Taubensee Steel & Wire Co.

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Most cabling has standards today. In some cases the standards are for a country, in others for the world. I believe the larger the market (a standard for the world) the faster the adoption, the lower the cost, the more the innovation, the better. Is standardization always possible?

No. There are both political and practical reasons why world-wide standardization is not possible. For new technology it is almost always political, such as a business or government trying to protect its own interests. For existing products it is usually practical. Consider how difficult it would be today to change all roads to right-hand drive. However, if the world had agreed all cars would be on the right from the beginning, it would be easy.

Morgan Kurk, CommScope.

As you know, a new invention or innovation is made almost every day in all fields with the aim of improving the quality of modern living, and every invention or innovation is linked to electricity in one way or another.

Naturally, in all the fields where electricity is used, there are needs for cables of different standards and new specifications arise or sometimes current cable standards may

Visit us at Wire DĂźsseldorf â&#x20AC;&#x201C; stand - 09 B13

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need to be altered. Thanks to globalization these improvements are benefited by all mankind almost simultaneously. At this very point, it is of special importance for the cable industry to ensure the living quality and safety of the people. On the other hand, due to the consolidations in the cable industry, global actors in this sector in many different regions of the world offer products for the same intended use. As a natural outcome of this picture, in our opinion, universal global standards for cable products have become imperative, which is expanding its coverage day by day, and being included in relevant regulations of many countries. For instance, if the specifications of a cable product manufactured in China and the U.S. for the same intended use are different, this poses great danger for human life. Some serious accidents have taken place because of this. On another issue, it is absolutely necessary to prevent the unfair competition and business practices arising from inappropriate quality cable products manufactured to lower the cost only without paying attention to the safety rules and yet addressing to the same intended uses as that of the good quality products. Hayrettin Cayci, Sarkuysan A.S. It would be great for us if this day would come.

When you manufacture production lines, you are obliged to adapt your range to all these specific cable designs and it is not so easy.

We would definitely save money and time. We would become more efficient on each line instead of working on the performance of 10 different lines.

Peggy Deuscht, Conductix-Wampler.

However, I think this will remain a dream. Each country protects its market developing specific standards. Each cable maker develops its own design to be different from competitors. The current economic crisis will lead all countries to increase these different standards, which are a form of protectionism without mentioning that. Peggy Deuscht, ConductixWampfler/Delachaux Group.

I don’t see that happening. There are too many markets where certification—whether UL, CE, ETL, etc.—is not required, and processing/material

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choice is the only competitive edge pricewise. We excel in these markets where individual manufacturers are responsible for building the quality into the products and are not just required to meet a standard. There are still customers out there who value quality over price. A global standard will not exist as long as there are customers willing to buy sub-standard products cheaply. There is no way to compete with these products except to do the same. Michael Genzel, Seminole Wire.

This is not easy, but it’s possible. An example of this route is the European HAR standard (for commonly agreed marking for cables and cords that comply with harmonized specifications). I am convinced, that introduction of universal standards, for “culturally homogenous” countries, e.g., EU, should be our prerogative. Marcin Szymański, TELE-FONIKA. WJI: Has demand for alternative energy forms (wind/solar) followed a rational growth path?

The demand for alternative energy has been increasing for many years and I am absolutely convinced the growth will even be faster in the coming years. This is really rational as the petrol resources are decreasing and each country wishes to be more independent (especially when price becomes so high). In addition, after the Japanese catastrophe, the nuclear energy will tend to decrease quite rapidly worldwide. The improvements in the production of alternative energy are huge and fast, and the engineer creativity is really amazing. However, I am not sure that all alternative energy will survive as some of them are not profitable (wind energy is not always efficient) or create pollution (production of solar panels for instance).

Anyway, we will develop new systems and improve the existing ones, but this is the way, driven by economic reasons and philosophic reason (Health and nature protection). Peggy Deuscht, Conductix-Wampler.

I think that we are seriously in need of alternative energy forms. Shi Aiwei, Beijing Force Automobile Wire Co. All industry growth is rational based on the conditions under which they are constrained. However, wind/solar hasn’t followed the same demand path as an industry governed purely by the free market. It’s influenced by two fundamental forces: price of other energy sources, which historically has swung widely in one direction or another, and government programs, which distort the industry. Other influencers that have impacted the industry in a more normal manner include the cost of the technology (turbines and photovoltaic cells) and environmental concerns. Morgan Kurk, CommScope.

WJI: Will fiber optics and wireless further squeeze copper cable out because of its bandwidth limitations, or is its long-predicted obit still premature?

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I have been working for Conductix for more than 17 years and I have always heard that story! For sure people who were predicting that event for early 2000 were wrong...but one day it will come true! From one hand, the copper cable bandwidth is still increasing and the mix copper/fiber is still much cheaper than complete fiber. In addition the competition in the telecommunication provider market is so strong that prices decrease quite rapidly as well as profitability, so copper still have some space. From the other hand, when the network is completely new, most countries tend to go to full fiber (when they can find skilled operators for installation). Wireless has some space also in countries where infrastructures are very limited (but connection is not so stable). My feeling is that copper, fiber and wireless have their own space and their own advantages.

Copper will not disappear so fast and bandwidth development is still quite amazing. Peggy Deuscht, ConductixWampfler.

For signal transmission they may squeeze copper cable out. Shi aiwei, Beijing Force Automobile Wire Co. WJI: Has your company expanded from its traditional core activities, and if so, why, and how has it worked out?

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MARCH 2012 | 49

FEATURE

Copper cable will continue to exist for a very long time. It has to do with two basic factors.

First, neither wireless nor fiber allows power to be transmitted simultaneously with the signals.

Second, the banMorgan Kurk, CommScope dwidth limitations of copper always seem to be exaggerated. For the last 30 years the bandwidth of twisted pair has increased from 10Mbit to 100Mbit to 1Gbit to 10Gbit. In each instance pundits have said this is all the media can provide, and in each case technology has created a path forward while still maintaining backward compatibility. This will continue for the foreseeable future. This translates into simple economics: copper cable will be around as long as it’s a cost-effective solution. Morgan Kurk, CommScope.

FEATURE

Visit us at Wire Düsseldorf stand 09 B37

No. We have not expanded from core activities, which is producing annealed wire, but we have consciously taken steps to upgrade ourselves technologically by automating our plant to an extent. We feel the Indian fastener industry is still quite restrictive to standard fasteners. Special fasteners are still being manufactured in countries like Taiwan, U.S., E.U., etc. This is primarily due to fact that quality of steel processing for this segment has not been to global standards. This was our primary reason to install India’s first-ever hydrogen wire annealing furnace from Ebner. We see Indian fastener manufacturers supplying world-class products and becoming an export hub, like Taiwan. Vinit Lohiya, Samrat Wires Pvt., Ltd. Rather than expanding from our traditional core activities, we’re expanding the scope of our core activities into non-traditional areas. A good example would be how EIS has transitioned out of standard costing and implemented Lean Accounting and Value Stream Costing.

Standard costing was developed back around 1925 and worked fine for mass production back in the days when Henry Ford was selling the Model T and his sales pitch was “any color you want as long as it’s black” Roy St. Andre, EIS Wire & Cable but the rules are changing.

If a company continues to transform its processes by applying Lean principles it’ll eventually get to a point where so many of it’s traditional methods of operating have changed that the conventional rules for accounting for performance no longer give an accurate picture of what’s really going on in the company so a new strategy must be employed if they’re going to remain competitive. Roy St. Andre, EIS Wire & Cable.

Yes, absolutely. We embarked on a path about eight years ago that has embraced federal R&D dollars in order to match the internal investments we were already making to help re-invent the technology of electrical intercon-

50 | WIRE JOURNAL INTERNATIONAL

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nects. Since then we have achieved $10M in federal R&D contracts and have an 80% capture rate on our white papers to attract more (the national average is 10% for Small Business Innovation Research contracts). Wire and cable has essentially remained unchanged for a century; so our goal with R&D has been to focus on non-traditional conductors and shielding. We now have an iStealth™ line of products (carbon nanotube (CNT) non-metal cable and shield); and iStretch® products that bring elastomeric solutions to a variety of markets. We are beginning to have substantial commercial success with our CNT materials, as our partners are helping us introduce novel solutions to aerospace challenges, such as lighter weight, noncorrosive and radio-translucent conductors and shields.

Eric Wagner. Minnesota Wire.

El Sewedy Electric began manufacturing cables in 1984 after many years of being in the cables business as a specialized cables distributor. Thereafter we followed an aggressive expansion plan in the cables sector, both within Egypt and internationally. The decision to expand from our traditional core activities was taken based on our view that there was a strong demand for other components in the power sector and given the our strong relationships with clients across the globe it was the obvious next path. Thus, we ventured into the production of raw

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materials (copper rods and plastics), transformers, insulators, energy management systems, wind turbines in addition to projects and development most notably power generation, transmission and distribution. We feel that it was a very good decision as our mission has been to deliver a one-stop solution to our clients globally. Ahmed El Sewedy, El Sewedy Electric.

So far, we have not extended. Shi Aiwei, Beijing Force Automotive Force Wire Co. Yes, we have branched out from one “nice” market into several. Always keeping within the same type of market.

It keeps us small but it also keeps us profitable. There is less competition for a $1,000,000 per year market than a $100,000,000 market. Michael Genzel, Seminole Wire.

As far as wire production is concerned, the answer is “yes.” As an example, we have undertaken specific technical and technological measures to commence production of layered welding electrodes intended for welding and regeneration of products from cast iron. Iron and nickel alloys are out of the scope of interest of our Institute, but we had considerable achievements in the production of bime-

MARCH 2012 | 51

FEATURE

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QUEINS

FEATURE

tallic wires (see patents No PL 167385 and PL 209391) that helped us to commence very quickly (within a single year) mass production of flux-cored Ni Fe42 type welding electrodes that were sought in the market. For the production purposes we adapted suitable technological line. Fabrication of the new product appeared to effective and profitable, which demonstrates the benefits of going beyond traditional core activities of the company. The main elements necessary to make suitable decisions in such cases are results from the assessment of technical and technological feasibility of an undertaking, personnel qualifications, and credible market analysis. Prof. Zbigniew Smieszek, Institute of NonFerrous Metals.

WJI: Has demand for alternative energy forms (wind/solar) followed a rational growth path?

Minnesota Wire has not pursued this area for its own products, though there are OEMs who would be well served to consider more non-traditional conductors in their leading edge products. It is our belief that the true demand for alternative energy has been exaggerated by non-market forces, principally from the federal govern-

ment. However, our work as a consulting firm in the defense and aerospace markets has netted us a contract with the U.S. Small Business Administration (SBA) that is helping business lead in this arena on its own terms, and based on real need.

Minnesota Wire created and hosts the Defense Alliance organization, which operates one of the nation’s three Advanced Defense Eric Wagner Technologies Clusters (ADTs) Minnesota Wire for the SBA, to contribute to Department of Defense and commercial needs for advanced power and energy technology (www.powerfordefense.com). This effort has led to over $10.2M in energy-related R&D and commercial contracts for the cluster’s member companies, and helped to create 250 high-technology jobs. Eric Wagner, Minnesota Wire.

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FEATURE

WJI: Will the logistical challenges in getting power to where it is needed prove to be a driver or a drag?

It is a certainty that increases in energy costs affect the logistical costs very negatively. This is a problem of many exporters and forces them to exit the markets.

However, we believe that it would be a more logical approach to turn this threat into an opportunity rather than exiting the market. Our company has had a similar experience. Sarkuysan had intensively felt the influence of such an instance three years ago in the U.S. market.

However, rather than exiting this market, for which the company had made great efforts and invested for so many years, our company decided to commence production in the U.S. in order to meet the requirements of our customers at a shorter period of time, thus increasing customer satisfaction greatly. The Sark Wire plant, in operation for two years in Albany, New York, has been very successful, and serves as a good example in this matter. Consequently, a logistical challenge has made Sarkuysan a company with overseas production operation thousands of kilometers away from its mother country. Hayrettin Cayci, Sarkuysan A.S.

