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the fabricator CONTENTS ®
February 2016
Vol. 46 No. 2

COVER STORY
74 Being better while being bigger
Metal fabricating represents a vital chunk of the U.S. manufacturing industry, and MEC
Inc., Mayville, Wis., shows just how big a business it can be. The fabricator has more than
$300 million in annual sales and multiple locations, yet it is still trying to focus on what
makes even the smallest fab shop successful: quick turnaround of quality products at a
fair price. In recognition of the company’s growth and success in maintaining a positive
culture, The FABRICATOR has honored MEC with its 2016 Industry Award. Cover photo
courtesy of Artist Group Photography and Video, Milwaukee.

FEATURES

74 80 Modern hydraulics: Six advanced capabilities for stamping presses

Advanced hydraulics and intelligent drive systems are now available to provide greater
metal forming precision and to improve stamping press productivity and product quality.

82 Considerations for designing parts for laser cutting

Laser cutting has been a widely accepted fabricating technology for almost 20 years, yet
with more new blood entering the industry, some fabricators lack a deep understanding
of the cutting technology. This tip sheet aims to boost their laser cutting IQ.

84 Brushing up assembly
Scratching a cosmetically critical part during assembly can be costly. This is where choos-
ing the right material for the assembly table surface can be critical. It’s here that the table
brush may be able to help.

86 Getting a solid connection for HSS

One architectural fabricator has developed a connection and fabrication system for the
modular construction of hollow structural sections, or HSS. Such connections show just
how efficient modular construction can be.

90 Better flow, better planning, less chaos

After rapid growth, a commercial lawn care OEM prepares for the future with better part
flow, better production controls, better communication, and better planning. The com-

82 pany’s continuous improvement initiative is well on its way.

94 Moving the family fab shop

Shop owner Tom Brizek knows all about moving a metal fabrication operation. His shop,
TAB Industries, is in the middle of its fourth move in nine years. When, where, and how
should a shop relocate? Brizek provides some insight.

96 What about submerged arc welding?

Knowing your applications will help you determine what kinds of auxiliary equipment
you need to manipulate a submerged arc welding head and get the productivity you
want.

98 How to crunch chronic defects with variables search

Variables search is not a well-known quality tool, but it can be helpful in rooting out
factors that produce scrap and rework at metal fabricating facilities. All that’s needed to
identify the sources of quality problems is a dedicated group and a disciplined approach
to the investigation process.

100 Keeping pace with technology

Quality is a given, but delivery time is not. Sjoberg Tool & Manufacturing Corp., Hartland,
Wis., knows that, so it has relied on the latest machine tools over the last 40 years to
squeeze time out of the production process.

100 104 Forming & Fabricating® 2016 Plate Processing System Buyers’ Guide©
106 Forming & Fabricating® 2016 Deburring Machine Buyers’ Guide©

6 The FABRICATOR FEBRUARY 2016

 The Power of
Partnership.
“Amada’s technology,
expertise, and commitment
took our business to the
next level.”
— Jim Lauer, President
Weaver Precision Fabrication & Finishing

Keeping pace with the high-speed of the fiber laser, a 6-shelf ASLUL 300
material handling/storage tower ensures maximum
flexibility and continuous productivity.

Co-Owners: Marian and Jim Lauer, Weaver Precision Fabrication & Finishing

Integrated Solution: Fiber Laser Technology, Automated

Material Handling /Storage and Advanced Bending
Located in Akron, OH, Weaver Precision Fabrication & Finishing has been success-
fully competing in the metal fabrication industry for over 70 years. Since purchasing
the business in 1998, Co-Owners Jim and Marian Lauer, have instituted a lot of changes.
The most significant change: investing in advanced technology enhanced by automation
— in other words, partnering with Amada. Jim Lauer expressed it like this: “We needed
to get high quality parts out the door in a hurry. Our aging laser was working 24/7 and not
keeping up with the demands of our shop. We were limited... and we hate to be limited.
After carefully studying all of our options, we chose Amada.”
Amada’s solution includes an FLCAJ 3015 fiber laser, an ASLUL 300 automated
material handling/storage system and an HG 1303 (a 143-ton, down-acting, hybrid drive
press brake). The FLCAJ’s innovative, 3-axis linear drive system delivers unmatched
speed and accuracy. According to Lauer: “The ASLUL provides an integrated lights-out
solution for automated material handling/storage, allowing us to take full advantage of the
fiber laser’s speed and versatility.” Marian Lauer adds: “Amada’s leading-edge equipment
and customer-centered approach immediately put us at ease about making a switch.
Now, we can leverage the speed and unique capabilities of the fiber laser to better serve
our existing customers and quote work that previously was not a fit for us.”

Amada’s industry-leading technologies

and automated systems ensure: A user-friendly, AMNC 3i touchscreen control and
offline programming, ensure speed and accuracy
• Expanded Capabilities (In addition to cutting mild steel
for any level operator. The HG also analyzes and
four to five times faster than their old CO2 laser, the FLCAJ adjusts part angles automatically, eliminating test
expands Weaver’s process range by quickly and precisely pieces and scrap.
cutting materials such as aluminum, copper and brass).
• Unmatched Precision (The HG 1003 is an ultra-high
precision and high-speed bending system. An advanced Dual
Servo Power drive system provides the ultimate in bending
control and accuracy for a full range of thin-to-thick materials).
• Maximum Flexibility (The ASLUL’s 6-shelf configuration allows Weaver
to quickly and easily switch between dissimilar materials and different gauges. JOIN AMADA AT
The HG’s large open height of 20.5" and stroke length of 9.8" ensures maximum Amada America, Inc.
bending versatility).
180 Amada Court
Reflecting on the decision to partner with Amada, the Lauers add: “Amada did much
IN SAN DIEGO, CA Schaumburg, IL 60173
more than sell us equipment. They restructured our entire manufacturing process to ensure
February 24 - 26, 2016 www.amada.com/america
maximum productivity. Prior to working with Amada, we had never encountered a machine
Register online @ fmanet.org
tool manufacturer that cares about their customers as much as we care about ours.” 877-262-3287
the fabricator CONTENTS ®
February 2016
Vol. 46 No. 2

MANAGEMENT STRATEGY
56 Biz Talk
Senior Editor Tim Heston shares the story of a small industrial building just off the
highway in northeast Pennsylvania. It has housed a few businesses, and their stories tell
a lot about what it’s like to be a small manufacturer in the U.S.
58 Around Washington
Congress finally provides permanent approval for Section 179 expensing deduction
and bonus depreciation laws.
60 Improvement Insights
The fab shop is ripe territory for unexpected (and usually bad) things to occur.
Columnist Dick Kallage says the best operations prevent them by doing as the
accountants do: auditing regularly.
66 Chief Concerns
Although the study of generations is an inexact social science, it may help company

66 leaders empathize, minimize conflict, and get everyone on the same page.

DEPARTMENTS
10 From the Editor-in-Chief
MEC Inc. is a fabricating operation with 17 locations and more than $300 million in annual
revenue. A shop of that size is good for the metal fabricating community because while it
is grabbing market share, it’s also grabbing the attention of policymakers.
14 Readers’ Forum
16 Calendar of Events
20 Industry News
39 From thefabricator.com
40 Applications

70
42 Product Highlights
44 The FABRICATOR’s Metal Market
44 Product News
62 Precision Matters
Columnist Gerald Davis reviews the similarities between drafting and illustrating. The use
of dedicated software is considered.
64 Bending Basics
Bending guru Steve Benson believes any fabricator who has a basic understanding of
notching can produce better products and devise more efficient operations.

108
70 Technology Spotlight
After having purchased waterjet-cut parts as part of his old job, Dan Sarmiento thought
he could develop a better waterjet cutting system. He displayed his handiwork at
FABTECH® 2015.

72 Technology Spotlight
A new battery-operated, hand-held marking unit has capabilities and software that are
typically found only on much larger units.
108 FMA: In The Know
112 Classified Ads
113 Advertisers’ Index
114 The Back Page
Contributing Editor Sue Roberts tells the tale of how Reggin Industries, Calgary, Alberta,
fabricated a sculpture of a baleen whale for a mall at the Vancouver Airport.

WHAT’S ON THEFABRICATOR.COM?
Learn the language of metal-making. The first step in troubleshooting material-related
problems in forming processes is to learn the lingo associated with metal creation. “Trouble-

114
shooting sheet metal defects: Part I” has the details.
Check out thefabricator.com blog. Josh Welton of Brown Dog Welding continues his Still Build-
ing America series at www.thefabricator.com/blog.

8 The FABRICATOR FEBRUARY 2016

 Next
Generation
Technology.
(far right) John Baker, President and Next Generation Owners, George Alexandrakis & Bella Baker Alexandrakis

“Amada’s punch/laser
technology increased
our production by 60%.”
— Bella Baker Alexandrakis,
Operations Manager
General A&E

General A & E’s next generation partners with Amada

to grow through diversification and new technology.
General A & E is a precision light gauge sheet metal fabricator that’s been operat-
ing in Hackensack, NJ since 1954. The 25-employee, ISO 9001 and AS9100 registered
shop is skilled to handle highly-complex aerospace work as well as more conventional
commercial parts. As the third generation takes over the business, they face increas-
ing customer demands for shorter lead times and a greater variety of parts. After a
thorough analysis of their entire manufacturing process, Amada provided the optimal
solution — the LC 2012 C1 punch/laser combination machine equipped with auto-
mated loading and part sorting.
John Baker, General A & E’s President, comments on the new equipment. “The C1
combines punching, tapping, forming and laser cutting into a single machine — allowing us
to respond quickly to customers’ changing demands while reducing costs. As of today, the
C1’s automated features allow us to get an additional 3 shifts of lights out production per
week. And, we’re in the process of programming to extend that to 5 shifts. The Company’s
Sales Manager and future co-owner, George Alexandrakis adds, “The C1 not only ex-
pands our capabilities, it also allows us to operate our older equipment with greater efficiency.
Since the C1 is highly-automated, the same operator can run another
turret punch press while the C1 provides unattended punching, cutting,
automated loading and part sorting.”

To maximize productivity, the MP 2512 C1

Amada’s punch/laser technology ensures: automated sheet load/unload system can
unload a sheet of tabbed parts (or scrap)
• Maximum Versatility (a 49-station Multi-Purpose Turret and load a new sheet in approximately
reduces costly secondary operations by providing 4 tapping tool 45 seconds.
stations and 3 innovative die stations which lift to ensure
scratch-free forming).
• Maximum Productivity (a 2.5 kW laser provides the power
to blank virtually any shape in material up to 1/4˝ thick. Amada
has synchronized the punching and laser cutting processes reducing changeover JOIN AMADA AT
times to less than half of the industry average). Amada America, Inc.
• Maximum Efficiency (The PR C1 automatic part removal and sorting system
180 Amada Court
takes productivity to a new level by automating the material handling process.
IN SAN DIEGO, CA Schaumburg, IL 60173
Mounted on the machine frame to maintain a compact footprint, the PR C1
automatically removes parts as small as 4˝ x 2˝ to as large as 20˝ x 20˝ and February 24 - 26, 2016 www.amada.com/america
Register online @ fmanet.org
weighing up to 26.5 pounds). 877-262-3287
 FROM THE EDITOR-IN-CHIEF
Read more from Dan Davis at www.thefabricator.com/author/dan-davis contributed $146.2 billion in real manufacturing
gross domestic product in 2014, according to the
Bureau of Economic Analysis. That represents about

The importance of 7 percent of all manufacturing GDP. It’s also a sec-

tor that has shown consistent growth since the end

a fabricator’s growth of the Great Recession, reaching levels unmatched

over the last 20 years.
Using 2012 data, the Manufacturing Extension
A large company grabs market share—and attention
Partnership reported that the sector has about
58,000 manufacturing establishments in the sector,

A
s Robert Kamphuis, chairman, president,
and CEO, MEC Inc., addressed the chal-
lenges of running a fabrication company
with more than $300 million in annual revenues,
I heard echoes of prior conversations I have had
with metal fabricators. Kamphuis wasn’t talking
about “shifting paradigms” or “capitalizing on syn-
ergies”; he was focusing on the need to streamline
processes and maintain fabricating flexibility. He
was talking like the owner of a 25-person shop.
Well, that’s not the case. MEC, which rhymes with
Shrek, is a manufacturing behemoth that is making a
lot of green. It has 17 locations, approximately 2,000
employees, and reported 2014 revenues of $335 mil-
lion. MEC has absorbed another fabricator that was
almost as large as it was at the time of the acquisition
three years ago and has expanded its manufacturing
footprint in Virginia. (You can read more about The
FABRICATOR’s 2016 Industry Award winner in “Being
better while being bigger” on page 74.)
MEC’s growth is a good thing because it shows
that the model that makes small to medium-sized
shops prized members of a community is scalable.
MEC’s growth is not like that of a company run by a
private equity firm, which buys into a company, ex-
pands to boost top-line growth, squeezes the busi-
ness until the last bit of perceived fat is drained from
it, and sells it to the highest bidder for a nice profit.
MEC is expanding its business with current custom-
ers, branching out into new geographic areas, and
acquiring other metal fabricating operations that
have solid financials and customers that comple-
ment MEC’s current lineup. The goal is to fill capac-
ity and look for new business that might cause the
fabricator to invest in new capacity. An expanding representing about 1.4 million workers. Those are
fabricating operation keeps employees working attention-grabbing numbers.
and provides for growth opportunities.
It also should be noted that Kamphuis and his
This is all great news for MEC and its
staff make these decisions with MEC employees in
shareholders, but why should other
mind. They also happen to be the company’s share-
fabricators care? Large companies
holders. Last year was the 30th anniversary of MEC
tend to grab the attention of those
becoming an employee-owned company.
who make policy, or who at least
influence the policymakers.
This is all great news for MEC and its sharehold-
ers, but why should other fabricators care? Large
MEC could easily shrink from the spotlight and go
companies tend to grab the attention of those who
about its business without scrutiny from the outside
make policy, or who at least influence the policy-
world, but it chooses not to. It’s confident in its role
makers. Large companies employ large amounts of
as a provider of manufacturing expertise, quality
people, and those people represent a large amount
product creation, and even supply chain manage-
of potential voters.
ment, and it is a proud supporter of the local commu-
I hear the complaints often enough about how
nity and regional educational efforts. It’s topped the
political leaders take small and medium-sized fab
FAB 40 list of successful U.S. fabricating companies
shops for granted. They make policy aimed to help
for five consecutive years now and has embraced the
manufacturing, but those actions rarely result in
role of being a large fish in a pool filled with very tal-
true benefits for metal fabricators. In fact, many see
ented competitors, albeit on a smaller scale.
it as just another example of how the federal gov-
Finally, MEC’s success is an inspiration to all
ernment finds a way to spend more money to ap- shops. A fabricator once told me that he had a mor-
pease a certain voting bloc. al obligation to continue expanding the business
A fabricator with a lot of employees and spread because it provided more opportunity for employ-
out geographically is more likely to have substan- ees to grow and increase their compensation. It’s a
tive conversation with policymakers because that noble gesture with a foundation of truth to it. Larger
organization has gravitas. It also can speak for an companies simply have more opportunity for career
entire industry, which happens to be a significant development for their employees.
contributor to the U.S.’s economic well-being. Metal fabricating is a big business that deserves to
Let’s face it. Many people, let alone politicians, be recognized. Big businesses increase the chance
don’t even know what metal fabricating is. Here’s of that happening.
one thing they can understand: The fabricated met-
al product manufacturing sector (defined as North
American Industry Classification System code 332)

® FMA’S CERTIFIED EDUCATION CENTERS

the fabricator
First Vice Chairman Jason Hillenbrand
Vivek Gupta Amada America Inc.
Texas ProFab Corp. FMA Certified Education Centers (CEC) are community
William Isaac
Second Vice Chairman and technical colleges, trade schools, and universities
EDITORIAL ADVISORY BOARD Lyle Menke MC Machinery Systems/Mitsubishi Laser
Mary Ellen Mika that specialize in training adults for careers in the metal
Peddinghaus Corp.
Dan Berdass forming, fabricating, processing, and machining sectors.
Secretary/Treasurer Steelcase Inc.
Bermo Inc.
William “Jeff” Jeffery Mark Prasek They offer coursework for local students year-round and
Charles Caristan IRMCO Rafter Equipment Corp. serve as host locations for many types of FMA professional
Air Liquide
Immediate Past James Rogowski development programs as requested. A council of mem-
Greg Cornett Chairman of the Board TRUMPF Inc.
bers convene six times a year to plan and execute special
Inalfa Roof Systems Edwin Stanley, GH Metal Solutions Gregg Simpson
programs on worker training for educators and human
Matthew Gehman Directors Ohio Laser LLC
Metal Locking Service Dirk Smith resource managers from companies of all sizes.
Teresa Beach-Shelow
Subramaniam Manivannan Superior Joining Technologies Inc. Super Steel LLC
To learn more about FMA’s CEC program and view a list
Aperam Stainless Solutions USA David Brown Pamela Swanson
Affiliations Unlimited Inc. Airgas USA of the current member schools, visit www.fmanet.org/
Jim Poe involvement/certified- education-centers/.
Rick J. Hargrove Steve Zerio
Iowa State University
Steel & Pipe Supply Co. Inc., Central Conveyor Co.
FMA OFFICERS AND DIRECTORS Storage & Processors To discover how your local community or technical college
President & CEO
Chairman of the Board Brian Havlovic Edward Youdell can become a member, call 888-394-4362 or send an e-
Al Zelt, ASKO Inc. Kawasaki Motors Mfg. Corp. USA Fabricators & Manufacturers Assoc. Intl. mail to info@fmanet.org.

10 The FABRICATOR FEBRUARY 2016

 READERS’ FORUM

Make Way for Female Welders
Editor’s Note: The December 2015 edition of the
“Welding Wire” included a link to “Make way for the
torch queen” (The Back Page, December 2015, p.
110), which generated the following response.
After so many years, I am glad to finally see some
recognition for our ladies.
In my career as a welding instructor in the U.S. Air
Force, I can say with pride that we trained a lot of good
female TIG welders who often excelled above the
guys. Women have a much steadier hand and make
excellent welders. I’m really glad to see that training
has finally taken priority with most employers.
Herschel Barnett
Welding & Automation Specialist
Red-D-Arc Welderentals
Dallas, Texas
Made More Difficult in America?
Rainier Welding is a steel fabricator that fabricates
many Alaska and Washington Department of Trans-
portation projects, as well as random work for other
municipalities. This includes bridges and ferry ter-
minals.
Many of these projects require pipe elbows and
other fittings, and most are federally funded, which
requires all steel items to be 100 percent melted and
produced in the U.S.  These federally funded proj-
ects allow for a maximum of $2,500 or 0.001 percent
of the contract price, whichever is greater, of foreign
steel for an entire project.
We have had great difficulty locating these items—
structural steel parts that are 100 percent melted
and produced in the U.S.—in the recent past. I’m
contacting you out of frustration. One manufacturer
I spoke with said it had found domestic tube to be
lower in quality than the foreign tube they purchase.
The government requires domestic steel to help
keep jobs in America, but U.S. companies don’t seem
to be interested in supplying American steel. When
we do find someone to make domestic fittings, for
example, they may cost $2,500 each. The same fitting
that has some foreign steel would cost about $75.
Bob Webster
Rainier Welding Inc.
Redmond Wash.
Editor’s Note: If you have any suggestions where a
structural steel fabricator might have success finding
a good source of fittings made from U.S.-produced
steel, please pass along the information to Dan Davis
at dand@thefabricator.com.
The Entitled Generation
Editor’s Note: The December 2015 edition of the “Fab-
ricating Update” e-newsletter contained a discus-
sion of people being asked to assume mentor roles
to younger workers. Here is one response from that
master-apprentice conversation.
After reading the “Fabricating Update,” I agree with
the person who is frustrated working with young
people. As an educator who currently  has senior
students, I am bewildered to try and understand
the right of entitlement that some students have. It
seems like they want to start at the top and work
their way down. It truly will be culture shock once
they leave the confines of high school.
Now I don’t want to paint them all with the same
brush. We have many who are the total opposite
and are overachievers and will be extremely suc-
cessful in their chosen career. I can only hope that
these other students are fortunate enough to pair
up with someone who is willing to pass on their
hard-earned knowledge.
Chris Code
Timiskaming District Secondary School
New Liskeard, Ont., Canada
The Universal Commonality:
Demanding Customers
Editor’s Note: In the December 2015 edition of “Fabri-
cating Update,” Editor-in-Chief Dan Davis pointed out
how on-time delivery really is one of the main differ-
entiators for fabricators that have similar fabricating
technology and skills. This scenario also apparently
exists outside the U.S. as well.
We are a metal fabricating shop that has grown over
the last three to four years because of the car industry.
As for on-time delivery, it’s very stressful for us
because the customers believe everything can be
made in minutes or hours. To help meet the custom-
er demands, we have a complete team of salesmen,
with their trucks, to deliver the best service to our
customers. We have worked to deliver parts to cus-
tomers in less than two hours after they have called
or e-mailed us.
We are located in the center of Mexico, and most of
the industrial customers are about 45 minutes from
our location. Our salesmen have mobile phones,
and they send us photos and comments that can
help us fulfill the customers’ special needs. We can
solve the problem in minutes, instead of days.
Its costs us a lot of money to maintain this type of
support, but we hope our customers value the on-
time delivery.
To tell you the truth, the only thing that we need
to deliver on time is will—the will of the customer
and the will of our team.
Juan Anaya
Metálicos Eternity
León, Guanajuato, Mexico

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the fabricator
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14 The FABRICATOR FEBRUARY 2016

It’s easy to miss movements on the Prima Power
Laser Genius. That’s because our innovative liner
drive motor technology provides unparalleled
speeds…even in small notches or narrow contours.

But the Laser Genius is not just another fast fiber

laser…and is definitely not your father’s laser.

We are the laser of today…and tomorrow.

The Laser Genius combines the following features to

provide unequaled precision for customers requiring
strict tolerances:

• Linear drives motors on all axes
• Advanced carbon fiber carriage
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CALENDAR OF EVENTS
FMA Annual Meeting
Feb. 24-26—San Diego
Fabricators & Manufacturers Assn.
888-394-4362
www.fmanet.org
Welding for the Non-Welder
March 7-10—Troy, Ohio
Hobart Institute of
Welding Technology
800-332-9448
www.welding.org
LeanFab Workshop & Tours
March 15-16—Rockford, Ill.
Fabricators & Manufacturers Assn.
888-394-4362
www.fmanet.org
FABTECH® Canada
March 22-24—Toronto
Fabricators & Manufacturers Assn.
888-394-4362
http://fabtechcanada.com
Design2Part Show
March 30-31—Atlanta
The Job Shop Co.
800-225-4535
www.d2p.com
Powder Coating 2016
Technical Conference
April 11-14—Atlanta
Powder Coating Institute
859-525-9988
www.powdercoating.org
Safety Conference
April 13-14—Dayton, Ohio
Fabricators & Manufacturers Assn.
888-394-4362
www.fmanet.org
Design & Manufacturing
New England
April 13-14—Boston
UBM Canon
310-445-4200
http://design-manufacturing-new-
england.designnews.com
Titanium Europe 2016
Conference and Expo
April 18-20—Paris
International Titanium Assn.
303-404-2221
www.titanium.org
Coil Processing Workshop/
World-class Roll Forming
Workshop
April 25-27—Charlotte, N.C.
Fabricators & Manufacturers Assn.
888-394-4362
www.fmanet.org
International Aluminum
Extrusion Technology Seminar
May 2-6—Chicago
Aluminum Extruders Council
847-526-2010
www.et16.org
Manufacturing 4 the Future
May 3-5—Hartford, Conn.
SME
800-733-4763
www.mfg4event.com
FABTECH Mexico
May 4-6—Mexico City
Fabricators & Manufacturers Assn.
888-394-4362
http://mexico.fabtechexpo.com
ALAW: Advanced Laser
Applications Workshop
June 6-8—Plymouth, Mich.
Fabricators & Manufacturers Assn.
888-394-4362
www.fmanet.org
Manufacturing Day
Oct. 7—North America
Fabricators & Manufacturers Assn.
888-394-4362
www.mfgday.com
To have your event considered for
publication, please send your event
information to dand@thefabricator.com.