MARCH 2012 | 53

PRESENTATION

OPS REPORT The Lean Six Sigma Experience at the Leggett & Platt Wire Group

By Steve Foust, Leggett & Platt, Inc., Wire Group

In late 2005 the Leggett & Platt Wire Group president suggested that we send two employees through Six Sigma training. While our group enjoyed continued success from our Continuous Improvement teams, program and savings record, we lacked the analytical approach to make datadriven decisions. Our group needed a more structured means of bringing large projects to successful completion. Since my fellow student, Jeff Howrey, and I also embraced continuous employment, we agreed that the training would be a wonderful idea.

On one level, we knew what it was. The lofty goal of Six Sigma is 99.997% perfection, which equates to 3.4 defects per million opportunities,via an organized method of problem solving, utilizing Chart 1. Improvements achieved in reporting time. a variety of tools. It is a means of improvement, using data to stabilize and improve process variation to increase process capability. However, the The Six Sigma journey actual deployment of Six Sigma proved to be a learning process, one that was partially intuitive yet at times it was To maximize the return on the Six Sigma investment, the more than that. At this point, we can report that Six Sigma Leggett and Platt Wire Group set five steps to follow: does work, and that it took a committed effort to make that 1. Choose the training provider happen. Before we discuss the process, here are the benefits 2. Create a support program and structure that we have realized: 3. Choose the right training candidates 4. Align projects with strategic goals • Employing the DMAIC (Define, Measure, Analyze, 5. Measure and maintain the results Improve & Control) process keeps a project group focused on the scope of the project Choosing the training provider • The DMAIC process enables Leggett to make better deciOne of our first steps was searching for the right training sions based on data and statistics provider. Using the internet, we found plenty of trainers, but • Introducing the tools learned in Six Sigma training helped most providers had multiple instructors who had little evius complete daily tasks and greatly improved the success of dence of industry experience. The larger training firms our smaller projects seemed impersonal and charged for project assistance.

• Employees will buy in to a concept that requires an effort When we did find suitable training, it was geographically if they can see the results 54 | WIRE JOURNAL INTERNATIONAL

MARCH 2012 | 55

PRESENTATION

undesirable. The goal for this initiative was to decrease conGroup employees all through the Management version cost, increase product quality and increase shareDevelopment Institute both in their classrooms and at our holder returns, so excessive travel costs appeared counter locations. We continue to be pleased with the curriculum intuitive. and Charlie’s willingness to assist Jeff Howrey and I began conwith our projects, as need be. The tacting universities within close basics of DMAIC (Define, proximity of our Leggett & Platt Measure, Analyze, Improve and corporate offices. We found the Control) have been learned. The Management Development DMAIC process works, and the Institute (MDI), an outreach tools taught by Charlie can be department for the College of used for other projects and everyBusiness Administration day decisions. Leggett uses at Missouri State University. It had a mature training proMinitab as our statistical software and Charlie provided ingram, started in 2002, with an experienced instructor, depth training of the software’s capability.

Charlie Carpenter. MDI sent us a detailed schedule and allowed us to contact him directly. Training and certificate Create a support program and structure programs have been available at MDI for many years.

Creating a support structure and/or program was one of Charlie Carpenter, the professor, has been teaching process the easiest tasks for the Leggett & Platt Wire Group. We predictability for 26 years and formal Six Sigma training for already had a mature Continuous Improvement program 15 years. MDI uses a single trainer, so each Green, Black that we could use to track projects using both an 8-D form and Master Black Belt within the Leggett & Platt Wire and log, PBAs (project benefit analysis) and trained facilitaGroup was taught the same methods. This enables ease of tors; consequently, all we needed was a support staff to offering technical and/or statistical assistance, remotely, for guide fellow Six Sigma personnel, Minitab training, project six different production facilities, since everyone speaks the phase structure, means of capturing data for analysis and “same language.” alignment with Leggett’s strategic goals.

Charlie has over 26 years of experience in consumer, To guide fellow Six Sigma personnel, Leggett decided to financial, industrial and pharmaceutical sectors. He has have two Wire Group corporate employees attain Black Belt implemented programs that reduce costs, reduce cycle time and minimize variation in business processes that result in improved productivity and quality of products and services to customers. His on-hand project experience, availability to assist us free of charge and MDI’s training center was a perfect match for our needs.

Charlie and MDI’s program requires two weeks of classroom instruction and completion of a project that saves over $50,000 to achieve Lean Six Sigma Green Belt certification. To gain Black Belt certification, individuals must complete an additional two weeks training and another project with $50,000 in savings. Master Black Belt certification is earned upon completion of your fifth project. The assessment of savings is calculated by the company.

Leggett utilizes a project benefit analysis to calculate savings on an annualized basis, which is approved by both financial and management personnel. The Wire Group has completed over 30 Six Sigma projects. One Chart 2. Comparison of time requirements for projects. of our latest Green Belt projects (see Charts 1 and 2) reduced entry time and paper work for quality reports.

Prior to our project, many of our reports were manually certification. The Black Belts would then guide future Six generated and required redundant data entry. The project’s Sigma employees through their projects. Long-term, our goal was to reduce the redundant workload and eliminate goal is to have at least one certified Black Belt at each operthe need of increasing overhead. The team utilized existing ation facility. For each project, we chose to have a project hardware, software and programming resources to electronisponsor, Black Belt(s), Green Belt(s), financial support, cally collect, transfer, aggregate and report various quality team champion(s) as well as other team members. We have data. Due to the success of this project, the Wire Group was found that the vast majority of those asked to take part in able to achieve their goal and free enough resource time to the process appreciated the opportunity. In terms of their assist with new strategic initiatives. overall performance, this effort has not only been a positive To date, Charlie has educated 31 Leggett & Platt Wire

PRESENTATION

experience for Leggett, it has also benefited the employee.

As of 2011, 35% of the trained personnel have received promotions.

Generally, the project sponsor is a higher level manager who has a direct interest in the completion of the project.

This is the go-to person when trouble arises with the project or team members, and is also the individual who will be able to pull the trigger on capital expenditures. The project sponsor will update the corporate management team and is the individual that can change the project charter. A project charter defines the problem, the project goal, constraints, assumptions, team guidelines and the roles of each team member, goals and team makeup.

The Black Belt (or Master Black Belt), is used as a support function for data gathering, data analysis and assists with team management. The Black Belt will ensure that the team remains focused on the program scope and that the correct combination of tools is used in each phase of the project. The Green Belt(s) support the Black Belts and have very similar rolls. The trained Six Sigma Black and Green Belts should assist with the final version of the problem statement, scope and goal sections within the project charter. Collectively, they make the program work.

of the project. We generally use Six Sigma employees that are in training, trying to achieve their next certification and process experts, for this role. The team champion “owns” the project, leads the team, produces the brown paper (informal presentation), executes the phase checklists and presents the project to the sponsor for approval of completion.

Training for Minitab, which is a statistical evaluation and manipulation software program, is provided by the instructor and proficiency increases only by use. Minitab is very powerful, and with use can be an easy tool to master; however, most trainees have never had practical experience with any statistical software. To manipulate graphs, to show specification limits, process shifts, operators and other factors, the user must manually customize each graph, which takes time and experience because the functions are not initially obvious. Our most proficient users have little or no problem with the software, while others have requested additional training. Our Black Belts are the most proficient with the software and are therefore tasked with most of the statistical analysis. Minitab training is one area that the Leggett & Platt Wire Group needs to improve upon and we are planning to have sessions at each of our locations using “real-life” data that our employees can relate to.

DMAIC application for Leggett & Platt

Chart 3. Employee participation in belt programs.

Financial support is imperative for every project. At Leggett, we utilize various accounting functions to lead our teams through projects. With the current and past market conditions, capital is at a premium; therefore, teams must provide current costs, potential savings and cost per opportunity. Being able to provide the top management with the projected Earnings Before Interest and Taxes (EBIT) impact allows each team to justify why an investment is justified.

This step helps makes the financial support flow, but a close scrutiny can also eliminate time wasted on unproductive projects that may have appeared to be worth pursuing. One such project that the Wire Group killed involved packaging.

The team desired to reduce the amount spent on packaging and freight of our products. The financial data, however, soon determined that the additional equipment and labor costs made the project unfavorable.

The team champion, at Leggett, is the day-to-day leader

56 | WIRE JOURNAL INTERNATIONAL

Leggett requires a phase checklist that covers the minimum criteria for the above-cited DMAIC phase completion.

The define phase will include the project charter, project goal and evaluation, project schedule, support structure, voice of the customer and a process map. In the measure phase, the team gains baseline performance information.

Leggett requires data collection plans, process capability, business impact, process sigma and other data used in the analyze phase. Upon the completion of the measurement phase and all other phases, the champions should re-evaluate the project charter and goals and, if needed, request a change from the project sponsor. In the analyze phase, the team uses the data collected to find potential root cause(s), test the data and process, brainstorm and produce hypotheses for the next step. The analyze phase is where the team finds out how each measureable effects process performance. Regression analysis, design of experiments, analysis of variance and cause and affect diagrams are some of the tools we employ during the analyze phase. In the improve stage, our project team uses the previous analysis, compares the possible solutions to the root cause analysis and pilots the best solution(s). The project benefit analysis is updated with the solution and pilots are conducted as needed.

During the improve phase, Leggett debugs and implements the solution determined by the project team. The control phase is usually completed shortly after improve and the Wire Group uses this time to monitor the process after changing to ensure the problem is fixed. Leggett will change processes, quality systems work instructions, procedures and train personnel to ensure the solution remains effective.

The last item Leggett needed was the most difficult: use

Align project with strategic goals Chart 4. Focus of Six Sigma projects.

able data attained in a format that had proper delimitation for transfer, without manual formatting. Leggett’s information system stores all the information needed. For most any analysis, we just needed the time to manipulate the information into usable data; consequently, our first project was to utilize Microsoft Access to transfer data out of our internal computer system using a series of macros, queries, tables and putting it into usable reports. Test data by heat, machine, tag and operator was available at each production location; however, the lack of delimitation created issues transferring the data into Minitab, Excel and Access. As we would transfer data, it would populate into multiple columns and rows and would combine data in some cases.

Also, if we wanted to add information populated in alternate data bases to the test data, it would require manual entry.

Another benefit from our project was the ability to combine tables and reports enabling us to analyze data not previously available.

Choosing the right training candidate Six Sigma training is expensive, and being chosen to receive this training should be considered a reward for current and previous workmanship. The Leggett & Platt Wire Group’s corporate and branch managers choose candidates that are high contributors, understand the various processes of the facility, are team players and have the ability to communicate within all levels of our organization. We do share our Six Sigma services, when requested and available, with our customers, so we also consider this factor. Other considerations include: is this person promotable? Will he or she stay with Leggett? Are they an analytical problem solver?

At a minimum, each trainee should be proficient with Windows, have basic Excel skills and work well in a team setting. Leggett’s employee choices for Six Sigma training has worked thus far. Our training sessions include both hourly and salaried employees, including high level managers and machine operators. To date, the Wire Group has trained 3 Master Black Belts, 8 Black Belts and 20 Green Belts. See Chart 3. Another educational tool consideration is facilitator training. The ability to organize and conduct meetings is vital to project success. The facilitator keeps the

This step was relatively easy. Each manufacturing facility already had a Continuous Improvement savings goal set by corporate. Projects supporting our safety, quality, customer satisfaction, conversion costs, new product development and reduction of working capital are most commonly accepted.

Using various process indicators, we can always find a potential project. See Chart 4. Our division managers must approve Six Sigma Projects before they begin. A division manager will be assigned as the team sponsor.

Measure and maintain the results The Wire Group already had a mature method of measuring Continuous Improvement activities. Every project is reviewed by the project sponsor, who is responsible for measuring the savings on an annual basis. Both at the division and plant levels, we review the project status, savings and projected completion date every month. A review of each plant’s key indicators allows the group to maintain our project’s success; the monthly review of these objectives compared to our goals will trigger any significant changes.