16 The FABRICATOR FEBRUARY 2016

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 EXPERIENCE & COMMITMENT
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Artco Group / Houston Blow Pipe (HBP) processes heavy thickness plate
by rolling, press forming and welding. Since its inception over a century
ago, we have processed and manufactured custom finished parts and
products from heavy pressure vessel quality plate for a variety of
industries in the Gulf, with a special focus on onshore and offshore oil
and gas. With over 100 years of pressure vessel fabrication expertise
and know-how, HBP can handle the most challenging industry steel plate
forming needs.

HBP is now bringing its expertise north to the Marcellus and Utica shale
regions with its establishment of a DAVI plate roll and full pressure vessel
welding services in Hannibal, OH. HBP’s parent company, Artco Group,
has operated within the 110 ACRE / 1.2m sqft Hannibal Industrial Park
since 2007. The Artco Group is already the premier heavy thickness steel
plate processor in North America. The addition of plate rolling and pres-
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 INDUSTRY NEWS
FMA report shows fabricators,
job shops facing uncertainty
Fabricators & Manufacturers Association Intl. (FMA), Rockford,
Ill., has released the Q4 2015 “Forming & Fabricating Job Shop
Consumption Report.” The report looks at small and medium-
size job shops and fabricators.
The overall sense of this most recent report is that fabricat-
ing shops are facing a lot of headwind and uncertainty, but not
enough to cause panic.
Nearly as many participants reported a decline (23 percent)
as reported improvement (24 percent) in Q4 2015, although 53
20 The FABRICATOR FEBRUARY 2016
percent indicated they are in a stable position. Capacity utili-
zation for participants was just more than 61 percent.
The demand for new orders is a key indication of what is
to be expected in the future, and the numbers here have de-
teriorated. Thirty-seven percent of participants experienced
declines in new order demand—almost twice the number that
experienced an increase (23 percent). Forty-one percent re-
ported stable conditions.
Most companies surveyed (68 percent) reported they are
planning to maintain their current number of employees. Thir-
teen percent said they intend to hire, and 19 percent reported
they will hire less. Most participants
said they have a very hard time finding
qualified people, which is a large reason
for their reluctance to hire.
Fifty-three percent of respondents ex-
perienced stable raw material costs, but
34 percent saw costs drop. Only 13 per-
cent experienced increased raw mate-
rial costs. For most companies (77 per-
cent), logistics costs remained stable,
while 18 percent reported higher costs
and 4 percent recorded lower costs.
With a 61 percent level of capacity uti-
lization, fabricators are having a tough
time deciding to add capital equipment.
Only forty-one percent of respondents
said their capital equipment purchase
plans are on track. That means most
respondents will delay these purchases
for a few months, with 28 percent say-
ing they will cancel them.
Most respondents said they believe
their companies will grow in 2016.
Thirty-nine percent were positive, and
38 percent said conditions are at least
stable. Even so, a significant number (23
percent) said conditions are not getting
any better.
Hobart Institute of Welding
Technology to break ground
on new facility
The Hobart Institute of Welding Tech-
nology (HIWT) will break ground on its
Next Generation Welder Learning Fa-
cility at its Troy, Ohio, campus in early
2016.
With more than 14,000 sq. ft. of space,
the new facility will be an addition to
the institute’s existing 13-acre campus,
offering welder education, welding pro-
cedures, welder qualification testing,
certification services, and specialized
training.
Van-Am Tool & Eng.
adds 5-axis laser system
Van-Am Tool & Eng. LLC has added a
5-axis laser system to its facility in St.
Joseph, Mo. The machine offers capaci-
ties up to 131.6 by 60.8 by 28.3 in., plus
4,000 W of cutting power, for processing
of flat plate, formed or drawn shapes,
tubing, pipe, and structural items.
The firm also offers tooling design
and build, machining, production metal
stamping, and full fabrication using
three laser cutting systems up to 6,000
W and 80- by 160-in. plate size, precision
CNC press brakes, and manual and ro-
botic welding.

Epic Welding and Mfg.
relocating to larger
North Dakota facility
Fabrication company Epic Welding and
Mfg. Inc. has moved to a 22,000-sq.-ft.
facility in West Fargo, N.D., and added a
5,000-sq.-ft. sandblasting area and a 65-
ft. paint booth.
The firm expected to hire four employ-
ees immediately and more in the future.
Southern Metal Fabricators
adds wing for automated
finishing operations
Custom metal fabricator Southern Metal
Fabricators Inc. has opened a new wing
at its facility in Albertville, Ala., adding
30,000 sq. ft. to its shop floor, most of
which is devoted to an automated fin-
INDUSTRY NEWS
CWA Foundation, CWBi partner with St. Joseph The no-cost welding curriculum uses such tools as 3-D
High School to launch national curriculum printing, a mobile application, and textbooks with augmented
The Canadian Weld- reality, providing uniformity across Canadian high schools.
ing Association In addition, CWAF has launched its Secondary School Weld-
Foundation (CWAF) ing Helmet Initiative and will be distributing 1,800 welding
and the Canadian helmets to various high schools across the country that have
Welding Bureau In- full-time welding programs; St. Joseph will be receiving 22
stitute (CWBi) have welding helmets.
partnered with St. In addition, St. Joseph High School will be receiving
Joseph High School $50,000 over 10 years from a funding partnership between
in Edmonton, Alta., to roll out ACORN, Canada’s first national CWAF and the Marinucci Family Foundation to go towards
end-to-end welding curriculum. its welding program.

When you need Waterjet Cutting on a

ishing operation. This allows the com-
pany to bring all blasting and painting
for its custom-fabricated ducts, tanks,
and carts in-house. very large scale, turn to Greiner.
At the heart of the new finishing op-
eration is a massive, controlled, auto-
mated paint booth that can accommo-
date large roller carts, which are used
to wheel products such as carbon steel
storage tanks in and out of the booth.
Automated sprayers hit inserted prod-
ucts from all directions at once. Follow-
ing paint application, the controlled
environment inside the booth rapidly
dries products, reducing dry times from
two days to two hours in some cases,
the company reports.
The company also installed steel grit
blasting equipment.
Metal Technology partners
with NASA to 3-D print rocket
engine parts
Metal Technology (MTI), a custom
manufacturing company specializing in 1.75-inch thick HY-80 Steel Plate rolled to
reactive, refractory, and high-tempera- 91.75-inch O.D. Holes cut into the cylinder
after rolling. Thermal cutting not permitted.
ture metals based in Albany, Ore., has
announced it is collaborating with NASA
Johnson Space Center (JSC) to 3-D print Our 5-Axis Waterjet Cutting System can easily
rocket engine parts. handle your big job.
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FEBRUARY 2016 The FABRICATOR 21

 INDUSTRY NEWS
Nuts, Bolts & Thingamajigs foundation
awards manufacturing scholarships
Fifteen students pursuing careers in manufacturing
each earned $2,500 or $3,500 toward their postsecond-
ary studies from Nuts, Bolts & Thingamajigs® (NBT),
the foundation of the Fabricators & Manufacturers As-
sociation Intl. (FMA), Rockford, Ill.
For the spring 2016 semester, NBT awarded manu-
facturing scholarships to the following students:
Ashley Dale, New Palestine, Ind.—Electrical engi-
neering/physics, Butler University
Veronika Dubravec, Rockford, Mich.—Mechanical
engineering, University of Michigan
Lois Felker, Kirkland, Wash.—Welding technology,
Lake Washington Institute of Technology
Austin Haas, Yakima, Wash.—CNC manufacturing/
machining, Perry Technical Institute
Krystle Hall-Johnson, Maywood, Ill.—Engineering
technology/mechanical design, Triton College
Jeremy Kaszycki, Rockford, Ill.—Manufacturing en-
gineering, Bradley University
Joseph Katula, Yorkville, Ill.—Biomedical and me-
chanical engineering, Case Western Reserve University
Gene Leitheiser, Robins, Iowa—Industrial mainte-
nance technology, Kirkwood Community College
Nikolas Mifsud, Penngrove, Calif.—Mechanical en-
gineering, San Jose State University
Oscar Molina, Rosemead, Calif.—Mechanical engi-
neering, Stanford University
Cody Oberlander, Yakima, Wash.—Instrumentation
and industrial automation technologies, Perry Techni-
cal Institute
Travis Olson, Horicon, Wis.—Welding technology,
Moraine Park Technical College
Tyler Rigby, South Park, Pa.—Mechanical engineer-
ing, Penn State Erie, The Behrend College (John Gross-
heim Memorial Scholarship recipient)
Joshua Smith, Loveland, Colo.—Biomedical and
mechanical engineering, Colorado State University
Ross Snyder, Platte City, Mo.—Mechanical engi-
neering, University of Missouri Kansas City
“We are pleased to award scholarships to these
deserving students and are happy to assist them in
reaching their academic goals,” said Edward Youdell,
president of NBT. “They recognize that skilled manu-
facturing careers can be rewarding financially and ful-
filling personally and will help them be more competi-
tive in the current job market.
“The most difficult U.S. jobs to fill today are those
in the skilled trades and engineering,” added Youdell.
“With majors in robotics and automation, CNC tech-
nology, structural and pipe welding, sheet metal
fabrication, engineering, and precision machining
technology, these students will be prepared for the
skilled-labor openings that American manufacturers
must fill.”
To be eligible for the scholarships, applicants were
required to be full-time students meeting a specified
minimum GPA and enrolled in an engineering or man-
ufacturing-related course of study, or a trade or tech-
nical program leading to a career in manufacturing.
Students were responsible for submitting academic
records and an engineering or manufacturing-related
program description with each application.
In addition to the scholarship, each winner also re-
ceived from NBT’s industry partner SolidWorks® Corp.
a copy of its Student Design Kit CAD software package.
U.S. expected to lead as the top
manufacturing nation by 2020,
says Deloitte report
The U.S. is expected to become the most competitive
manufacturing nation over the next five years, with the
current leader China sliding into second position, ac-
cording to the upcoming “2016 Global Manufacturing
Competitiveness Index” report from Deloitte Touche
Tohmatsu Ltd.’s Global Consumer & Industrial Products
Industry group and the U.S. Council on Competitiveness.
The prediction is based on an in-depth analysis of
survey responses from more than 500 CEOs and se-
nior leaders at manufacturing companies around the
world. The country index rankings are included in a
preview of findings released at the Council’s annual
National Competitiveness Forum held Dec. 4, 2015.
“The ‘2016 Global Manufacturing Competiveness In-
dex’ shows the importance of policy, investment, and
innovation for company- and country-level competi-
tiveness,” said Deborah L. Wince-Smith, president and
CEO of the Council. “Its findings help companies shape
their business strategies in order to compete success-
fully and create jobs.”