The Leggett & Platt Wire Group uses its quality systems to sustain our results by revising our procedures, work instructions and documents; the Wire Group includes these items in our internal process audits.

Summation Leggett & Platt’s Six Sigma journey has proven to be one that was well worth taking. Like any major project, it required a serious effort, but the results have shown that the process works, and that employees can see this, which has resulted in our Six Sigma program having across-the-board support and a firm ongoing role in our company’s future.

Steve Foust, a Six Sigma Master Black Belt, is the quality systems and planning manager for the Wire Group of Leggett & Platt, Inc. This report was given during the operational presentation session at Interwire 2011.

MARCH 2012 | 57

PRESENTATION

meetings focused on project scope so ideas can be introduced, action items are produced with clear and SMART (Specific, Measureable, Attainable, Relevant and Time Based) goals, and morale is increased. This “organizer” shares team minutes with managers, eliminating finger pointing. Adding these minutes and action items to the brown paper (working copy of the project to date) enables anyone to see the current state of the project and know who or what is holding up progress.

TECHNICAL PAPER

TECHNICAL PAPER The influence of shaft-furnace burner settings on dissolved oxygen in melted cathodes.

Oxides produced at the interface between flame and cathode do not always dissolve into the copper during the melting process.

By John Hugens

A modern copper-melting shaft furnace is a cylindrical vertical furnace approximately 10 meters from hearth to sill in height and two meters in inside diameter. Burners with premix flames line the lower third of the furnace in rows or groups. Premix pressure at the burners is normally in the range of 10 to 100 in. water column (WC.) Copper, generally in the form of cathodes but also other copper solids, is charged at the furnace sill and exits through the bottom of the furnace in liquid form through a small tap-hole. The critical combustion ratio, which is almost always in the slightly reducing or slightly oxidizing combustion range, is generally checked or controlled by analytical examination of samples of the premix feeding the burners. The analysis can be performed prior to the combustion of the sample as percent oxygen in “premix” or after the combustion of the sample as percent CO or H2 in the “postmix.” Both methods can be used to analyze and determine a combustion ratio in terms of the level of excess fuel (or air in the case of lean combustion) being used during furnace operation. The level of excess fuel in the combustion process has been thought to influence the level of dissolved oxygen in the melted copper in specific ways.

The original shaft furnace patents issued in the 1960s by A.J. Phillips and Richard Baier state that one of the primary discoveries in the invention of the furnace was its ability to produce improved copper for casting in the ETP range.

Additionally, the authors implied that some degree of control of the oxygen content of the metal produced was possible through the manipulation of the combustion ratio of the shaft furnace burners. The mechanism for oxygen control of the copper at variable ratio levels was thought to coincide with the extension of the unburned interior part of the flame onto

58 | WIRE JOURNAL INTERNATIONAL

the copper surfaces being melted. For example, as the flame gets longer due to incompletely burned gas and air, the incompletely burned mixture paints the copper with presumed oxides that re-dissolve to some extent into the copper 1.

Even though these furnaces have been in extensive industrial use for more than 30 years, this assertion has not been re-tested in a formal manner. Most shaft furnace operators accept the idea that the combustion ratio, usually indicated by carbon monoxide or hydrogen (CO or H2) levels in the burner sample postmix, influences the oxygen content of the copper melt produced. However, little has been tested concerning the relationship between the oxygen dissolved in the melted metal and furnace burner combustion. This study is intended to open a discussion on these relationships among the community of those who use these furnaces. Some of the issues its addresses include problematic areas, such as: how much control of dissolved copper oxygen is available to the furnace operator from the furnace combustion itself; how much must be added or removed subsequent to melting; and what are the maximum and minimum combustion ratios available to the operator during furnace operation?

An investigation of these questions is available through the study of a commercially operating shaft furnace. The variables of combustion ratio, product oxygen content, charged material and product quality are recorded in a regular way by most furnace operations. By fixing the type of charge material, varying the combustion ratio and comparing these values with dissolved copper oxygen content, the relationship of the two variables of combustion ratio and oxygen content can be determined under operating conditions and be used as a guide for operations under varying melting circumstances.

Encore Wire Corporation operates a vertical shaft-melting furnace at its operations in McKinney, Texas. Its present annual production rate is approximately 200,000 tons of copper rod. The oxygen content of its cast bar is targeted to 250 ppm (.025%). Its CO control target is approximately 1.0%.

The oxygen content in the copper issuing from the furnace is approximately .009% (90 ppm), and extra oxygen is added through contact of the molten copper with air by natural and artificial means before the casting process.

The original patents for the copper-melting shaft furnace describe the relationship between the combustion settings of the furnace burners and the oxygen content of the melted copper. The U.S. patents (Phillips and Baier, number 3,366,455 and 3,199,977) describe the utilization of the oxygen content of the premix from the furnace burners to indicate the combustion ratio between fuel and air. They indicate that in order to achieve a level of oxygen from the shaft furnace of .05 % (500 ppm) or below, the oxygen level in the premix going to the burners would have to be controlled in a range of approximately 18.50% to 18.95%. To achieve a level of .035% or below, the level of oxygen would need to be 18.65% to 18.95 %. Finally, to achieve a level of below .01%, the amount of oxygen in the premix would have to be 18.70% to 18.85%2. Premix oxygen contents of below approximately 18.8% indicate an excess of fuel relative to perfect combustion conditions, and are thus considered reducing.

Conversely, greater levels of oxygen in the premix indicate air in excess of the amount required for perfect combustion in the burners, and these measurements indicate an oxidizing burner setting.

Fig. 1 illustrates the Phillips-Baier hypothesis that was developed from the experimental tables in the patents3. These are the actual results of a melting test performed during the initial investigations of the furnace, They illustrate the hypothesis that as the burner flame lengthens on either side of the stoichiometric (perfect) combustion ratio of approximately 18.8% oxygen in the premix, the pencil-shaped blue areas of incompletely burned premix in the center of the burner flame come into greater contact with the copper,

Fig. 1. Baier-Phillips Hypothesis for oxygen in premix and oxygen dissolved in Cu5.

painting the surface of the copper with â&#x20AC;&#x153;floating islandsâ&#x20AC;? of copper oxides. These floating oxide islands then partially dissolve into the copper, and their prevalence during very lean and very rich combustion levels coincide with increased levels of oxygen dissolved in the copper issuing from the taphole. These concepts will be clear to anyone who has spent periods of time watching copper melt through the eye-piece of a shaft-furnace burner. The formation of what appear to be surface oxides on the liquefying copper at comparatively lean and rich combustion ratios is clear to the operator. However, the behavior of these substances once they move from view is an area of conjecture. The Phillips-Baier hypothesis, as stated in the patent, assumes that they are probably oxides and that they may re-dissolve and increase the oxygen content of the copper. It is clearly stated that their observation of films and islands is correlated with the times that the furnace produces copper with elevated dissolved oxygen levels4.

In order to address this issue with modern shaft furnace sampling analysis, one must translate the combustion range in question from oxygen in the premix to CO in the postmix.

It is important to note that this changes the axis of the graph from reducing on the left and oxidizing on the right to oxidizing on the right and reducing on the left side. The curvature of the CO levels, with respect to ratio, changes the slopes between the two graphs. The conversion can never be perfect because the exact chemical characteristics of the gas used at the time of the original experiments is unknown, and the amount of CO produced by the burners at certain combustion ratios depends on the chemistry of the gas in terms of its carbon-to-hydrogen ratio. However, converting the premix oxygen analysis graph to postmix CO analysis graph using available conversion graphs, one can chart the relation, which should generally correlate with the ratios used on the original test. See Fig. 2. Further, these CO burner settings and ranges should be familiar to anyone who uses a copper-melting shaft furnace to produce ETP copper.

Fig. 2 shows that oxygen increased both on the lean and rich sides of the combustion scale. Stoichiometric (balanced) combustion at 0% excess fuel occurs at approximately 18.8%

Fig. 2. Philips-Baier Hypothesis for CO in postmix and oxygen dissolved in Cu.

MARCH 2012 | 59

TECHNICAL PAPERS

Background

TECHNICAL PAPERS

oxygen in premix or 1.2% CO in postmix.

Figs. 1-2 show that, in terms of excess fuel and air, the original study measured a range from 19% excess fuel (18.65% oxygen in premix, or 4% CO in postmix) to about 10% excess air (19.00% oxygen in premix, or 0.5% CO in postmix). Unacceptable levels of oxygen greater than 500 ppm appeared in the copper at approximately these ratio boundaries.

Experimental design The equipment used in the melting experiment was a shaftmelting furnace equipped with 15 burners on premix manifolds. The tests of the Phillips-Baier hypothesis were performed when the furnace had been producing rod for at least three days at a rate of 21-tons/hour. Samples of copper issuing from the tap-hole were taken and analyzed for oxygen at 30-minute intervals. As a control sample, the shaft furnace was monitored for an eight-hour shift in normal operations with the CO at its normal level of 1.2 % during cathode melting. The charge material during all tests was ASTM Grade A cathode from well-known cathode suppliers. No materials other than cathodes were charged to the furnace during the tests, and the furnace was charged with cathodes only for two hours before any testing was performed. Copper oxygen samples were taken with a LECO oxygen analyzer and analyzed by the plant lab technician. Postmix CO samples were analyzed continuously by a Rosemont IR CO analysis system drawing premix through a stainless steel sample tube furnace operating at 900°C at a flow rate of approximately .3 liters/minute. Copper oxygen samples were taken at the furnace slag box with a 10-cc graphite crucible, before the addition of oxygen to the copper.

Tests in 0-4% CO range. Initial tests were performed within the ratio range that was described in the original shaft furnace patent. The range of CO examinations was chosen by the original study, which indicated that oxygen should begin to be added to the copper rapidly at postmix CO concentrations greater than 2%. Therefore running the CO values past

Fig. 3. Encore Wire postmix versus O% in Cu over the 0 to 4 % CO ratio control points.

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2% up to 4% should show increasing oxygen concentrations in the Cu according to the Baier-Phillips hypothesis. These ranges chosen for examination were purposefully made a little shorter than the original tests, on the oxidizing side of the combustion spectrum, to prevent loss of production by the operator.

The CO content was held stable at four points over a dayâ&#x20AC;&#x2122;s production at 21 tons per hour. Postmix CO samples, premix pressure readings, copper oxygen analysis were taken by the previously described procedures. A plot was taken of the observed CO% data vs. oxygen % dissolved in the Cu, along with the control samples from a daylong test as described below.

Control test. A test was performed at normal CO (1.2%) during a day of 21-ton/hour production at Encore Wire. The furnace postmix CO was held as constant as possible during this period and the samples were analyzed. Control test results were then integrated into the results for this initial testing.

General operating survey tests. Because of the interesting results tests of the furnace in the 0-4% operating range, many additional samples were taken at approximately 0.5% CO intervals over a six-month period at ratio range between 0.3% CO and 6% CO under identical charge material and operating parameters. These samples were collected and analyzed to determine the overall behavior of the furnace copper oxygen content at the slag vessel with respect to the postmix CO analysis of the burner gas.

Visual flame observation: Burner flames were observed at various operating pressures and CO levels to determine the length of the flames during at different premix pressures. The burner flames were observed while firing the burners in open air. The objective was to determine if there could be a relationship between flame length and copper-oxygen pick-up.

Results Tests in 0-4% CO ranges. The initial tests of the furnace in the 0-4 % range are shown in Fig. 3. The furnace showed a

Fig. 4. General test of CO versus oxygen in Cu in the .4-6% range CO.

Fig. 5. Postmix sample CO versus flame length in inches.

Discussion The Phillips-Baier hypothesis that the oxygen content of copper from a shaft furnace increases markedly upon decreasing oxygen percent in the premix (which correlates to CO in the postmix) does not seem to hold over the original ratio interval originally indicated. However, oxygen in the melted copper does appear to rise slowly at richer ratio control levels. The compared behavior over the original study interval is shown in Fig. 6.

The behavior of dissolved copper in the oxygen emerging from the shaft furnace varied greatly from that described in the original patents with respect to the excess fuel setting of the shaft furnace burners in range originally tested. The behavior described in the original patent is shown by the red line in Fig. 8 while the observed behavior is shown by the blue line. Some indication of rising oxygen levels in the melted copper was seen above 5% postmix CO, but it is unlikely that furnaces will ever be operated in this range for ETP rod production.

The general survey test illustrated in Fig. 4 shows that, as the CO content of the postmix in the shaft furnace burners increases, the oxygen content in the copper generally falls. It appears that a slight increase may start to appear at CO postmix contents higher than 5% (20% excess fuel). This is a much higher point than indicated in the original shaft-furnace studies.

Finally, the flame length of the burners as fired in open air is stable between 1.5 and 3% CO, but it decreases and increases more rapidly on either side of this interval. This area of flame length stability in air does not immediately appear to correlate with any feature of the behavior of the oxygen content of the copper.

There could be many reasons for the difference in behavior between the original results and the presently observed behavior. It is known that the flame stability of the originally tested shaft furnaces was improved greatly over the years since the development of the original test furnace. It is probable that the original shaft furnace burners were experiencing flame failures and loss of the combustion front during the

Fig. 6. Expected behavior (red) versus observed behavior (blue).

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wide variation of copper-oxygen concentration levels at each CO ratio control point, however, the results also showed a clear decrease in the copper-oxygen level content as the furnace postmix CO increased to 4 %. No clear increase in the copper-oxygen concentration was exhibited as the CO ratio control point was increased. It was clear that on any CO ratio control point the copper oxygen content could vary by as much as 80 ppm during normal operation. The range of copper oxygen contents observed in this test ranged between 18 and 150 ppm. Following this test a new group of samples was taken extending the testing range to 6% CO ratio control points to see if there was any possibility that the oxygen would increase as predicted by the Philips-Baier hypothesis.

The results are shown in Fig. 4.

General operating survey tests. When the data of the oxygen in Cu vs. CO in burner postmix was compared over these wider range of samples it appeared that copper oxygen increased at CO ratio control point levels above 4%. The ability to operate the furnace at these levels was compromised because of the high temperature of off-gas the furnace produced at these levels, so the number of samples taken was limited. The variation of the oxygen at individual CO control points was still very large but seemed to indicate that at significantly higher CO control points, the O content in furnace copper may increase slightly, although not as strongly as suggested in the Phillips-Baier patent.

The graph in Fig. 4 still indicates an increase in copper oxygen with CO control point levels at concentrations above 5% and the range of variation was decreased. Because of difficulties in obtaining suitable samples in this range, the number of samples is limited, and,the results are left open to interpretation. However, it is unlikely that furnace operators will choose to run their furnaces in this range because of excess fuel consumption and other factors.

Flame length test. A test of flame length versus firing pressure was performed with a burner firing in open air to observe the flame characteristics. See Fig. 5.

General observations. Rod quality remained consistently at the highest grade throughout the tests.

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original tests, and that the un-burning gas and air mixtures add oxygen to the melting copper by exposing the melting copper to oxygen and methane mixtures without exposure to hydrogen and CO. The original shaft-furnace burner design was not optimized for reducing flames, while the modern designs can accommodate this better and maintain flame stability over a wider reducing range.

The original shaft furnace combustion system also incorporated in its design a degree of nonuniform mixing of the premix at the burners as limited by the factor K shown in equation 1. The maximum and minimum oxygen content in a plane of premix across the premix flow prior to combustion should be less than 2/3 of K6: K=(.06321A)/(B+.01)A

Eq. (1)

where A = volume percent of oxygen in oxygen containing gas employed to form the melting stream. For example, for air, A=20.7; and where B = the theoretical amount of pure oxygen in volumes of oxygen at standard conditions required to burn one volume of the fuel. For example, for natural gas, B = 2. It may be that variations in this content influenced the oxygen values in a manner not observed in this test, where the spread was essentially zero.

When observing the shaft furnace burners at very high CO set points, it certainly does appear that a large amount of oxides are being formed in front of the burners, appearing as darker islands and slicks on the melting copper. It may be that the increased reducing strength of the gas inside the furnace due to the richer combustion overcomes the formation of oxides as long as the combustion front at the burner is stable and forming reducing gasses. Alternately, when the flame front at the becomes broken and melting copper is exposed to cool premix, H2 and CO reducing gasses are not formed rapidly enough in the reaction zone around the melting copper to reduce many of the oxides formed during flame impingement.

The amount of time the copper spent blanketed by reducing gases during these tests was also greater that the original tests, in which the samples were presumably taken directly after the issuance of the copper from the furnace tap-hole and may have contributed to reducing the supposed oxide films or the copper itself. However in that case, this new data would be more relevant to actual operating conditions.

A return to the original questions This presentation set out to find answers to two questions.

Below are the findings.

How much control of dissolved copper-oxygen is available to the furnace operator from the furnace itself, and how much must be added or removed subsequent to melting.

The tests showed that the existing control of oxygen from the furnace depends on the burner postmix CO content on a modern furnace. Operating points for the oxygen content ranges desired in the melted copper can be estimated from the graphs provided in these tests. There is a clear variation of approximately 80 ppm in copper oxygen that occurs during operation at any common control point. But the maximum and minimum values of this range decrease up to a control point of approximately 5% CO. What are the maximum and minimum combustion ratios available during furnace operation?

The operating tests showed that highest quality ETP copper can be produced from as low as 0.4 percent CO postmix content and as high as 5% postmix content with the addition of additional oxygen before casting. There was no time during the tests when casting or rod defects increased markedly due to changing the combustion ratios. The results also show that, with the control of the firing rate, the shaft furnace can produce copper close to the oxygen free range in the area of 3-4% CO ratio control points. This may be a desirable feature for those who wish to melt cathodes and produce low oxygen copper.

Conclusion

Fig. 7. Picture showing blue “pencil” point shapes in flame.

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The results suggest that the Baier-Phillips hypothesis that oxygen is added to the copper by unburned gas and air at the center of the flame over the range of roughly 0.5 to 4% CO in postmix does not appear to hold true in the modern shaftfurnace operation. Upon reflection, most current shaft-furnace operators of all current makes would probably agree with this observation.

While it appears to be obvious, as Phillips and Baier described, that copper oxides are formed in front of the burner “pencil shapes” in increasing amounts above and below perfect stoichiometric combustion conditions (about 1.5 % CO in postmix), the oxides do not seem to dissolve in the copper and may be reduced by the CO and H2 in the modern furnace at reducing ratios up to approximately 5% CO in postmix. Alternately, on the more excess-air side combustion spectrum, oxides seem to dissolve and report to the copper to be cast. The fact that the original shaft furnace tests showed oxygen pickup by the copper in the 0.5-4% CO in postmix

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range may have been due to flame failures in the original burner design or some mixing phenomena. It was not possible to duplicate this behavior during these tests.

The apparent copper oxides clearly increase and decrease as a result of the position and proximity of the melting cathodes in front of the burner flame. This can be observed by any shaft-furnace operator and may account for some of the variability in the oxygen dissolved in the copper and the CO in the burner flame as the cathodes fall into different positions in front of the burners. This variation was clearly documented in the original patent.

The Phillips-Baier hypothesis may generally hold in modern furnaces in the richer area of the combustion spectrum above 5% CO. Some potential oxygen pick-up was observed in this area, while no flame failures were observed. It is assumed that in this range that oxides are produced faster through contact with the burning premix than reducing gases form to reduce them. However, further work needs to be done to confirm the behavior of the melting copper in this ratio region.

In view of the results, it may be fitting to analyze some of the suppositions about the design and operation of copper melting shaft furnace combustion systems.

In any case the behavior of the modern shaft furnace is better explained by the existing curve than the original explanation, and provides a model on which to improve the behavior of oxygen in current furnace operations and accurately influence future furnace and casting plant designs.

Acknowledgements The author wishes to express his gratitude to the Encore Wire Corporation operators and management team for their extra work and patience, and for permitting the test work to be done with their equipment during their operations.

References 1. Phillips and Baier, U.S. Patent No. 3,366,465, p.6, l.40.

2. Ibid, p.12, l.10.

3. Ibid, p. 26, l.60.

4. Ibid, p. 6, l.45.

5. Ibid, p. 26, l.20 6. Ibid, p. 8, l.56

John Hugens is global market manager for copper for Fives North American Combustion Inc. (formerly North American Manufacturing), Suwanee, Georgia, USA. His 30 years of experience in the nonferrous metals and combustion industries include management of shaft furnace and continuous Hugens casting research programs, supervision and operation of lead and zinc plant operation, and operation of precious metal recovery plants. He earned his master’s degree in economics from the University of Utah, and is a graduate of the New Mexico Institute of Mining and Technology. This presentation was made at the Global Continuous Casting Forum that was co-located with WAI’s 81st Annual Convention, Atlanta, Georgia, USA, May 2011.

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ANDRITZ Maerz Direct-to-Wire technology: optimized FRHC copper production New technology for producing FHRC copper rod has been found to be effective and efficient not just for small production but for large volumes as well, making it an attractive alternative for ETP copper rod producers to consider using.

By Timm Lux, Jörg Köhlhofer and Christine Wenzl

Direct-to-Wire® (DTW) technology from Germany’s ANDRITZ Maerz GmbH employs a new method to optimize production of fire-refined high conductivity (FRHC) copper rod from copper scrap. The technology can be used in either new or existing copper rod production plants by two types of furnace concepts that can meet the requirements of different production volumes and product mixes.

Introduction ANDRITZ Maerz DTW technology, developed with its partner, METTOP, minimizes the production costs of FRHC copper, while making the refining technology understandable and manageable. The DTW technology is increasingly in demand because FRHC copper rod has become a growing alternative to Electrolytic Tough Pitch (ETP) copper rod for some applications. In contrast to ETP,

Fig. 1. Relation between scrap quality/production costs.

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the FRHC copper cable scrap cannot be charged to the ETP-producing cathode shaft furnace in large amounts. It is hard to differentiate both types of scrap in advance, a matter of concern for companies focusing on ETP copper rod that want to enter the FRHC copper rod market.

The DTW technology is based on ANDRITZ Maerz’s experience in furnace building and Mettop’s knowledge in copper metallurgy. Innovations such as Mettop’s nitrogen purging system, Maerz’s high pressure refining systems and special refining additives achieve optimum refining results at minimum production costs. Depending on scrap quality, a different refining approach is chosen. Good quality scrap can be refined in a single refining stage using only silica, limestone or iron to build the right slag, while lower scrap qualities may require multi stage refining with more additives, like boric acid, to remove undesired impurities.

The production costs are also taken into consideration, which are inversely proportional to the used scrap quality.

See Fig. 1. The optimum balance between cheap low-quality copper scrap and rising production costs has to be found for economic production. Per a customer’s individual requirements, the FRHC copper can be produced with either one or two flexible furnaces for melting, refining and casting or a combination of one melting furnace combined with two refining furnaces. Below are generally recommended setups for production volumes using ANDRITZ Maerz technology: • 20 to 60 t per day. With an(elliptical) drum-type furnace for melting, refining and casting, expandable by a second furnace for minimum investment (See. Fig. 2.

• 40 to 500 t per day with a flexible tilting furnace for melting, refining and casting, also expandable by a second furnace. See Fig. 3.

• 240 to 1000 t per day with a high efficiency hearthshaft furnace for melting in combination with two drumtype furnaces for refining and casting. See Fig. 4.

liquidus T, good removal of basic oxides (e.g., PbO), while disadvantages are magnetite problem under oxidizing conditions, high Cu solubility, high viscosity and bad removal of acidic oxides (e.g., As2O3).

CF slag (basic). The advantages are wide liquidus range, good removal of acidic oxides, no magnetite formation under oxidizing conditions and lower Cu solubility than fayalithic slag (but still high). the disadvantages are higher liquidus T (ca. 1,300 C) than fayalithic slag, limited SiO2 solubility, bad removal of basic oxides, very low viscosity and high refractory attack.