The ability of the U.S. to take the top spot may be
largely due to the country’s investment in research,
technology, and innovation, which enhances the
competitiveness of its industries and drives economic
development, according to the study “Advanced Tech-
nologies Initiative: Manufacturing & Innovation,” a
2015 report also published by Deloitte Global and the
Council.
“Manufacturing competitiveness, increasingly pro-
pelled by advanced technologies, is converging the
digital and physical worlds within and beyond the
factory to both customers and suppliers, creating a
highly responsive, innovative, and competitive global
manufacturing landscape,” said Craig Giffi, a leader in
Deloitte U.S. Consumer & Industrial Products Industry
group and co-author of the report.
The index forecasts that the top 11 countries will
remain consistent between now and 2020, with some
exchange of rankings. In addition to China and the U.S.
retaining the top two spots, Germany and Japan will
remain at third and fourth, respectively. India, cur-
rently 11th on the list, is expected to jump to as high
as fifth place. South Korea, Canada, and Singapore
are expected to drop one spot each because of India’s
rise, while Taiwan and the U.K. are expected to drop
two spots. Mexico, meanwhile, is expected to move up
from eighth to seventh.
The next nine spots, however, show how the indus-
try anticipates that developing markets will continue
to mature and become more formidable over the next
five years. Malaysia is expected to rise from 17th to
13th, Vietnam from 18th to 12th, and Indonesia from
19th to 15th. Conversely, European nations including
Switzerland, Sweden, Poland, and Netherlands are ex-
pected to drop as many as six spots in their ability to
compete.
In addition to the country ranking, the report pre-
view identified the top drivers of manufacturing com-
petitiveness. Talent was the leading driver, with access
to skilled workers widely seen by executives surveyed
as the most important factor, followed closely by the
cost of wages and materials. Productivity of the work-
force rounded out the top three.
The availability of a quality local supplier base was
a distant fourth.
Visit www.deloitte.com/globalcompetitiveness to
learn more about the “Global Manufacturing Competi-
tiveness Index” and “Advanced Technologies Initia-
tive” efforts.
Disconnect in pricing, demand will affect
2016 cold-formed steel framing market
Growing demand from the slowly recovering U.S.
construction market, as well as a weakening Chinese
economy, has created a disconnect in the normal
movements of pricing and demand for cold-formed
steel framing and related products, according to Kath-
ryn Thompson, CEO of the Thompson Research Group,
Falls Church, Va.
INDUSTRY NEWS
In a forecast prepared for the Steel Framing Indus-
try Association, Thompson notes that the current
momentum in the construction market is driving in-
creased demand for steel studs and wallboard—a fac-
tor that normally supports increased pricing.
“However, a glut of steel from China and subtle
changes in types of buildings are temporarily keep-
ing a lid on price rises. The good news for 2016 is that
the outlook for construction volumes continues to be
positive. The federal antidumping legislation and con-
tinued calibration of production volumes by domes-
tic mills will ensure that the steel markets remain as
healthy as possible in the current environment,” said
Thompson.
The forecast also indicates that new construction
will be the key driver in both residential and nonresi-
dential construction markets, with growth between 7
and 10 percent; trends throughout Q3 2015 were over-
whelmingly positive.
By the end of 2016, the passage of a federal trans-
portation bill would lift public construction from an
otherwise flat or lackluster performance, the forecast
says.
Larry Williams, executive director of the Steel Fram-
ing Industry Association, said, “For the nimble and
informed, 2016 is a year of opportunity. The prospect
of real growth in the coming year presents to all those
who manufacture, distribute, and install steel framing
the best opportunity in nearly a decade to increase the
use of our products.”
 INDUSTRY NEWS
NIST issues Notice of Intent to fund
new manufacturing innovation institutes
The U.S. Commerce Department’s National Institute of Stan-
dards and Technology (NIST), Washington, D.C., has issued
a Notice of Intent to fund up to two institutes as part of the
National Network for Manufacturing Innovation (NNMI). The
Commerce Department will provide up to $70 million per in-
stitute over five to seven years. Commerce funding must be
matched by private and other nonfederal sources. The insti-
yromeus2005.qxp 11-05-2005 13:20 Side 1
tutes are expected to become self-sustainable within the time
period of the award.
Flexible, effective, fast
Automatic, oscillating deburring system
for stainless, aluminum and other materials.
Deburring of punched,
“The collaborative, cutting-edge technologies being de-
signed, developed, and commercialized at our NNMI institutes
are essential to America’s long-term economic growth, com-
petitiveness, and job creation,” said U.S. Secretary of Com-
merce Penny Pritzker. “Our new institutes will build on the
success of the existing seven, and for the first time, the topic
areas have not been chosen in advance but will depend on in-
dustry interests and input. Together, our growing network of
institutes will ensure America remains on the leading edge of
the 21st century economy.”
“Each institute serves as a regional hub of manufacturing
excellence, providing the innovation
infrastructure to reinforce the competi-
tiveness of the U.S. manufacturing sec-
tor as a whole,” said Undersecretary of
Commerce for Standards and Technol-
ogy and NIST Director Willie E. May.
NIST is open to receiving proposals in
any topic of interest to industry, partic-
ularly those relevant to manufacturing
robotics and biopharmaceutical manu-
facturing. These two subject areas were
identified by the President’s Council of
Advisors on Science and Technology
(PCAST) Advanced Manufacturing Part-
nership as technology areas critical to
supporting national needs.
Jaco Vessel Eng. receives
certification for U and R work
Jaco Vessel Eng., Pico Rivera, Calif., has
obtained certification from ASME for the
manufacture of pressure vessels. It also
has received certification from the Na-
tional Board of Boiler and Pressure Ves-
sel Inspectors for metallic repair.
Tank and chamber work requiring the

laser cut and U stamp is already underway. With the R

certification, the field service group will

machined pieces be positioned to repair and modify met-

al tanks/vessels, piping, and structures.

• No critical heating Meco receives $125,000

voucher for innovation
of the surface Greeneville, Tenn.-based metal fabri-
cator Meco Corp. has been awarded a

• No destruction $125,000 voucher for innovation and

product development as part of a new
of protective foil. program, RevV! This state-funded, $2.5
million pilot program, created by the

• Rounding state of Tennessee in partnership with

the University of Tennessee and the
edges without Department of Energy’s Oak Ridge Na-
damage to the tional Laboratory (ORNL), assists Ten-

surface nessee manufacturers by providing ac-

cess to ORNL researchers and facilities,
with the ultimate goal of producing jobs
• Deburring of in Tennessee.

3 dimensional Meco’s project was one of 13 selected

in the first year. The proposal fell under
pieces is possible. RevV!’s Tier 2 group, which will allow the
56-year-old manufacturing company to
enter into a long-term R&D partnership
with ORNL.
Kennametal completes sale
of noncore businesses
Pittsburgh-based Kennametal Inc. has
Dry, Oscillating Deburring Technique completed the sale of several noncore
businesses related to certain castings,

Hansen & Hundebol Inc. steel plate fabrication, and deburring

operations to Madison Industries.
3402 Oakcliff Road Phone: (770) 452-1271 The sale is in alignment with the com-
Suite B-7 Fax: (770) 452-7090 pany’s previously announced portfolio
Atlanta GA 30340 E-mail: fladder@bellsouth.net simplification strategy and its plans to
Web: www.fladder.com reduce its manufacturing footprint by
20 to 25 percent.

24 The FABRICATOR FEBRUARY 2016

 INDUSTRY NEWS
TRUMPF training earns Waukesha Metal Products welcomes seventh- More than 50 seventh-grade classes from Milwaukee Pub-
certification for student veterans graders as part of Be the Spark campaign lic Schools will have the opportunity to experience hands-on
TRUMPF Inc., a manufacturer of fabri- In December, Waukesha Metal Products, Sussex, Wis., hosted learning, meet industry professionals, and explore potential
cating machinery and industrial lasers 23 students from Alcott School as part of the Metropolitan Mil- career paths at area businesses in an array of fields and in-
for flexible sheet metal processing, has waukee Association of Commerce’s Council of Small Business dustries. This program, underwritten by Southwest Airlines,
announced that its training center in Executives’ (COSBE) Be the Spark Education Tours program. Waukesha Metal Products, and Superior Support Resources,
Farmington, Conn., has been approved The seventh-graders were welcomed by President/CEO grew out of the understanding that the future success of local
by the State Approving Agency (SAA) of Jeff Clark, who also serves as chair of the COSBE Education businesses is rooted in a strong and sustainable workforce. By
the Connecticut Office of Higher Educa-
Committee. The students participated in a short presentation, giving students access to local businesses, they can begin to
tion to train eligible Veterans Affairs (VA)
learned about the variety of career paths in manufacturing,
22851 Fabricator 2016.ai 1 1/11/16 12:15 PM
see how their education and course selection directly relate to
educational beneficiaries.
and toured the stamping and tooling facility. their future careers.
The SAA approval stems from a rigor-
ous application process followed by a
site survey of the training facilities. With
this certification, the training center be-
comes the first and only center in the
machine tool industry that is both IACET-
certified and certified by the SAA to train
eligible veterans. Tuition now is covered
by the VA education assistance program.
Sousa & DeMayo announces
new ownership
Sousa & DeMayo, a 64-year-old custom
design and metal component fabrica-
tion company in Attleboro Falls, Mass.,
has been acquired by mechanical engi-
neer Greg Hunter.
The company, which has been family-
owned until this acquisition, employs
25 people in the production of electri-
cal enclosures for power distribution,
molds for floats used in offshore oil
drilling, display consoles, chassis, plat-
forms, hoppers, and machine guards.
Hunter has 30 years of experience in
product design, engineering manage-
ment, and operations. Under his lead-
ership, the company has purchased
a 4-kW Amada laser, new software to
program the laser, and new electro-
static paint guns. The company also has
expanded its engineering and design
capabilities with the addition of a new
SolidWorks® CAD system.
Miro Tool & Mfg. changes name
to Miro Mfg. Inc.
Miro Tool & Mfg., Waukesha, Wis., has
changed its name to Miro Mfg. Inc. to
represent its expanding manufacturing
capabilities as it transitions from tool
and die shop to metalworking contract
manufacturer.
The company specializes in metal
stamping, fabrication, and machining
and maintains a full-service toolroom to
support its metalworking production.
Since adding stamping capabilities
in the late 1990s, the company has
expanded its fabrication capabilities
with laser cutting, waterjet cutting,
and welding. Plans for 2016 include a
facility expansion to accommodate ad-
ditional machinery, capacity, and grow-
ing business.