The DTW process allows wire production directly from scrap after pyrometallurgical refining without the electrorefining production step. See Fig. 5. The fire refining includes an oxidation step to oxidize the less noble impurities in the copper, and a reduction step to achieve the required oxygen content for FRHC copper as described below. Between oxidation and reduction, the slag formed during the oxidation is removed. Depending on the input material quality a multi-stage oxidation may be required, possibly with special additives and slag-forming agents.

The DTW process uses various copper scrap types of different quality. Compared to the traditional recycling route with two refining stages, the input material qualities for the DTW process are limited, but the electrorefining costs can be saved. Suitable qualities are scrap classes 1, 2, and 3 (Table 1), the total input typically being composed of different amounts of the three classes. The low grade (class 3) scrap is desirable based on economics, but its use is metallurgically limited because of the high impurity content.

Quite often the amount of class 3 scrap is limited to 10%.

A typical international product standard for FRHC is U.S. Standard C11020, which requires: Min. 99.90% Cu+Ag; Max. 0.04% O2; Max. 0.04% impurities (400 ppm). Table 2 shows the European standard. The DTW process steps are oxidation, deslagging and reduction.

The oxidation step is defined by the impurity elements in Fig. 2. Combination of two elliptical furnaces with a the input materials and can be adjusted by slag design and rod casting line. selection. The reduction step depends on the product requirements and the reductant that is used. For the overall process, the main aspects such as process time and economics have to be considered. The oxidation can be done by using air, oxygen-enriched air, or pure (technical) oxygen. During this stage, the metals less noble than Cu are removed from the melt, namely Fe, Al, Si, P, and Zn. Removal of As, Sb, Ni, Pb and Sn is also possible to a certain extent. Generally, slagging depends on gas flow rate, oxidation time and temperature. A suitable slag is needed to remove impurities and collect their oxides. The Cu loss to the slag and the total slag amount also have to be considered. The main slag criteria includes: liquidus temperature and liquidus range; solubility of impurities and Cu; Fig. 3. Combination of two tilting furnaces with a rod viscosity; Cu loss in slag (dissolved + entrained); casting line. slag amount; refractory attack; separation metal/slag phase; and additives (amount, price).

The most common slag system in Cu metallurgy is the system CaO-FeOx-SiO2 (See Fig. 6).

The slag composition and slag basicity is decisive for impurity removal. The presence of further slag components (basic oxides: Na2O, BaO, SrO, CaO; neutral oxides: MnO, FeO, ZnO, MgO, BeO, Cr2O3, Fe2O3, Al2O3, TiO2; acidic oxides: SiO2, P2O5) also influence the slag basicity. and hence the slag properties.

The advantages and disadvantages of the three main slag types are as follows Fig. 4. Combination of a hearth shaft furnace with two Maerz Fayalithic slag (acidic). Advantages are low drum-type furnaces and a rod casting line.

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Metallurgical background

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FCS slag. The advantages are low liquidus T, good impurity removal (As and Sb like CF, but better for Pb), low Cu solubility, medium viscosity. The disadvantage is a narrower liquidus range than fayalithic slag (can be widened by Na2O or Cu2O).

Conventional slag types have limited use because some problematic elements like Pb (basic oxide), Ni (basic oxide), Sn (neutral oxide), and Sb (neutral oxide) are difficult to remove as they have a similar enthalpy of oxide formation as Cu. Further, the oxidation of the impurities is determined by their distribution coefficients in multicomponent slags, namely there are mutual influences.

Therefore, it is difficult to find one slag that can be used to remove all impurities. To overcome this problem, there are generally two approaches that improve impurity removal: • Multiple oxidation + reduction steps

Fig. 5. Copper recycling routes.

• Addition of fluxes like soda or other special chemicals However, the factors process time, as well as refractory attack and costs for additives have to be taken into consideration. Generally, there are two DTW process variants, namely without and with addition of special additives.

The deslagging operations are mainly depending on the slag type (viscosity), slag amount, and training of operators. However, the degree of deslagging (i.e., amount of slag remaining in the furnace after deslagging) is essential for final product quality, as the impurities are re-reduced from the remaining slag during reduction.

The reduction process is determined by the required quality (oxygen content) of the final product (FRHC: min.

99.90% (Cu+Ag), max. 0.04% O2). Important factors are the choice of a suitable reductant (e.g., LPG, natural gas, hydrogen) and suitable means of introducing the reductant into furnace (e.g., tuyere system).

The aim of the DTW process is to exploit the advantages of modern furnace technologies to achieve optimum results with just conventional (oxygen-based) oxidation and slag design. The main technological advantages are a good furnace design, an effective reduction tuyere system, and a gas purging system for better homogenization, deslagging, and reaction efficiency improvement. These features allow reducing the impurity content of the melt to low levels, even without adding expensive special fluxes.

When using certain input materials, the resulting impurity concentrations in the melt are too high for this special flux-free DTW process variant. For these cases, a special additive mixture was designed using thermodynamic calculations (software Factsage) and experimental investigations. This mixture supports the conventional (oxygen-based) oxidation and slag, so that materials with higher impurity levels can be treated in this DTW process variant. The special furnace features and resulting high efficiency and short process times help to minimize refractory attack during the stage where the additives are used.

Furnace systems for FRHC copper

Fig. 6. Slag system CaO-FeOx-SiO2.

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Maerz supplies melting and refining furnaces for primary and secondary copper production, as well as for industries processing copper materials such as cathodes and high-quality scrap. For FRHC production (different copper scrap grades) the following furnaces and combinations of furnaces are used for existing/new FRHC rod lines: • 20 mt to 60 mt Drum Furnace (with elliptical shape) (melting, refining and casting) • 40 mt to 500 mt Tilting Reverberatory Furnace (melting, refining and casting) • 12 to 48 mt/h Hearth-Shaft Furnace (melting) with two 60 to 250 mt drum-Type Furnaces (refining and casting)

TECHNICAL PAPERS Table 1. DTW process scrap classes.

Table 2: FRHC Cu specification according to European Standard EN 1977: 1998 (equivalent to ISO 1337:1980).

Drum-type furnaces. Widely used for melting, refining and casting of FRHC copper range between 20 mt and 40 mt capacity, these furnaces have an elliptical shape for improved melting efficency. They typically cast between 1 to 1.5 times per day. Drum-type furnaces used only for refining and casting of FRHC copper have capacities of up to 250 mt and can cast up to 3 times per day. The larger furnaces can be used with a hearth-shaft furnace to receive the molten copper via a launder and achieve final refining to FRHC copper quality. Combined with a hearth shaft furnace they can provide enough copper for 35-48 mt per hour rod casting lines. Fig. 7 shows a rotary furnace.

Drum-type furnaces are most efficient for refining because of their deep copper bath. For oxidation, compressed air or oxygen-enriched air is injected through highpressure tuyeres located deep below the molten metal.

Reduction of dissolved oxygen is done in a similar way by injecting reductants. The oxygen content, a key quality for

FRHC copper, reached inside a drum-type furnace is lower than that inside a tilting furnace. The refining tuyeres are positioned beneath the metal bath by rotating the furnace about the longitudinal axis to take advantage of the increased bath depth. The ability to submerge multiple tuyeres and inject refining gases at high velocity increases the process efficiency and provides lower media consumption and shorter process times. Installation of nitrogen purging elements helps the deslagging and increases the rate of bath homogenization. Purging elements also accelerate the oxidation and reduction speed.

Tilting reverberatory furnace. First developed by Andritz Maerz, this flexible furnace allows melting, refining and casting of larger amounts of copper scrap in a single flexible aggregate. Compared to the smaller 20 to 40 mt drum type furnaces used for melting, it offers fast charging of larger amounts of scrap material and a high rate of heat transfer for fast melting, due to a larger bath surface.

Fig. 7. A 200 t drum type refining furnace.

Fig. 8. A tilting furnace from the charging side.

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The furnace is charged with scrap through the large door openings in the upper sidewall by a mobile charging machine or a rail-based, automated high-capacity charging machine that can be equipped with a scale system for measurement of the copper scrap charged into the furnace.

After charging, the doors are closed and the charge is melted. The procedure is repeated until the furnace capacity is reached. Oxygen burners or oxygen-enriched burners can be used to increase efficiency. Fig. 8 shows a 180 mt tilting furnace from the charging side. Once filled with molten material, the furnace is rotated in the refining position to submerge the tuyeres. Oxidation air is injected to remove impurities and form the slag layer. Further additives are added to help removal of critical elements like nickel and others. The furnace is rotated back to the home position when oxidation is completed as indicated by the level of dissolved oxygen in the molten copper. The furnace is rotated to the deslagging position to remove the slag from the bath surface. The impulse of the burner flame and the purging system pushes the slag to the deslagging door.

Once the slag is removed, the furnace is rotated again to the refining position for reduction with or without further oxidation until the final desired metal composition is achieved, and the molten copper is cast into the rod casting machine. Due to the roof construction of the tilting furnace and tight closing door system, the furnace pressure can be easily regulated to keep the production area free from smoke and allow very low oxygen contents in the copper.

Hearth-shaft furnace. Based on the principle of a common cathode shaft furnace, the Maerz hearth-shaft furnace (see Fig. 9) can also melt large amounts of slag generating copper scrap with very high energy efficiency. With two drum-type refining furnaces, the hearth-shaft furnace (HSF) combines efficient heat transfer of the shaft furnace for melting with the operating flexibility of the tiltingreverberatory furnace, while achieving even better refining results. The single furnace unit has two different sections: The shaft section is responsible for melting while the hearth section provides volume for collection and handling

Fig. 9. A hearth-shaft furnace with drum-type furnace.

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of the liquid copper. Scrap material is charged into the shaft with a skip hoist. Four to eight burners are mounted radially around the lower shaft section and serve as the primary source of energy for melting. Melting rates of up to 50 mt per hour can be achieved. The hot waste gases rise through the shaft and preheat the solid scrap in the upper part of the shaft. The molten copper and slag flow into the hearth for further heating and treatment. The hearth section collects the molten copper slag mix to the maximum capacity, which typically range between 35 mt and 250 mt of liquid copper. The hearth area is heated by one or two burners in the hearth end wall opposite the shaft. Waste gases from the hearth burners exit the furnace through the shaft section, contributing significantly to scrap preheating and furnace efficiency. Separating the collected liquid copper from the still unmelted solid copper allows the molten copper bath to be superheated as melting continues, which results in a significant reduction to total cycle time. If the hearth area capacity is reached, floating slag can be removed by the purging system in the bottom of the furnace. The liquid slag-free copper is then transferred by a heated launder to one of two drum-type furnaces for further refining and casting.

Optimized production of FRHC copper The goal of DTW technology is to minimize production costs of FRHC copper by advanced refining technology that is understandable and manageable for operators, using metallurgical experience and new calculation methods.

Addressing other aspects can further optimize production and minimize the costs. These include: natural gas, oxygen, compressed air and electricity consumption; wear and spare parts, including refractory lining; diesel oil for charging machine; cooling water; labor; and financing.

Many FRHC copper lines with small annual capacities (8,000 to 50.000 mt a year) were recently realized for a minimum investment. These lines use small drum-type, tilting or even traditional stationary furnaces with capacities between 20 to 150 mt for melting, refining and casting.