FEBRUARY 2016 The FABRICATOR 25

 INDUSTRY NEWS
Commerce Report spotlights benefits to metals
and ores of Trans-Pacific Partnership
U.S. Undersecretary of Commerce for International Trade Ste-
fan M. Selig has released the Trans-Pacific Partnership (TPP)
“Opportunities for the U.S. Metals and Ores Sector Report.”
The report details how the elimination of various tariffs and
other TPP commitments to level the playing field will benefit
U.S. companies competing in TPP markets. The metals and
ores sector includes products such as iron and steel; alumi-
num alloys; titanium products; and ores of molybdenum, cop-
per, and zinc.
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The U.S. metals and ores industry employed 1 million work-
ers in 2014. During the same time period, exports totaled $3.1
billion to the TPP markets where the U.S. does not currently
have trade agreements. The report details the current barriers
the sector faces in TPP countries and demonstrates how the
industry stands to benefit once the trade agreement enters
into force.
Currently there are five TPP countries with which the U.S.
does not have preferential market access: Brunei, Japan, Ma-
laysia, New Zealand, and Vietnam. Once TPP becomes law:
• Japan will eliminate import taxes on 99.7 percent of U.S.
metals and ores exports immediately.
• Brunei will eliminate import taxes
on 99.3 percent of U.S. metals and ores
exports immediately.
• Vietnam will eliminate import taxes
on 85.1 percent of U.S. metals and ores
exports immediately and 95.4 percent
within four years.
• Malaysia will eliminate import taxes
on 80.4 percent of U.S. metals and ores
exports immediately and 86.8 percent
within four years.
To view the full report, visit www.
trade.gov/fta/tpp/industries/metals.asp.
Entertainment Mfg. Group
expands anodizing plant
in Florida
Entertainment Mfg. Group, a high-pre-
cision metal production manufacturing
and cabling company, has opened the
doors on its new anodizing division,
Halo Metal Finishing, in its Fort Myers,
Fla., manufacturing facility. The expan-
sion has more than doubled the size of
the company’s facilities and includes the
addition of manufacturing equipment.
With a working envelope of 22 by
74 by 60 in. and a three-bar operation,
the new anodizing equipment has the
capacity to run thousands of parts per
shift. “We have been utilizing the anod-
izing process on our own in-house metal
projects and now feel confident to offer
the process to the public for their use,”
said CEO Kevin Kirchner.
The division currently offers Type I
and Type II automated anodizing in un-
dyed and organic black colors. The next
phase of the expansion will include a
five-color system and powder coating,
which will continue to be used in-house
and offered to the public.
ARaymond celebrates
150 years of innovation
The ARaymond Network, a provider of
fastening and assembly products for the
automotive industry, marked 150 years
in business in 2015.
The firm was founded in Grenoble,
France, in 1865 by Albert-Pierre Ray-
mond. While looking for a more practi-
cal fastener to replace the traditional
glove button, he invented the press
stud. Since then, led by five generations
of the same family, the company has
evolved from a small factory into a com-
pany with global reach.
The ARaymond Network now has
design offices and manufacturing facili-
ties in 25 countries, including the U.S.,
Brazil, China, India, Russia, Thailand,
Singapore, Korea, and locations within
Europe.
26 The FABRICATOR FEBRUARY 2016

Deere announces factory
workforce adjustments
Deere & Co. has informed about 220
employees at John Deere Seeding and
Cylinder in Moline, Ill., that they will be
placed on indefinite layoff effective this
February.
The layoffs reflect the company’s fore-
cast that agricultural machinery sales
will decrease in fiscal year 2016. Deere
said the actions are taken to align the
size of the manufacturing workforce at
individual factories with market demand
for products made at each location.
In the past manufacturing employ-
ees at John Deere Seeding and Cylinder
have experienced seasonal layoffs in
the spring and returned to work in the
fall. This layoff is indefinite with no spe-
cific call-back date.
Continued growth predicted in
aluminum extrusion market
RnRMarketResearch.com, Maharashtra,
India, has released its “Global Aluminum
Extrusion Market Report”, which predicts
the aluminum extrusion market will
grow at 7 percent CAGR through 2019.
Growth in the automobile industry
is anticipated to drive the growth of
this market during the forecast period.
Aluminum extrusion is replacing steel
in some vehicles because of its light
weight, leading to fuel savings and re-
duced greenhouse gas emission. Alumi-
num also is easily recyclable and corro-
sion-resistant.
The report segments the aluminum
extrusion market into mill-finished,
anodized, and power-coated products.
The mill-finished segment accounted
for 58 percent of the market share
during 2014 and is expected to reach
around 13 million metric tons by the
end of 2019.
Building and construction is the larg-
est end-use market for aluminum ex-
trusions. The growth of this segment is
anticipated to be at a rate of 7 percent
during the forecast period.
China accounted for about 62 per-
cent of the global market share for alu-
minum extrusions during 2014, and its
share is expected to grow at a rate of 7
percent during the forecast period.
The complete report is available at
www.rnrmarketresearch.com/global-
aluminum-extrusion-market-2015-
2019-market-report.html.
NAM releases study examining
benefits of crude oil pipelines
A new study from IHS Economics and
commissioned by the National Associa-
tion of Manufacturers (NAM), Washing-
ton, D.C., reveals the impact crude oil
pipelines have on U.S. manufacturing
growth and employment and the ad-
vancement and development potential
for manufacturers if new crude oil pipe-
lines are constructed.
According to the study, 6,805 miles
of new crude oil transmission pipelines
were constructed in 2015 in the U.S. at
a cost of $11.57 billion. This is on top of
61,379 miles of U.S. onshore crude oil
pipelines operating at the end of 2014.
From both construction and mainte-
nance in 2015, crude oil pipelines sup-
ported 276,497 jobs, including 26,884
manufacturing jobs. The top employ-
ing industries for crude oil pipelines
INDUSTRY NEWS
include fabricated metals, machinery,
chemicals, nonmetallic minerals, and
primary metals.
Crude oil pipelines contributed $31.4
billion to GDP, including $4 billion from
manufacturing. At least 66 different
manufacturing subsectors, out of 86
total, benefited from the construction
of crude oil pipelines by $10 million or
more in 2015 alone. These include iron
and steel, fabricated metals, cement,
machinery, and paints and coatings. To
read the full study, visit www.nam.org.
Epic Systems completes
automated welding application
for Titanova
Design-and-build integration company
Epic Systems Inc., St. Louis, recently de-
signed, engineered, and built a custom
automated laser welding machine for
Titanova Inc. to use in its laser job shop.
Titanova offers heat-treating, clad-
ding, remanufacturing, brazing, and
welding services, as well as process de-
velopment, metallurgical analysis, X-ray
alloy analysis, and integrated laser pro-
cessing systems.
 INDUSTRY NEWS
Plant News
Amsterdam-based Constellium N.V. has announced plans to
construct a new facility in Bartow County, Ga., for the manu-
facture of aluminum automotive structures. Construction of
the plant—a $20 million investment by Constellium and a $12
million investment by developer Seefried Properties—will be-
gin in early 2016, with start of production anticipated in 2017.
The planned 84,000-sq.-ft. greenfield facility may be ex-
panded up to 220,000 sq. ft. to adapt to customers’ supply
needs in the future. The company expects to create about 150
high-tech manufacturing jobs at this location by 2019.
www.ati-ia.com/utilitycoupler
“ We had seconds to connect air,
Hangzhou, China-based DunAn Group has announced
plans to open its first U.S. manufacturing facility, DunAn Pre-
cision Inc., in Memphis, Tenn. The facility, which will produce
heat exchangers, will create more than 100 jobs. The site is ex-
pected to open in early 2016.
General Motors will invest more than $356 million in a new
engine line in Flint, Mich., and driveline and powertrain com-
ponents in Saginaw and Grand Rapids, Mich., creating more
than 50 jobs and helping to retain nearly 500 positions.
As part of an amended agreement with the Michigan Strate-
gic Fund under the Michigan Economic Growth Authority tax
credit program, GM will invest $1 billion in Michigan by 2030.
OCT Pipe has announced plans to
build a 1 million-sq.-ft. seamless steel
pipe manufacturing facility in Norfolk,
Neb. The $111 million project is expect-
ed to create 180 jobs. Completion is an-
ticipated in July 2017.
Universal Trailer Corp. is construct-
ing a 200,000-sq.-ft. manufacturing plant
in Bristol, Ind. According to the com-
pany, the facility will feature advanced
manufacturing techniques not currently
used in the cargo trailer industry.
The firm manufactures for the en-
closed cargo, horse, livestock, motor-
sports, snowmobile, ATV, motorcycle,
utility, vending, and custom specialty
trailer categories.
Winnebago Industries, an Iowa-
based recreational vehicle maker, has
announced plans to open a manufac-
turing facility in Junction City, Ore. The
plant, expected to open in the second

fluid and power to an assembly half of 2016, will employ 200 people.
Shop installs duplex milling
platform. Hello ATI.” machine
Gardena, Calif.-based
TCI Precision Met-
als has installed an
Amada THV430 du-
plex milling machine. According to the
company, the machine provides four
times the output of traditional milling
machines to help shorten customer
lead times.
The firm’s Custom Machine-Ready
Blanks™ are milled in width and length,
using the machine’s twin spindle, in one
setup instead of two. One or more of the
blanks can be produced together up to
the machine’s overall dimensional ca-
pacity of 16.93 by 16.93 by 5.91 in.
The blanks are milled to the cus-
tomer’s net specifications and can be
furnished as close as ±0.0005 in. dimen-
sionally and as close as 0.0002 in. in flat-
ness, squareness, and parallelism.
Precoat Metals acquires
some assets of Consolidated
Metal Products
The fully automated ATI Utility Coupler delivers what no manual St. Louis-based coil coater Precoat Met-
solution can. Speed and reliability. Unique among all other automated als has acquired the metal coil coating
solutions, ATI’s built-in engineered rotational compliance ensures reliable and processing assets of Consolidated
coupling. And our common mounting flats are compatible with ATI’s vast Metal Products (CMP), a business unit of
selection of tool changer utility modules. ATI is also compatible with Consolidated Systems Inc. (CSi).
DeviceNet, Ethernet and Profinet. So, if you’re ready to add a new level of The assets, located in Columbia, S.C.,
speed and reliability to your manufacturing process just say, “Hello ATI.” will be operated as Precoat Metals – Co-
See it now at www.ati-ia.com/utilitycoupler. lumbia, a toll processing facility offering
the application of paints and other coat-
ings and films to metal coils, in addition
to slitting, blanking, leveling, emboss-
ing, and packaging services.
www.ati-ia.com/utilitycoupler Precoat Metals, a unit of Sequa Corp.,
operates 16 coil coating lines in 14 loca-
tions, with more than 1,000 employees.

28 The FABRICATOR FEBRUARY 2016


Steel News
Steel producer Nucor has announced it
will close its St. James Parish direct re-
duced iron facility in Baton Rouge, La.,
following scheduled maintenance and
not reopen until prices for raw materials
improve.
“Operating performance at the steel
mills segment in the fourth quarter of
2015 is expected to decrease from the
third quarter of 2015,” Nucor said in a
news release. “Our sheet and bar steel
mills in particular have experienced de-
creased margins as selling prices have
Flack Steel purchases
CSi’s Consolidated Metal Products business
Cleveland metal service center Flack Steel Ltd. has completed
a transaction with Consolidated Systems Inc. (CSi) for the pur-
chase of selected assets of its Consolidated Metal Products
(CMP) business. The acquisition expands Flack Steel’s product
offering and market penetration opportunities for bare and
painted carbon steel, galvanized steel, stainless steel, and alu-
minum.
The deal includes the working capital and associated non-
physical assets, including the trade name of Consolidated
INDUSTRY NEWS
Metal Products. The deal does not include the coil coating line
and processing equipment in Columbia, S.C.
CMP will continue to supply painted and processed metal
products for the construction, appliance, and transportation
markets.
Per the agreement, more than 20 CMP purchasing, sales,
quality, and marketing professionals will join Flack Steel but
continue to operate out of the Columbia office.
This is the second significant expansion for Flack Steel in
as many years. In 2013 Flack Steel Ltd. merged iwth GlobeNet
Metals LLC to form a new steel sales model.

ARE YOU ?
eroded more than the decline in raw
material pricing.”

THE KELLER LINE

SMS group has completed the mod- Vent Box Flap Pipe
ernization of the compact strip pro-
duction (CSP®) mill at Nucor Steel in
Berkeley, S.C. The modernization of the
double-strand machine, supplied by
SMS group in 1996, included increasing
the final strip width to 74 in.
In addition, one of the two casters
was fitted with new molds, a new four-
cylinder oscillation system, wider seg-
ments, and a new bending and straight-
ening unit. A seventh finishing stand
and a new X-Pact® level-2 automation
system were added to the rolling mill.
CAN YOUR EQUIPMENT WITHSTAND THIS?
The automation system includes pro-
file, contour, and flatness control sys-
tems, as well as a cooling model.
SMS also installed an induction heat-
ing system between the furnace and IM VE EFFICIENCY
rolling mill so that the temperature of
the thin slabs can be increased right be- OPTIMIZE YOUR CESS
fore they run into the rolling mill.
United States Steel Corp., Pitts-
burgh, has temporarily idled its Granite
City Works steelmaking and finishing
TECT YOUR PEOPLE
operations in Granite City, Ill.
The idling is part of an ongoing ad-
justment of steelmaking operations
throughout North America to match
customer demand.
The company routinely adjusts pro- Ask the ‘s for your
duction at its operating facilities to re-
flect market fluctuations. This is a result
Dust / Mist / Wet solution.
of continued challenging global market
conditions including fluctuating oil pric-
es, reduced rig counts and associated
inventory overhang, depressed steel
prices, and unfairly traded imports,
which continue to have a significant
impact on the business, the company WE CLEAN THE AIR
states.
KELLER USA, INC. FORT MILL, SC WWW.KELLERUSA.COM 803-396-2000 SOLUTIONS@KELLERUSA.COM
FEBRUARY 2016 The FABRICATOR 29
 INDUSTRY NEWS
Supplier News
Abtex Corp., a manufacturer of machine/brush deburring sys-
tems for the manufacturing industry, is completing a 66 per-
cent expansion of its production facilities in Dresden, N.Y. The
additional space is required to expand the company’s brush
manufacturing capacity in response to increasing market-
place demand.
In addition, the firm has been named 45th in the Rochester
Top 100 program, presented by the Rochester Business Alli-
ance Inc. and KPMG LLP. The program recognizes the fastest-
growing private companies in the Rochester, N.Y., area.
TUBE TO SHEET.
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The LC5 Fiber Laser for tube & sheet
is the only fiber laser production machine tool that
can process tube and flat sheet, all in one machine.
Thanks to its design, switching from tube to sheet is
immediate, automatic and does not require retooling.
Changeover with the LC5 is fast, making it an
attractive addition to your metal processing capability
and a production workhorse.
The machine can handle bar up to 255" in length,
and tube to 4.75" diameter. The processing of sheet
metal is fully automatic and allows for sheet up to
118" x 354".
Equipped with a fiber laser with power to 3 kW,
an automatic pallet changer and independent controls
for both tube and sheet, the LC5 is an ideal choice for
tube and sheet processing.
LC5
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30 The FABRICATOR FEBRUARY 2016
Industrial oven manufacturer Davron Technologies Inc.
has added 20,000 sq. ft. to its facility in Chattanooga, Tenn.,
doubling the floor space devoted to heavy manufacturing
and enlarging its electrical shop. This expansion responds to
the company’s 100 percent increase in sales volume and 50
percent increase in manufacturing workforce over the last 16
months.
Davron’s sister company, Metro Services Inc., which had
shared the building, has been relocated to another facility,
freeing up an additional 7,500 sq. ft. of warehouse space for
Davron. This space will be used as a dedicated area for stock-
1/4/16 2:36 PM
ing and staging components for its in-
dustrial ovens, such as burner, convey-
or, and ignition control parts.
Kalamazoo, Mich.-based Dimplex
Thermal Solutions (DTS), the North
American chiller manufacturer of Kool-
ant Koolers, has announced a strate-
gic partnership with Glen Dimplex
Deutschland, the Germany-based
manufacturer of Riedel process cooling
equipment, to offer global distribution
of both product lines. Both companies
are owned by the Glen Dimplex Group
of Ireland.
Riedel chillers are used to cool laser
applications. Koolant Koolers chillers
are designed for the machine tool in-
dustry, specifically for filtration, heat in-
duction, resistance welding, laser, and
spindle cooling applications. The two
brands now will be aligned through the
DTS sales network.
Dynabrade Inc., an industrial abra-
sive power tool manufacturer based in
Clarence, N.Y., has acquired the assets
of National Detroit Inc., Rockford, Ill.,
a manufacturer of pneumatic abrasive
power tools. Production operations will
be relocated to Dynabrade’s Clarence,
N.Y., headquarters.
National Detroit’s product line in-
cludes random orbital and gear-driven
sanders, buffers, polishers, grinders,
and related accessories.
Exact Metrology has signed an agree-
ment with ProCon X-Ray for exclusive
rights to distribute the company’s prod-
uct line throughout the U.S. Located in
Germany, ProCon manufactures X-ray
and CT systems for industrial nonde-
structing testing applications.
Products vary from portable units
and desktop models to full-size, stand-
alone systems. Each of the standard
units can be customized to meet cus-
tomer-specific job requirements.
Exact Metrology offers portable scan-
ning and measurement technologies,
as well as contract measurement for
2-D and 3-D laser scanning services,
reverse engineering services, noncon-
tact inspection, metrology services, 3-D
digitizing and training, and CT scanning
services.
Industrial abrasives manufacturer
Flexovit USA Inc. is rebuilding its man-
ufacturing and warehouse facilities in
Angola, N.Y. Most of the 100,000-sq.-ft.
facility collapsed from record snowfall
that hit the western area of New York
in November 2014, dumping 5 to 7 ft. of
snow in 48 hours.
Since that event the company has
resumed manufacturing of resin-

reinforced grinding/cutting wheels and
abrasive flap discs in undamaged sec-
tions of the property. It also has main-
tained sales and distribution services at
its four distribution centers.
Rebuilding of the 62,000-sq.-ft. plant
and warehouse will restore the compa-
ny’s full production capabilities. Com-
pletion is expected in fall 2016.
bination plasma/waterjet machines and waterjet surface tex-
turing technology. The CAD/CAM software has been tailored to
suit each machine in its range.
Matheson, a provider of welding and industrial gases, sup-
plies, and equipment based in Basking Ridge, N.J., has ac-
quired 3-D Welding & Industrial Supply Inc., an independent
welding supply company with seven facilities in central Texas.
Matheson is the largest subsidiary of Taiyo Nippon Sanso
Corp. Group.
Custom coating provider MetoKote Corp., Lima, Ohio, has
announced the acquisition of Malcolm Enamellers ACP Ltd.
(Malcolms), a coating company in Wednesbury, U.K.
INDUSTRY NEWS
Now a wholly owned subsidiary of MetoKote Corp., Mal-
colms currently houses two electrocoat lines that can process
parts up to 10 ft. and 1,100 lbs., as well as a dual-purpose sys-
tem that provides powder coating and wet painting. Malcolms
is accredited to BS EN ISO 9001:2000 quality standards by BSI
and has an in-house testing laboratory.
Falmouth, Maine-based Southworth Intl. Group, a pro-
vider of ergonomic material handling equipment, announced
the acquisition of Marco Group AB, a European manufacturer
of similar lifting and positioning technologies in Ängelholm,
Sweden.
(continued on page 33)

Hardide Coatings, a provider of

advanced surface coating technol-

IT’S MORE THAN

ogy based in Oxfordshire, U.K., has an-
nounced that its Hardide-A tungsten
carbide coating has met the technical
performance requirements as a poten-
tial alternative to hard chrome plating WELDING. IT’S ART.
on some specific Airbus aircraft com-
ponents, such as airframe and landing
gear components.
Following an eight-year program of
development and testing, the carbide
coating has met the Airbus require-
ments for thick chemical vapor deposi-
tion (CVD) tungsten carbide coatings. It
is considered a suitable alternative for
hard chrome plating, the use of which is
being banned in September 2017 under
EU REACh environmental health and
safety regulations, unless otherwise
authorized by the EU Commission, as
it uses carcinogenic hexavalent chro-
mium salts in its production. Increas-
ingly tight restrictions are also being
imposed in the U.S. by OSHA. Whether you need a welding power source, a robot, or a complete system that
brings it all together, OTC DAIHEN offers a full suite of high quality welding
The coating is resistant to abrasion,
solutions. OTC DAIHEN has the tools for today’s metal artist.
erosion, corrosion, chemicals, and im-
pact. Applied by low-temperature CVD,
the process can coat external and inter-
nal surfaces as well as complex shapes.

MANUAL SINGLE SOURCE PRE-ENGINEERED

Lantek, Mason, Ohio, has reached a WELDING PACKAGES ROBOTIC SYSTEMS
global agreement to supply its Lantek
Expert CAD/CAM software with Monza,
Italy-based Waterjet Corp.’s line of wa- 1400 Blauser Dr, Tipp City, OH 45371
www.daihen-usa.com
terjet cutting machines. 888-OTC-ROBO
The waterjet machines include can-
tilever, bridge, and 5-axis flying-bridge
designs. The company also offers com-