These small lines all feature high specific production cost per ton due to their size and efficiency. Another approach for optimized FRHC copper production is using larger furnace systems. Fig. 10 shows the significance of the size and efficiency factor for the following examples: • a 20 mt drum-type furnace: one natural gas/air burner, 5 mt/h rod casting line, 4-5 h of casting per day • a 60 mt tilting furnace: two natural gas/air burners, 7.5 mt/h rod casting line, 8-9 h of casting per day • a 180 mt tilting furnace: two naturals gas/air main burners, two natural gas/oxygen roof melting burners, 25 mt/h rod casting line, 7- 8 h of casting per day • a 600-800 mt hearth-shaft furnace system with two 150 mt drum type refining furnaces, 35 mt/h rod casting line, 18-24 h of casting per day, natural gas/oxygen shaft burners, natural gas burners for hearth area and drum type furnaces Fig. 10 shows the different production costs, which are

Conclusion The amount of FRHC copper rod produced per year has increased as it has become an alternative to ETP copper in many applications. Another driver is the difficulty differentiating copper scrap that is ETP from FRHC, the latter of which cannot be charged in cathode shaft furnaces. There are multiple reasons for ETP copper rod producers to con-

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calculated for a standard operation cycle with average times for charging, melting, oxidation, deslagging and casting. For an easier costs-per-ton comparison, the production costs for the 20 mt drum type furnace are set to 100 as a base value that result in: costs of 100 for a 20 mt drum type furnace; costs of 94 for a 60 mt tilting furnace; costs of 49 for a 180 mt tilting furnace; and costs of 30 for a 600800 mt hearth-shaft furnace system with two drum type refining furnaces. The main drivers for the small furnaces are the costs for labor and natural gas. It can be seen that the 20 mt drum-type furnace and refining furnaces from the hearth-shaft furnace system offer lower costs for refining due to their higher refining efficiency compared to an average tilting furnace. With increasing furnace capacity, nearly all production costs per mt decrease. The only exception are the costs for cooling water, wear and spare parts and refractory between the 20 mt drum type furnace and the 60 mt tilting furnace. This is caused by more and larger water-cooled door openings and by a more complex tilting furnace structure and refractory concept.

This comparison shows clearly the main disadvantages of the smaller furnace systems compared with a large modern ANDRITZ Maerz hearth-shaft furnace system, even taking the financing of the project over five years into consideration.

Fig. 10. Production costs comparison without investment costs. sider entering the FRHC copper market. ETP producers tend to use rod lines with annual capacities of more than 200,000 mt because of the cost advantages. FRHC production had been limited to small production systems with limited efficiency, but ANDRITZ Maerz’s Direct-to-Wire (DTW) technology now makes it possible to build furnace systems for smaller lines with an improved efficiency as well as large furnace systems for efficient annual production of up to 260,000 mt of FRHC copper, or more. These furnace systems can be either installed in new lines or used to upgrade the various existing copper rod lines already in use today. For all the above reasons, current and future copper rod producers should consider DTW technology.

Timm Lux is head of marketing and sales for the Copper Division of Andritz Maerz GmbH, Düsseldorf, Germany. Before joining the company in 2008, he started his career at ThyssenKrupp Steel Europe as a technical management trainee. He studied at RWTH Aachen University, Germany, and Technical University of Catalonia (UPC), Barcelona, Spain, earning a degree in mechanical engineering and economic sciences. Jörg Köhlhofer, Lux Köhlhofer Wenzl general manager of the Andritz Maerz Copper Division, joined the company in 1995. He previously was designer engineer and team leader at Mettop GmbH, Leoben, Austria, since 2007. She previfor the electrical reduction furnaces product division of ously was a research assistant and project leader in the Mannesmann Demag Hüttentechnik. He earned a Dept. of Nonferrous Metallurgy at the University of mechanical engineering degree with a specialty in engiLeoben, where she earned Ph.D. and M.Sc. degrees. This neering design from Hochschule für Technik und presentation was made at the Global Continuous Casting Wirtschaft des Saarlandes (HTW) - University of Applied Forum that was held in conjunction with WAI’s 81st Sciences. Christine Wenzl has been a senior metallurgist Annual Convention, Atlanta, Georgia, USA, May 2011.

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PRODUCTS & MEDIA PRODUCTS New spiral spring machine offers both low cost and high value At wire Düsseldorf 2012, Germany’s WAFIOS AG plans to presents its new universal spiral spring machine, the SPM 2 model, at its booth in Hall 10, F22.

A press release said that the SPM 2 spring machine stands out due to its combination of low cost and high customer value. It cited the model’s ability to produce a broad range of spiral spring products as well as an extremely high output, which together result in an excellent price/performance ratio. The produced spiral springs, it said, are designed for the automotive sector and the electronic industry, while another application field the SPM 2 can serve is the “white goods” industry. The rigid machine concept, it said, guarantees the highest repeat accuracy and precision and meets the highest quality requirements.

The release said that WAFIOS AG is celebrating a special anniversary this year: the granting of the company’s first patent for spring coilers 100 years ago.

Contact: WAFIOS AG, www.de, www.wafios.us.

Company furthers the scope of its product range with new system At wire Düsseldorf 2012 at the company’s booth (Hall 11 G40), staff from Italy’s Continuus-Properzi will be prepared to discuss a new innovation from the company, a newly designed LOGOS 2.0 Evolution wiredrawing machine for high-carbon steel.

Staff will be at the booth to discuss the manufacturing capabilities and advantages of the LOGOS 2.0 Evolution as well as the rest of the technology from the company, which notes that it invented the methodology and process of continuously casting and rolling nonferrous rod in the 1940s. ContinuusProperzi, a global leader of CCR lines for nonferrous wire rod production, offers a complete product line that

70 | WIRE JOURNAL INTERNATIONAL

includes all the necessary elements, from furnaces and casting equipment, to rolling equipment and double spoolers. The Properzi organization, which includes Properzi International, Inc., in the U.S., provides unparalleled continuous casting and rolling technology for the production of aluminum and copper wire rod on a global basis, a press release said. The copper rod can be produced from either copper cathodes or 100% low-quality copper scrap to yield top quality copper rod, it said, adding that the product line also encompasses machinery for the production of nonferrous ingots with a track and belt system.

The product line is complemented by the offerings of the company’s Wire Machinery Division, which include newly designed drawing lines for high carbon, stainless steel, and AS wire, as well as complete PC strand lines, PC wire lines and steel rope lines.

Contact: Continuus-Properzi, hq@properzi.it or Properzi International, Inc., info@properzi.us; www.properzi.com.

Electron beam accelerators offer wide coverage and high speeds Showcasing its technology at its booth (Hall 10 E44) at wire Düsseldorf 2012, Belgium’s IBA Industrial reports that Easy-eBeamTM V2, the company’s most recent generation of electron beam accelerators, can provide wire insulation crosslinking down to 0.22 sq mm at speeds of up to 1000 meters per minute.

A press release said that Easy-e-Beam comes with a new intuitive PLC control system, an improved design that reduces implementation time and standard software modules that allows for easy integration with key industry manufacturer’s equipment. The unit is based on the proven industrial reliability of the Dynamitron® accelerator that it said provides superior insulation treatment thanks to its homogeneous crosslinking. It noted that crosslinked insulation and jacketing provide halogenfree wire and cables with improved properties—such as resistance to abrasion, high temperatures, UV, chemicals, mechanical forces—that are required for automotive, railway and photovoltaic applications.

The release said that the company has more than 400 accelerators installed worldwide, including more than a hundred for wire and cable crosslinking.

Contact: IBA Industrial, www.iba-cables.com, info-industrial@iba-group.com.

At wire 2012, Germany's SIKORA AG, will display its latest measuring and control technology at its booth, Hall 9 A-41, showcasing multiple types of its sophisticated equipment A press release said that the SIKORA booth will feature the FIBER LASER 6003, which measures the diameter of optical fibers with an accuracy of ± 0.05 micrometers while providing information on the ovality, fiber position, spinning, vibration frequency and amplitude. It noted that the model also offers the most reliable detection of smallest lumps and neck-downs down to a size of 5 μm.

The booth will display the company’s X-RAY 6000 series for the measurement of the diameter, wall thickness, eccentricity and ovality at insulating and jacketing lines. The model, it said, provides a selectable measuring rate of 1 to 3 Hz or optional 10, or 100 Hz. It will also show the innovative diameter gauges of the LASER Series 6000, which offers a measuring rate of 2.5 kHz for

bottom-draining ng design allows Our bottom-drainin coupling back-to-back coupl ing of multiple air wipes in line, while maintaining drier them. product between th hem. Additionally, Additionally, the performance e of the unit is enhanced as a stand-alone stand d-alone wipe over ™ Air Wipe. our original Air Miser M

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the highest accuracy, it said, noting that options enable an operator to read the diameter value directly from the device.

Other equipment to be shown includes the company’s LENGTH 6000 model for non-contact online measurement of produced cable lengths and its PREHEATER 6000 system, a conductor preheater that ensures optimum adhesion of the insulation on the wire, as well as additional new product solutions in the pipeline, it said.

WIRE DÜSSELDORF

March 26–30 Hall 9 Booth F05-01

Huestis Industrial Industriial machines – our performancee is legendary! legendary!

For more details or to place p an order order,, call us at 800-972-9222, 0-972-9222, 800 or email us at sales@huestis.com salees@huestis.com

www.huestisindustrial.com www .huestisin ndustrial.com herr Pay-offs, Accumulators, Spoolers, Air Wipes, Pay-offs, TTake-ups, ak a e-ups, Bunc Buncher Cold Pr essure W elders, Cable Jac ket e Strippers, Custom Mac hinery Pressure Welders, Jacket Machinery

MARCH 2012 | 71

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Full line of measuring equipment to be displayed at wire 2012

PRODUCTS & MEDIA

Contact: SIKORA AG, sales@sikora.net, www.sikora.com; in the U.S., SIKORA International Corp., sales@sikora-usa, www.sikora-usa.com.

Industrial series of cables now has a Canadian tray rating Logistics prohibit operating rolling mills from trade shows, but France’s REDEX reports that at its booth at wire 2012, Hall 11 A-26, it will offer attendees the next best thing: a live, interactive video broadcast showing the production of flat copper and aluminum wires on rolling mills that are waiting for delivery in its main factory.

A press release said that the event, which will occur

every show day at 4 pm, is designed to offer interactivity between the booth and the factory team. Guests, it said, will be able to watch a live display of the rolling mills during the wire processing at full speed. On the control display clone of the machine, they will be able to see and to interact with all operational data: parameters settings, the real-time measurements, the production reports, etc.

Technicians, both at the booth and at the factory, will be available to answer questions, it said. The video of the set-up and manufacturing will demonstrate REDEX’s skills in control systems as well as remote monitoring capabilities used for both diagnostic and maintenance, it said.

A company spokesperson said that this marks the first time that REDEX has made this type of presentation, and that the focus has been on making it especially interactive, allowing attendees to choose settings on the same interface as it is implemented on the machine to see how it works.

Contact: REDEX, www.wire-rolling-mills.com, info@redex.fr.

Low fiber count cable line introduced U.S.-based CommScope, Inc., has launched what it describes as a unique and cost-effective fiber optic cable solution, the Low Count Fiber Drop cable, designed specifically for one or two fiber drop applications in FTTx networks.

The cables, a press release said, part of the company’s

72 | WIRE JOURNAL INTERNATIONAL

expanding portfolio of high-performance, high-bandwidth cables for telecom applications, provide cable and multiservices operators the flexibility of deploying a fiber optic cable designed specifically for the drop portion of a network. It said that the cable was designed to be both small (4 mm × 2 mm) as well as lightweight (8 lb per 1,000 ft) for easy handling and field preparations. The all-dielectric cable was also designed to complement and further enhance the value of CommScope’s BrightPath® Optical Solutions (BOS™), eliminating the time and cost associated with bonding and grounding, it said, noting that “the innovative, gel-free solution fulfills this niche in the FTTx architecture.”

Doug Wells, vice president, Outside Plant Solutions, CommScope said that the FTTX cables can be used for outside plant designs.

“Some operators are using expensive fiber optic drop cables, containing up to 12 fibers that were designed to accommodate various applications that extend way beyond the true drop application. The Low Count Fiber Drop is a design uniquely focused on addressing the specific requirements in the tap to subscriber connection.”

Contact: CommScope, Inc., www.commscope.com.

Extrusion dies with microstructures create low-friction products Innovative extrusion dies from U.S.-based Hoowaki LLC use microstructured surfaces to lower friction on wire and cable polymer jackets, providing easier installation.

A press release said that standard extrusion dies are modified with the unique surfaces required to reduce friction, and that the micro-features are then transferred to the product during the normal extrusion process, requiring few or no adjustments to the process and no adjustments to the material. Hoowaki’s approach, therefore, requires minimal modification to existing manufacturing processes, does not introduce any new materials and is costeffective for high-volume production, it said.