FEBRUARY 2016 The FABRICATOR 31

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 INDUSTRY NEWS
(continued from page 31) Website News Plus Ten Stainless, Benicia, Calif., has introduced a rede-
The acquisition accelerates South- signed website at www.plustenstainless.com. The mobile-
Appleton, Wis.-based arc welding product manufacturer
worth’s presence in both the European friendly, updated website offers quick access to the compa-
Miller Electric Mfg. Co. has unveiled a redesigned website at
and Asian markets, and it supplements ny’s product catalog.
www.millerwelds.com. The site has been streamlined and
the company’s existing product supply Features include immediate search and quote access, com-
optimized for use on mobile devices.
in China for both domestic and interna-
Visitors can log in to the site or through a social media ac- prehensive technical information, and details on square and
tional trade.
count and create a profile to review product registrations, pre- parallel cold saw cutting services.
United Generations LLC, Wauke-
vious orders, and newsletter subscriptions. The site features The company supplies stainless steel plate, duplex stain-
gan, Ill., a privately held family holding
a more consistent approach to product categories and allows less steel plate, Prodec® plate, and aluminum plate, as well as
company, has acquired the Pangborn
customers to filter, sort, compare, and buy select products FIRSTCUT+® precision cold saw cutting services.
Group, a designer, manufacturer, and
supplier of surface preparation equip- and accessories quickly and
CSU-201601-Fabricator Std easily, the company
Full FBTCH states.
CANADA.qxp_CSU-Fabricator Std Full Pg 1/13/16 12:55 PM Page 1 (continued on page 34)
ment and related aftermarket parts and
services, from Atlas Holdings LLC.
Based in Fairburn, Ga., Pangborn
employs more than 250 people at nine
facilities around the world. All locations
will remain in operation, and the com-
pany headquarters will continue to be
led by the current management team.
Wagner Group, Elgin, Ill., has an-
nounced the acquisition of C.A. Tech-
nologies LLC, a manufacturer of spray
guns, paint finishing equipment, pre-
cision atomizing nozzles, and aircaps
based in Louisville, Colo. Wagner Group
manufactures liquid coating, powder
coating, and dispensing systems.
K&K Industries expands
prototype manufacturing
Custom sheet metal fabricator K&K
Industries, Bellingham, Wash., has ac-
quired Automated Metal Technologies,
Redmond, Wash. With this acquisition,
the company has added 8,500 sq. ft. of
manufacturing capacity, new equip-
ment and technology, and now can
deliver prototype parts in three to five
days and follow-on production quanti-
ties in less than two weeks.
K&K’s equipment includes lasers; tur-
ret punches; press brakes; hardware
insertion machines; GMAW, GTAW, and
spot welding machines; and a 4-ft.-wide
Surface Finishing Tools
graining machine. Its lasers can cut mild
steel up to 1.0 in. thick, stainless to 0.5 for Metalworking
in. thick, and aluminum up to 0.25 in.
thick.
Steel u Stainless Steel u Aluminum
Joining Technologies launches
full-service machine shop
Joining Technologies Inc. has opened is your power tool source.
a full-service machining facility at its
headquarters in East Granby, Conn. The
shop provides weld tooling and fixtures
Find your solution… visit www.csunitec.com
to the company’s multiple divisions and When it comes to industrial applications, you need power Scan to watch
directly to customers.
tools you can rely on to get the job done. CS Unitec's
Joining Technologies offers preci-
industrial power tools and accessories are built to last. Our
sion fusion processes, including laser
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line of surface finishing tools grind, bevel, deburr, prep and
ditive manufacturing, and weld system finish steel, stainless steel, aluminum and more. Demo Videos
design and integration for joining metal
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FEBRUARY 2016 The FABRICATOR 33
 INDUSTRY NEWS
(continued from page 33)
SuperMax Tools, St. Paul, Minn., a manufacturer of drum
and brush sanders, has announced the launch of a redesigned
website at www.supermaxtools.com.
The home page offers a new Popular Products section.
Product pages now include tabs with machine specifications,
features, videos, and frequently asked questions. Additional-
ly, the new website allows users to share products and pages
that interest them with others across Facebook, Twitter, and
Google+.
A streamlined dealer locator map lists dealers within a 200-
mile radius when searching by zip code.
YOUR INDUSTRIAL
SUPPLY DESTINATION
LOCAL PRODUCTS. LOCAL EXPERTS. LOCAL SOLUTIONS.
While other national suppliers tout 24 to 48 hour lead times, we’ve built our business
to provide today’s needs today – from tools and abrasives, to MRO items and safety
supplies – with customized local inventory to support your business, best-in-class
vending and bin stock solutions that keep product flowing to your points of use, and
metalworking experts who will present the most efficient products for your operation.
IT’S ALL RIGHT AROUND THE CORNER AT YOUR LOCAL FASTENAL STORE
Material handling equipment provider UniCarriers Ameri-
cas Corp., Marengo, Ill., has launched a new website at www.
unicarriersamericas.com, offering mobile-friendly content,
search function, and updated equipment information.
The new site also features an improved dealer portal, put-
ting all of the dealer resources in a single location. Dealers
have access to training, marketing, analysis, software, and
administration tools.
The United States Cutting Tool Institute (USCTI), Cleve-
land, has launched its Careers In Manufacturing website at
www.mfgcareers.org. The website promotes careers in
manufacturing and provides resources
for students, educators, parents, and
manufacturers.
The site was developed to help iden-
tify training resources for careers in
manufacturing and to provide other in-
formation about the opportunities that
are available.
“We developed this site to help pro-
mote manufacturing as a viable and
rewarding career option,” said Steve
Stokey, USCTI president. “There are
many misconceptions about manufac-
turing today. Today’s manufacturing
provides clean and modern facilities
and careers that vary from skilled labor
to plant management to engineering.”
In addition to the links to industry
resources, the site also includes blogs
with news about manufacturing ca-
reers, internships, externships, and ap-
prenticeships. The site will be updated
on a regular basis to promote Manufac-
turing Day and other local and regional
efforts to support U.S. manufacturers.
People News
Abtex Corp., Dresden, N.Y., a manufac-
turer of brush and machine deburring
systems for the manufacturing indus-
try, has promoted Damian Clemens
to systems group manager. Clemens
joined the company in 2014 when Abtex
acquired his employer, Nihmble Tech-
nologies.
Aperam Stainless Services & Solu-
tions USA, a provider of stainless steel
products in Sterling Heights, Mich., has
hired Subramaniam (Mani) Manivan-
nan as director of operations and con-
tinuous improvement.
Manivannan previously worked at
Ford Motor Co. in assignments includ-
ing supply chain, warranty, lean, and
powertrain quality lead. He also has
served as supply chain manager at Rolls
Royce, as global lean production sys-
tems continuous improvement director
at Franklin Electric, and was in charge of
quality/lean at Accuride Corp.
Chicago-based Charter Steel, a steel
service center that distributes ferrous
metals, has hired Damon Wos as vice
president, sales and member of the ex-
ecutive team. He oversees the commer-
cial and service groups and contributes
to the strategic direction and manage-
ment of the company. Wos previously
worked at Central Steel & Wire Co. for 15
years in various sales and management
positions.
CMS North America, a manufacturer
of waterjet cutting systems and CNC
machines in Caledonia, Mich., has hired
Brian Sherick as national sales manag-
34 The FABRICATOR FEBRUARY 2016
 INDUSTRY NEWS
er for the waterjet Born July 26, 1925, in Brooklyn, N.Y., Engelberger earned the American Machinist Award, the Golden Omega Award at
division. a bachelor’s degree in physics and a master’s degree in elec- the Electrical Electronics Insulation Conference, the McKech-
Sherick has 19 trical engineering from Columbia University. He founded nie Award from the University of Liver-
years of experi- Unimation Inc. in 1956, the world’s first industrial robotics pool, the Egleston Medal from Columbia
ence in the wa- manufacturer. Working closely with inventor George Devol, he University, the Beckman Award at the
terjet industry, developed the first industrial robot in the U.S. LabAutomation Conference, and the Ja-
having previously Engelberger has been inducted into the U.S. Manufacturers pan Prize.
Brian Sherick led a sales region Hall of Fame, the National Academy of Engineering, and the Epic Systems Inc., a St. Louis- based
for Flow Intl. Corp. In his new role, he is Connecticut Academy of Science and Engineering. Other ac- design and build firm, has hired Jacob
building the sales organization through colades include the SME Progress Award, the Nyselius Award Jacob Becker Becker as project engineer. Becker has
direct sales efforts and partnering with from the American Die Casting Institute, the Leonardo da Vinci
(continued on page 36)
strategic distributors. Award from the American Society of Mechanical Engineers,
Coldwater Ma-
chine Co., Coldwa-
ter, Ohio, a produc-
er of equipment
for discrete manu-
facturing, has ap-
Patrick Morris
pointed Patrick
Morris as new business development
manager focusing on the aerospace
and aviation markets in the Southeast
region. Morris has extensive sales ex-
perience in the aerospace and aviation
industries, having served as sales man-
ager at Unison Industries and most re-
cently Eaton Aerospace.
Metal fabrication firm DeWys Mfg.
Inc., Marne, Mich., has hired Ryan
Crandell as weld engineer overseeing
all manual and robotic weld process-
es. Crandell has a bachelor’s degree in
welding engineering technology and an
associate degree in welding technology
from Ferris State University, as well as an
Associate of Science degree from Grand
Rapids Community College. While in
school he had a yearlong internship at
DeWys Mfg., where he worked to im-
prove automation capabilities. He pre-
viously worked as a production welder
for nine years.
Duval Precision Grinding, Chicopee,
Mass., a provider of precision grinding
services, has hired Jeff Hockenberry as
production manager. He is responsible
for scheduling jobs, providing technical
support on the machine floor, produc-
tion control, expedition of lead times,
and coordination of outside services.
Hockenberry has more than 20 years of
experience in the machining and grind-
ing industry, as well as FAA overhaul re-
pair and aerospace manufacturing.
Joseph F. Engelberger, an engi-
neer and entrepreneur who pioneered
the robotics field, died Dec. 1, 2015, in
Newtown, Conn. Widely known as the
“Father of Robotics” and creator of the
world’s first industrial robot, Engelberg-
er revolutionized modern industrial and
automotive manufacturing processes
and went on to establish robotics in hu-
man services. He was 90 years old.

FEBRUARY 2016 The FABRICATOR 35

 INDUSTRY NEWS
(continued from page 35)
a degree in electrical automation tech-
nology and control system technology
from Ranken Technical College.
The company also has promoted Eric
Coale to business development coordi-
nator. Coale joined the company almost
three years ago as business develop-
Eric Coale ment and sales assistant.
Fives Group, Hebron, Ky., has ap-
pointed Stéphane Mayer as new head of the metal cutting
and composites business line. Mayer has held several aero-
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space leadership positions, including president/CEO of Daher ing role in business development, and
and CEO of ATR. Rob Doneth has been promoted to
president. Doneth has been with the
Wes Paisley has been appointed interim CEO at Fives Ma-
company for four years, serving previ-
chining Systems Inc. Paisley has been with Fives Group since
ously as an automation manager.
2005. He has served as CEO of Fives North American Com-
Mark Ross has been named the CEO/
bustion and CEO of Fives Intralogistics. He also serves on the
CFO. He has been with Hawk/ALM Posi-
board of directors for Fives Inc.
tioners for three years, formerly serving
Hawk Technology Ltd., a designer and manufacturer of tool-
as president of ALM (an independent
ing, fixtures, robotics integration systems, and vision inspection subsidiary of Hawk Technology) and
systems in Rock Island, Ill., has announced several promotions. CFO of Hawk.
Josh Clare, previous president/CEO, has taken on the lead- Houghton Intl. Inc., Valley Forge, Pa.,
a provider of metalworking fluids and
services, has appointed Mike Shannon
as CEO. He joined the company as vice
president of global operations, supply
chain, IT, and EHS in 2009, most recently
serving as COO.
Marcello Boldrini has become presi-
dent, Asia Pacific, in addition to his
previous roles as senior vice president,
Houghton Intl. and president, Global
Mining and Metals. Boldrini joined
Houghton in Au-
gust 2015.
Tulsa, Okla.-
based Mathey
Dearman has
hired Mike Brace
as key account
Mike Brace manager. He has
more than 20 years of sales and opera-
tional experience. A previous employee
of Miller Electric, Brace is an AWS cer-
tified welding inspector and an AWS
certified welding sales representative.
Mathey Dearman designs and builds
cutting and beveling machines and
clamping, aligning, and reforming sys-
tems for pipe and tubing.
Methods Ma-
chine Tools Inc.,
a supplier of pre-
cision machine
tools, automa-
tion, and acces-
Brittany Speroni
sories based in
Sudbury, Mass.,
has announced
that Brittany
Speroni, mechan-
ical engineer, has
been named as a
2015 recipient of
Manufacturing En-
Peter Jung gineering maga-
zine’s 30 Under 30
Automatic Traversing
Container Load Systems awards for her talent and leadership in
science, technology, engineering, and
mathematics (STEM). She joined the
company in 2012 and works in the au-
tomation department designing robot
end-of-arm tools, as well as quoting and
managing projects.
36 The FABRICATOR FEBRUARY 2016
 INDUSTRY NEWS
The company also has announced APPLUS RTD; general manager at UT Quality; and quality man- dent of North American sales and marketing. He has nearly
the appointment of Peter S. Jung to the ager/project manager at Tyco Thermal Controls. three decades of experience in industrial manufacturing and
position of marketing manager. Before United States Steel Corp., Pittsburgh, has announced that distribution. He formerly served as senior vice president of
joining Methods, he spent four years as Geoff Turk, vice president - service center solutions, will pursue sales and marketing for ITW Welding Group and also worked
deputy general manager of sales and other opportunities following the recent at Detroit Diesel Corp. and Cummins Inc.
marketing at Doosan Infracore America. transition of the commercial entities. He Doug Schenher, previously vice
Before that Jung held positions of pro- will lead the integration of the industrial president of customer satisfaction, has
gressive responsibility in web develop- and service center solutions teams until assumed the role of corporate vice pres-
ment, IT, digital marketing, and plan- completion in Q1 2016. ident, providing leadership and guid-
ning at various companies. Dayton, Ohio-based Yaskawa Moto-
8187 New Koike BrdsLine Fabricator Feb-2016 1/8/16 12:30 PM Page 1 ance on organizational development
Steel product manufacturer Nucor man has announced that Scott Jenkins and planning for the Motoman Robotics
Corp. has announced that Chairman Scott Jenkins has joined the company as vice presi- Doug Schenher (continued on page 38)
Emeritus and former President/CEO
Daniel R. DiMicco has been inducted
into the North Carolina Business Hall
of Fame by the Junior Achievement of
Central Carolinas and the North Caro-
lina Chamber of Commerce.
DiMicco led Nucor Corp. from Sep-
tember 2000 through December 2012.
During this time, Nucor completed
more than 50 acquisitions for a total in-
vestment of $6.5 billion. In 2008 DiMicco
received the Charlotte Business Jour-
nal’s Business Person of the Year Award.
The Harvard Business Review included
him in its 2010 top 100 list of “The Best
Performing CEOs in the World,” and he
is a member of the IndustryWeek Manu-
facturing Hall of Fame.
Richmond, Ind.-based Osborn, a sup-
plier of industrial brushes, polishing
compounds, and buffs, has hired Steve
Economos as its western territory sales
manager for its Load Runners® division
of idler rollers, cam followers, and rail
systems.
In this role, he is responsible for man-
aging the company’s sales team in the
California, Washington, Oregon, Utah,
Arizona, New Mexico, Colorado, Idaho,
Texas, and Montana territories. Econo-
mos has more than 15 years of experi-
ence working in sales, management,
and business development.
Roll-Kraft, a tooling supplier to the
tube and pipe and roll forming indus-
try based in Mentor, Ohio, has named
Sanjay Singh as president. He joined
the company in 2013 as executive vice
president. Former President Chuck
Gehrisch, who has led the company
for decades, will continue in his role as
chairman and CEO.
Stanley Inspection, a Houston-based
provider of inspection, NDT, and heat-
treating services and a division of Stan-
ley Black & Decker, has named Jeremy
Guretzki as its new president. He has 29
years of experience in the energy sector
and 25 years in the NDT/inspection busi-
ness, previously serving as general man-
ager at Shaw Pipeline Services. He also
worked as operations manager at JNX/