Hoowaki custom designs the features based on material and application, the release said. The design process, it added, takes into account material shrinkage and drawdown to

Armored fiber cable can offer more crush resistance, cuts costs U.S.-based Siemon announced that it has added a multiple armored cable option to its comprehensive line of high-performance MTP-based plug-and-play fiber cable assemblies.

A press release said that the armored cable offers seven times the crush resistance of standard fiber to protect highperformance channels, eliminating the need for fiber ducting and cutting material and labor costs by up to 50%. The cables are available in 40Gb/s and 100Gb/s-capable OM3 and OM4 multimode fiber cable constructions as well as standard 62.5/125 and 50/125 multimode and singlemode.

The added durability, it said, supports rugged-environment intrabuilding backbone and horizontal installations and eliminates the need for ducting to protect non-armored fiber

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cable. It noted that, compared to the installation of nonarmored fiber with separate innerduct or conduit, the use of armored cable can cut installation costs by up to 50% or more for both materials and labor.

The armored fiber cables, available in 12 to 144 fiber counts in increments of 12 fibers and in custom lengths, offer future-proof support of critical links up to 40Gb/s and 100 Gb/s application speeds, the release said. In both armored and non-armored varieties, Siemon OM3 and OM4 multimode MTP assemblies have passed independent thirdparty testing by Experior Labs, confirming 40Gb/s and 100 Gb/s-readiness and performance margins in accordance

All inquiries within North America for machines, spares and dies, contact:

Joe Snee Associates, Inc. PO Box 236, Seekonk, MA 02771 Tel: 774-991-0504 Email: joe@jsnee.com

PPressure ressure W Welding elding Machines Ltd Bethersden, Kent England TN26 3D 3DYY Te el: +44 (0) 1233 820847 Tel: Fax: +44 (0) 1233 820591 Fax: E-mail: pwm@btinternet.com Welders W elders and dies available from PWM or authorised distributors only y. only.

MARCH 2012 | 73

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provide features that are the optimal geometry on the final product. The company has shown up to a 20% reduction in dry sliding, and up to 80% reduction in lubricated sliding, significantly boosting the surface capabilities of standard polymers, it said. Low-friction surfaces, it noted, have already been applied to polypropylene, polyethylene, nylon, silicones and fluoropolymers using this process.

Hoowaki’s unique surfaces, the release said, can also be used to increase extruder productivity and reduce the drag between the die surface and the polymer, without changing the process parameters. These surfaces, it said, allow polymers to flow smoothly, providing greater quantities of high-quality product.

Contact: Hoowaki LLC, tel. 864-354-6174, info@hoowaki.com, www.hoowaki.com.

PRODUCTS & MEDIA

with the latest IEC 1280-4-1 Edition 2 and TIA/EIA-455171A standard.

Contact: Siemon, www.siemon.com.

Expanded cable line offers ‘brilliance’ in applications Newly designed “Brilliance Audio Snake Cables” from U.S.-based Belden, Inc., offer ultra-rugged construction and deliver superior flexibility over a broad range of indoor and outdoor conditions.

A press release said that the new cables, which include an outdoor and direct burial analog audio, plenum jacketed and plenum “Banana Peel” snake cable lines, are wellsuited for in-the-field and permanent installation to connect multiple channels in low-level (microphone) and high-level componentry where ruggedness is essential.

The three cable lines, it said, each feature a foil shield that is bonded to the jacket, which is designed to maintain high performance while improving ease of termination. The water-blocked product series, it said, consists of six standard product codes with constructions ranging from one to 12 pairs. These products, it added, are suitable for direct burial and are outdoor-rated without the installation difficulties associated with gel installations.

In the plenum product series, Belden offers nine product codes, including the recent additions of four, six, eight and 12-pair constructions with an overall jacket, the release said. Each pair, it noted, is individually jacketed, eliminating the need for heat shrink, which simplifies field termination and reduces labor costs.

The patented Banana Peel construction includes two, four and six-pair audio snake cables that are easy-toinstall composite cables, the release said. The cables are bundled and affixed to a center spline, eliminating the need for an overall jacket and are easy to split, requiring less effort and installation time while coming in an overall smaller O.D. and a better bend radius, it said.

Contact: Belden, Inc., www.belden.com.

MEDIA Reports cover fiber optics outlook for unmanned aerial systems markets U.S.-based Information Gatekeepers, Inc. (IGI), has released a series of reports on the fiber optic potential for Unmanned Aerial Systems (UAS), which it describes as “one of the largest and fastest growing military and aerospace markets.”

A press release said that the tragedy of 9/11 and the Iraq and Afghanistan wars have resulted in the U.S. mili-

74 | WIRE JOURNAL INTERNATIONAL

tary pouring money into UAS R&D, systems, subsystems, components, and services. IGI Consulting, it said, has initiated a series of reports covering this market for companies not involved yet in these markets but that may be considering entering the market.

The series of reports serve as marketing guides, with information on the markets and potential buyers, through the following volumes: Vol. 1, The Fiber Optics Market for Military Unmanned Aerial Vehicles (UAVs); Vol. 2, The Fiber Optics Market for Commercial Unmanned Aerial Vehicles (UAVs); Vol. 3, The Market for Civil UAV Applications; Vol. 4, Unmanned Systems Integrated Roadmap 2011-2036; and Vol. 5, UAV Directory. The table of contents for the reports can be seen at IGI’s website.

Contact: Dr. Hui Pan, Information Gatekeepers, Inc., hpan@igigroup.com, www.igigroup.com.

Literature sheet details product line U.S.-based Silo Fasteners, part of the Elgin Fastener Group (EFG), offers a new literature sheet detailing the company and its product offerings.

A press release said that the sheet lists Silo’s product offerings such as the company’s 5/8-18 lug bolts, form pins and ½ -13 round-head fin neck bolts as well as other bolts, pins and special rivets for concrete form, highway construction and general distribution markets. The literature also provides a company background, from Silo’s start in 1990 in Kansas City, Missouri, to its acquisition by EFG in February 2011. The company, which relocated to Versailles, Indiana, to join Elgin Fastener Group’s Ohio Rod Products division, has provided EFG with entry to new markets as well as expansion of its participation in the construction market, with access to ISO quality systems, it said.

Contact: Silo Fasteners, tel. 812-689-8905, www.silofasteners.com.

WIRE ASSOCIATION INTERNATIONAL MEMBERS seeking positions are entitled to free “Position Wanted” classified ads. Limit: one ad per issue, three ads per year. This benefit is not transferable to nonmembers or to companies.

BLIND BOX INFO: Responses to Blind Box ads should be addressed to: Wire Journal International, Box number (as it appears in print or on-line), P.O. Box 578, Guilford, CT 06437-0578 USA.

CLASSIFIED AD RATES: • $1.30 per word for WJI and on-line classifieds at wirenet.org (20-word minimum). • Blind box numbers, add $25. • Boldface headlines, add $6 per line (up to 18 characters per line). Specify category.

PAYMENT POLICY: All ads must be pre-paid.

CAREER OPPORTUNITIES HIGH ENERGY LEADER NEEDED. A fast growing carbon wire producer, located in the northeastern U.S., is seeking a high energy leader who possesses extensive knowledge in the carbon wire industry. Candidates must have an Engineering degree, coupled with managerial experience; General Manager experience preferred.

Candidates must have extensive experience in the cold drawing and coatings of carbon wire. Competitive compensation and lucrative bonus plans includ-

DEADLINES: Copy is due a full month in advance.

Contact: classified@wirenet.org for more details.

ed. Please forward all resumes and inquiries to wireresumes@ rogers.com. _______________________________ PROCESS ENGINEER SOUGHT. Tri Star Metals, LLC is a rapidly growing distributor and manufacturer of stainless, nickel and aluminum alloys offering global sourcing capabilities and state ofthe art manufacturing facilities to produce specialty alloys that meet the most demanding customer needs. Tri Star Metals has served customers for over 25 years from its mod-

ern facilities, conveniently located in the Chicago, Illinois, suburb of Carol Stream, and more recently from its manufacturing facility in Freeport, IL and its Limerick, PA, distribution center serving the east coast.

Job Description: Process Engineer, Freeport, IL, Manufacturing • Job will provide day-to-day technical support for manufacturing of stainless and nickel-base alloys wire products including electro-plating of wire. This includes establishing manufacturing process parameters, process controls

Visit us at wire Düsseldorf -stand 11 A44

Visit our stand # 215 at Wire Expo 2012

COMMISSION BROKERS, INC. EQUIPMENT SPECIALISTS TO THE ELECTRICAL WIRE & CABLE INDUSTRY APPRAISERS • COMMISSION BROKERS • INDIVIDUAL PIECES OR ENTIRE PLANTS

FOR SALE 1 - NIEHOFF Model SPH801.1.G.E.A Automatic Spooler 1 - NEB 12-C #2 Braider, Long Legs, Motor 3 - TMW 24-Carrier Cable Braiders, 6” Horn Gears 1 - EDMANDS 18-Wire, 6+12, 16” Planetary Cabler Line 2 - NEB Model C62-2 12-Wire 8” Vertical Planetary Cablers, 1987 1 - CONAIR 39” Continuous Belt Caterpuller Capstan, Model 6-39 3 - DAVIS STANDARD 3.5”, 4.5” 24:1 L/D Extruders 1 - D/S 2.5” 24:1 L/D Hi-Temp Extruder 1 - D/S 2” 30:1 L/D Hi-Temp Extruder 1 - SKALTEK 1600mm Motorized Payoff, Model A16-4K 1 - HALL 40” Motorized Payoff w/Dancer 1 - CLIPPER DF6 Dual Cone Flyer Payoff (24” Reels) w/Reel Jacks 1 - ROSENDAHL 630mm Parallel Axis Dual Reel Take-up, never used 1 - NOKIA Model EKP50 Parallel Axis Dual Reel Take-up, 1997

1 - SPHEREX 18” Dual Reel Take-up, refurbished 1 - CLIPPER Model SP16 Dual Spooler 1 - TULSA Model WTR-2416 Respooler 2 - AL-BE Model MS12 Respoolers, 12” Reels 1 - REEL-O-MATIC Model PRR1 Rim Drive Powered Reel Roller 1 - REEL-O-MATIC Model RD-5 Rim Drive Take-up w/Coiling Head 1 - TEC Model DTC630 D.T. Twister 2 - ENTWISTLE 4-Wire 24” D.T. Twisters, Model 4WDT24 1 - FINE Preheater, Model IP4000-180-1, 2007 1 - SCHLEUNIGER Model HS4140 Hot Stamper 1 - EUBANKS Model 4000-04 Cut and Strip Machine 1 - EUBANKS Model 9800-03 Cut & Strip Machine 1 - GETTIG Tape and Labeling System 1 - CARPENTER 3-Head Stripper, Model 74-C 3 - CARPENTER Strippers, Model 70-B 1 - MICRODIA Crosshead, Model M9000/10XFL

Contact: Martin Kenner

COMMISSION BROKERS, INC. P.O. Box 8456 • Cranston, RI 02920-0456 • Tel. (401) 943-3777 • Fax: (401) 943-3670 WEB: www.commissionbrokers.com • E-MAIL: marty137@aol.com

MARCH 2012 | 75

CLASSIFIEDS

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WIRE JOURNAL INTERNATIONAL CLASSIFIED AD INFORMATION NAME _________________________________________________________________________TITLE _________________________________________________ COMPANY ____________________________________________________________________________________________________________________________ ADDRESS ___________________________________________________________________________________________________________________________ CITY ________________________________________STATE _______________POSTAL CODE _____________________COUNTRY _______________________ PHONE ______________________________FAX________________________________EMAIL _______________________________________________________ AD CATEGORY____________ ISSUE YOUR AD BEGINS___________E-mail_____________________________________ NUMBER OF ISSUES RUN _______LAST ISSUE ________________RUN TILL FURTHER NOTICE? YES____ NO ____ FULL RUN (WJI & ON-LINE) YES____ NO ____

BLIND BOX? YES____ NO ____

WAI MEMBER? YES____ NO ____ WAI MEMBERSHIP # ______________________ (Applies only to “Position Wanted”)

and assisting with root cause analysis of process failures.

• Candidate will need to be able to understand customer and industry specifications and be able to provide product specific manufacturing processes to meet those specifications.

• Will interface on a regular basis with sales,manufacturing and management personnel as well as customers.

• Identify,investigate and execute cost savings opportunities in the manufac-

76 | WIRE JOURNAL INTERNATIONAL

turing process and support functions of the organization.

• Make disposition of non-conforming product.

• Key traits for this individual would be outgoing, able to communicate well verbally and in writing with both professionals and operating personnel,be self-directed and able to make decisions with limited information and limited supervision.

• Supervise, run and maintain the

Please e-mail the requested information to: WAI’s Cindy Kirmss at ckirmss@wirenet.org.

For more details, you can call her at 203-453-2777, ext. 116.

mechanical testing and metallurgical laboratory.

Job Qualifications: • Four year degree from an accredited college in Mechanical Engineering, Metallurgical/Materials or Chemical Engineering.

• At least two-years of experience in a manufacturing environment- preferably in stainless wire drawing I long products, or related metals manufacturing

_______________________________ ENGINEERS AND TECHNICIANS NEEDED. CNA Technology, LLC, located in Greenville, North Carolina is currently recruiting for experienced engineers and technicians to work in a fast past - team oriented Coaxial Cable Manufacturing environment. All qualified candidates should have experience in processing of foamed insulation jacketing extrusion and preferably welding know-how of trunk and distribution products. A background in Drop cable products is a definite plus.

We offer a competitive salary and benefits. All applicants will be treated in a

confidential manner. Resumes can be submitted to kbryan@cablenetwork.net _______________________________ TWO POSITIONS TO BE FILLED. Global Wire & Cable Manufacturer expanding its sales & engineering office, which is located in the Houston, TX area, has two key job openings at that location.

1) NATIONAL SALES MANAGER with growth toward International Project Business. We are looking for a National Sales Manager for outside sales activities as well as completing inside sales tasks. The qualified candidate shall be self-motivated and enjoy working with customers and co-workers. Target is to grow from this position into our international project business, mainly in Latin America.

and/or Oil & Gas Industry • Sales experience with wire designs acc. to UL 13/2250/1270 • Participation at shows and conferences • Willingness to travel Excellent work environment with competitive pay and benefits. Please submit your resume with salary requirements to the attention of BLIND BOX 3-1 at blindbox@wirenet.org.

2) ENGINEERING MANAGER/ UL-WIRE SPECIALIST. Reports to: Director of Sales/Engineering. We are looking for an Engineering Manager or a Product Engineer who is ready to take the next step. The person shall be selfmotivated and enjoy working with customers and in a team environment.

Key Competencies: • Knowledge of Wire & Cable designs acc. to UL 13, UL 2250 and UL 1277 (PLTC/ITC and TC Types) • Strong communication skills for interaction with customers and coworkers • Ability to give effective presentations to customers with appropriate follow-up

Key Competencies: • Thorough knowledge of Wire & Cable designs acc. to UL 13, UL 2250 and UL 1277 (PLTC/ITC and TC Types) • Substantial understanding of production methods for UL 13/2250/1270 wire types • Good communication skills to engage in technical discussions with customers and co-workers • Ability to give technical presentations to customers

Requirements: • College degree in business or engineering or similar • Fluent in English and preferably Spanish • Sales experience in project business

Requirements: • College degree in engineering or similar • Several years experience in Wire & Cable manufacturing environment • Experience in project business and

Sheaves - Pulleys Cable Guides ProcessSheaves.com 866-344-6774 MARCH 2012 | 77

CLASSIFIEDS

experience.

• Competent in use of Window's OSbased computers including Microsoft Office (Word, Outlook, Excel, Access, etc.)

• Able to fluently communicate (both verbal and written) in English. Other languages are a plus (German I Spanish) • Must be willing to relocate to the Freeport,IL general area for full time presence in the Freeport Manufacturing Facility.

• Good working knowledge of cold drawing of wire, heat treating,plating and cold heading are a plus.

Tri Star Metals, LLC provides a total compensation package including competitive salary, medical, vision, HSA (Health Savings Account), vacation, 401K retirement savings program, and paid holidays. Please send resumes to: careers@tristarmetals.com.

CLASSIFIEDS

wire designs acc. to UL 13/2250/1270 • Participation at shows and conferences • Participation at committee meetings such as IEEE, Fieldbus Foundation etc.

• Willingness to travel Excellent work environment with competitive pay and benefits. Please submit your resume with salary requirements to the attention of BLIND BOX 3-2 at blindbox@wirenet.org.

PERSONNEL SERVICES “LET OUR SUCCESS BE YOUR SUCCESS” Wire Resources is the foremost recruiting firm in the Wire & Cable Industry. Since 1967 we have partnered with industry manufacturers to secure the services of thousands of key individual contributors and managers.

Contacts: Peter Carino, pcarino@ wireresources.com or at www. linked in.com/in/petercarino1, or Jack Cutler, jcutler@wireresources.com.

Wire Resources Inc, 522 E Putnam Ave, Greenwich, CT 06830, tel. (203) 622-3000 or (800) 394-WIRE. Visit our website at www.wireresources. com.

for high performance for drawing and bunching Soft wire (Bare/Silver/Tin etc) and Hard Wire (nickel/Hyenss 25/ Stainless Steel/Titanium ,etc.).

• DS Hai Dies services wire manufacturers in the United States as well as Internationally.

• SEMI-FINISHED PCD for sale – D12, D15, D18, D21, D24, D27, an economical solution available for customers to refinish themselves. We always have finished dies available as well.

DS Hai Dies is looking for sales Representative in Europe and Asia.

Please contact Simon Farjoun at simon@dshaidies.com or tel. 860-8841270 or 860 574 4771.

APOLLO DIA-CARB COMPANY. Buy & sell new/used Natural and PCD DIAMOND DIES. Fair prices and excellent lead times. Contact Paulette, Owner-Sales, by telephone at 1-508226-1508 or by e-mail at apollodie@ comcast.net.

MOLONEY DIE COMPANY. Low prices on all sizes of new, used and recut carbide dies. We also recut tapered nibs. Fast turn-around.

Quality service since 1985. Tel. 904388-3654.

MEDIA MACHINERY WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous & NonFerrous; Marldon Rolling Ring Traverses) & Used Wire & Cable Equipment (buttwelders, coldwelders, color-o-meters and pointers). Tel: 727863-4700 or by e-mail, please send to urbassoc@verizon.net.

DIES TO ALL WIRE AND CABLE MANUFACTURERS: IWD (International Wire Dies) division of DS Hai Dies , LLC announces the opening of another new and bigger factory in Gilman CT .

United States .

• We can supply high quality Diamond and PCD dies at very competitive prices. A few of our specialities are dies

78 | WIRE JOURNAL INTERNATIONAL

THE PRACTICAL APPLICATION OF THE PROCESS CAPABILITY STUDY. Creating a universal language for problem solving, this new (published in 2011) 135-page, indexed softcover book was written by industry expert Douglas B. Relyea, founder and senior partner of Quality Principle Associates, a New England-based consulting firm that specializes in the education and application of data analysis techniques to industrial problem solving. The book delineates the process capability study, a powerful tool that, when understood and implemented, provides benefits to every department within a manufacturing organization.

With easy to read, step-by-step flow diagrams on how to perform process capability studies and measurement process analyses, the book’s coverage includes:

the benefits of statistical process control over statistical product control; realworld industrial examples and case studies illustrating how to use the techniques; ways for management to determine if the investment in process capability studies is providing an appropriate return; methods to correct lack of stability and capability once either condition has been identified, such as the ANOVA technique and the simple three-factor designed experiment; and a flow chart that enables machine operators to execute a process capability study without interfering with productivity. A great deal of information is available on the technical concepts of the process capability study, much of it emphasizing the mathematics. Unfortunately, concentrating on the math and fine distinctions, such as the difference between alphaand beta-type errors, has created barriers preventing many from fully appreciating the basic concepts, the simplicity, and the usefulness of the tool. This book shows you how to use the process capability study to increase return on investment from your statistical process control/Six Sigma effort and make your company more competitive. The list price is $45, $40 for WAI members.

FERROUS WIRE HANDBOOK. This comprehensive 1,168-page hardcover book is a definitive industry resource for ferrous wire written by WAI members and edited by former WAI President Robert M. Shemenski, was published in 2008. The 36 chapters cover topics that include: equipment types, processes and specialty applications of steel wire manufacturing.

Specific subjects include continuous casting; controlled rod cooling; rod defects; pickling and coating; descaling; deformation in cold drawing; wiredrawing theory, machinery, and finishing equipment; lubrication; heat treatment; stress relief; annealing; oil tempering; patenting; corrosion; galvanizing; statistical process control; bridge rope and strand; and nails, barbed wire, mechanical springs. List Price is $235, $195 for WAI members.

ADVERTISER . . . . . . . . . . . . . .PAGE

ADVERTISER . . . . . . . . . . . . . .PAGE

Ace Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Howar Equipment Inc/ACM . . . . . . . . . . . . . . . . . . . . . . . .20

AIM Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 2

Howar Equipment Inc/BOCK . . . . . . . . . . . . . . . . . . . . . . .53

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . .31

Howar Equipment Inc/Metavan . . . . . . . . . . . . . . . . . . . . .52

Bergandi Machinery Co . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Howar Equipment Inc/Unitek . . . . . . . . . . . . . . . . . . . . . . .46

Beta LaserMike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49, 71

Bongard Trading GmbH & Co KG . . . . . . . . . . . . . . . . . . .75

Inosym Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 4

Keir Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Cemanco LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Lesmo Machinery America/A Appiani . . . . . . . . . . . . . . . .19

Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . . .75

Micro Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Niagara Composites International, Inc . . . . . . . . . . . . . . .50

Fisk Alloy Wire Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Gem Gravure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Parkway-Kew Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

GCR Eurodraw SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

PolyOne Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 3

Howar Equipment Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . .73

MARCH 2012 | 79

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX

ADVERTISER . . . . . . . . . . . . . .PAGE PRO-pHx Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Queins Machines GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . .51 REDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Reel-O-Matic Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

May 2012 WJI • Green Focus: Part 1 Advertising Deadline: April 1, 2012

Sanxin Wire Die Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Sheaves Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 SIKORA AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Steel Orbis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Suzuki Garphyttan Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Talladega Machinery & Supply Co . . . . . . . . . . . . . . . . . . .4 Turkish Electro Technology (TET) . . . . . . . . . . . . . . . . . . .76 Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . .79 Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . .23 Wyrepak Industries Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . .53

WIRE ASSOCIATION INTERNATIONAL ADS WAI Operations Summit & Wire Expo 2012 . . . . . . . .14-17 WAI membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

WIRE JOURNAL

I N T E R N A T I O N A L

NORTH AMERICA

EUROPE

Robert J. Xeller Anna Bzowski Wire Journal International 1570 Boston Post Road P.O. Box 578 Guilford, CT 06437-0578 USA Tel: 203-453-2777 Fax: 203-453-8384 sales@wirenet.org

U.K., France, Spain, Holland, Belgium, Denmark & Scandinavia Jennie Franks David Franks & Co. 63 St. Andrew’s Road Cambridge CB4 1DH, England Tel/fax: 44-1223-360472 franksco@btopenworld.com

80 | WIRE JOURNAL INTERNATIONAL

SALES OFFICES ASIA/WAI INDIA OFFICE Germany, Austria, & Switzerland Dagmar Melcher Media Service International P.O. Box 103 D-82402 Seeshaupt Germany Tel: 49-8801-914682 Fax: 49-8801-914683 dmelcher@t-online.de

India Wire & Cable Services Pvt. Ltd. (WCS) 501, Rainbow Plaza, S. No. 7 Pimple-Saudeagar Vil. Rahatani, Pune - 411017, India Huned Contractor mobile - +91 988 1084 202 hcontractor@wirenet.org