FEBRUARY 2016 The FABRICATOR 37

 INDUSTRY NEWS
(continued from page 37)
Division and the
Drives & Motion
Division. Schen-
her has been with
the company for
11 years.
Doug Burn-
Doug Burnside side, previously
senior director of customer care, has
been promoted to vice president of cus-
tomer satisfaction. He has been with
the company for 10 years.
Laboratory Testing announces
continuation of Nadcap
accreditation
Hatfield, Pa.-based Laboratory Test-
ing Inc. (LTI) has been audited and ap-
proved for continued accreditation by
the Performance Review Institute Aero-
space Program (PRI Nadcap).
The renewed accreditations demon-
strate conformance for NDT services
(liquid penetrant testing, magnetic par-
ticle inspection, and ultrasonic testing)
and Aerospace Quality Systems AC7004.
The full-service testing and calibration
laboratory also holds Nadcap accredita-
tion in materials testing.
The IFH Group acquires
Bowman Mfg.
The IFH Group Inc., Rock Falls, Ill., a
producer of industrial fluid storage and
handling systems and fabricator of cus-
tom hydraulic reservoirs and fuel tanks,
has acquired Bowman Mfg. Co. Inc., Ar-
lington, Wash., to create The IFH Group
West LLC.
Bowman’s manufacturing operation,
in an 88,000-sq.-ft. facility, is based on
precision sheet metal fabrication capa-
bilities, augmented by design engineer-
ing, value-added assembly, and engi-
neering support. New capabilities that
the acquisition brings to IFH include
manufacturing of custom enclosures
such as chassis for audio switching
equipment, backup power stations, so-
lar system battery enclosures and ma-
rine diesel, as well as kiosk design and
fabrication.
Women in Manufacturing,
CWRU partner to bring
executive education, training
to women
National association Women in Manu-
facturing™ (WiM) and Case Western
Reserve University’s (CWRU) Weath-
erhead School of Management have
announced the creation of a Leader-
ship Lab for Women in Manufacturing,
which will provide executive education
and training to WiM members in mid- to
high-level management roles in manu-
facturing careers.
Scheduled to launch in spring 2016,
the program comprises three sessions
over eight days on topics including bias
barriers and opportunities, leadership,
and skills and strategies.
Courses will be held on the CWRU
campus in Cleveland and taught by fac-
ulty members Dr. Diana Bilimoria, Dr. El-
len Van Oosten, and Dr. Kathleen Buse.
Registration rates for the Leadership
Lab for Women in Manufacturing pro-
gram depend on the size of the com-
pany, and scholarship opportunities
may be available from WiM based on
specific eligibility requirements.
For more information, contact Kris-
tin Moore at 216-503-5700 or kmoore@
womeninmfg.org.
Precision Cut Industries
acquires Marelco
Contract manufacturer Precision Cut In-
dustries (PCI), Hanover, Pa., has acquired
Washington, D.C.-based Marelco Inc.
The new division will complement
PCI’s current capabilities of laser cut-
ting, welding, forming, and assembly.
Marelco’s core competencies are
punching metal components, forming,
welding, CNC machining, wet painting,
and silk screening.
Marelco has been in business for 30
years and employs about 20 people.
PCI, founded in 1998, employs about
100 people.

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38 The FABRICATOR FEBRUARY 2016

practi 1926-01 Fabricator_Print_Ad_v1.indd 1 12/9/15 12:07 PM
 FROM THEFABRICATOR.COM
Read more from Nick Martin at
www.thefabricator.com/author/nick-martin

11th
A job to remember ANNUAL

Even when the shop floor is hectic,

custom fabricators will go the
extra mile to “do the right thing”

M
any customers walk in our shop and want something right then and there.
This is fine for small jobs, as we are one of the dying breed of shops that still
take walk-ins. Often we don’t have time to complete these small orders and
are better off letting them simmer for a few days until we can work them in. Feb. 24-26, 2016
Sometimes you get a call like we did this past Friday. The lady on the phone Paradise Point Resort & Spa
seemed a bit distressed and needed a coffin made for her dog that just passed away. San Diego, Calif.
She called at 11 a.m., and we normally close at noon on Fridays. Leaving early makes
for a nice weekend, but as anyone in our shop will tell you, Fridays are extremely
hectic. We try to pack in a full day’s work in half the time, and something always pops
up that has to be done that day.
It would be safe to say that everyone at Barnes MetalCrafters loves dogs. My dad,
Tim Martin, the shop owner and the owner of two dachshunds, talked to the lady on
Amada America Inc. Invites YOU
the phone and said we would make the coffin for her. We had around an hour to com- to the 2016 Technology Update
plete this task that not many shops would even attempt or take on. But nobody wants during The FABRICATOR®’s
to be in the position the dog owner was in, so we all felt the need to help her out.
Leadership Summit
Dad handed me a piece of paper with a
sketch he drew when he was on the phone Join Jason Hillenbrand, Laser
with the anxious caller. He told me to make Product Manager (pictured), and
a NEMA 3 enclosure to the dimensions (see fellow machine tool suppliers as
Figure 1). We quickly told the team what
they discuss equipment advances
available to improve production
was going on, and they were ready to tackle
and increase the bottom line during
this job. The FABRICATOR®’s 11th Annual
Laser operator Jason Barnes met me at Leadership Summit on Thursday,
Figure 1 my desk and asked what metal we needed. Feb. 25 in San Diego, Calif.
This box was quickly fabricated to accom- I told him at least a full sheet of 14-ga. gal-
modate a request from a walk-in customer The experts on the panel will
vanized and a small drop. He took off, and I
looking for a coffin for her dog. showcase their cutting edge
began to key the numbers into a template solutions allowing you to compare
I had in Autodesk® Inventor®. I had this thing designed and nested on the laser in and contrast processes. Mark your
about 10 minutes. calendar for this popular, open
I left my office and told Jason I would find a drop of 14-ga. galvanized if he wanted exchange to get your questions
to get the first sheet cutting on the laser. Nick Trueheart was at the press brake and answered about opportunities
asked for the drawings so that he could tool up the machine. available in today’s fabrication
This was a pretty familiar job for Nick, so he set up the brake and was ready to start market—you’re sure to be on the
folding up the parts as soon as they were ready. A few minutes later, Jason and Nick road to excellence with a clear
were walking the parts to the brake where the correct program was all ready to go. sense of emerging trends for
In about six bends these parts were making their way to a welding table where
2016 and beyond.
Randy Davis was ready to do his part. He was prepared to stay late if needed to help

REGISTER TODAY!
out the customer.
About 20 minutes later, Randy was letting his welds cool before applying some
cold galvanizing spray to protect them. We also decided to add some handles to the
enclosure to make it easier to carry. Luckily, we had some of these lying around. We
put them on and added some spray paint on those welds. Conference Fees:
Dad and I stuck around the shop for a few minutes after noon so that we could help $945 FMA members / $1,195 General
the customer load the enclosure in her car. It barely fit in her backseat. The whole
situation was a bit awkward because she had her two kids with her. She wasn’t in
the best of spirits, and I politely told her that I was sorry. She just smiled and said,
Visit fmanet.org/annualmeeting
“Thank you.” or call toll-free 888-394-4362.
Most shops wouldn’t jump on this job like we did, but sometimes you have to do
the right thing. She told us she didn’t have anywhere else to go to get the job done. Platinum Sponsor:
Given that this wasn’t the most difficult job to do, we knocked it out extremely fast
and made the customer happy.
Nick Martin is a product designer, Barnes MetalCrafters Inc., 113 Walnut St. West, Wilson,
NC 27893, 252-291-0925, www.barnesmetal.com. Image courtesy of Barnes MetalCrafters.
www.amada.com
FEBRUARY 2016 The FABRICATOR 39
 APPLICATIONS

Tooling with scan-in programming helps increase production by 60 percent

SITUATION
Recently a national customer of ALM Positioners
needed tooling for a positioner it was purchasing
for its assembly line.
The customer had been using a manual fixture to
make 15 assemblies per day. The required unbolt-
ing, moving of the fixture, and rebolting onto a new
fixture added time and labor to the process.
RESOLUTION
ALM Positioners referred the customer to Hawk
Technology Ltd. Hawk designed and built tooling
with a user-interface PLC that allowed the customer
to scan in the required part information in about 15
seconds.
Since every assembly that comes through pro-
duction is different, the programming has been very
significant in increasing efficiencies. With the new
tooling and programming, production has jumped
to an average of 25 assemblies per day—an increase
in production of more than 60 percent. The time to
change out a tool has decreased by 15 minutes per
assembly.
Hawk now is transitioning the ALM hydraulic posi-
tioners into servo positioners to help condense floor
space. The firm also is implementing a new process
for design and job flow for the customer, creating
process sheets (design and job) and conducting and
implementing safety studies.
Hawk Technology Ltd.
8080 Centennial Expressway
Rock Island, IL 61201
309-787-6200
www.hawktechnology.com

Satellite dish assembly process tweaks result in

labor savings, throughput increases for metal stamper
SITUATION
Highlands Diversified Services (HDS), London, Ky.,
is a provider of metal stamping, secondary opera-
tions, powder painting, and assembly serving the
automotive, appliance, telecommunication, aero-
space, and office equipment markets.
In the manufacture of a satellite dish assembly
(dish, mounting base, and support arm), HDS’s pro-
duction process was not as fast and effective as de-
sired. Stamping press operators and paint-line work-
ers were dependent on a forklift to remove their full
totes and bring them parts, respectively. Operators
placed stamped satellite dishes on paint racks that
held only two dishes at a time. All of the components
of the dish assembly were packaged on an entirely
manual packaging line.
With these methods, the company completed 228
skids per shift.
RESOLUTION
HDS recently reviewed the entire process and made
improvements across the board. First, it created a
staging area dedicated to the satellite dish assem-
bly only. Located close to the paint line, the staging
area has reduced the time spent by the forklift driv-
er handling associated totes, reducing forklift driver
labor by 25 percent per shift.
The company redesigned the paint rack to hold
four dishes rather than two. With this new configu-
ration, the company paints an average of 6,000 dish-
es per shift—a throughput increase of 100 percent.
Two robots have been installed at the end of the
line to place the assembly kits on pallets. A stretch
wrapper has been added, eliminating manual wrap-
ping of finished pallets. These packaging improve-
ments have resulted in a labor reduction of 25 per-
cent (three individuals from the packaging line).
With the robots and stretch wrapping, workers can
complete 240 skids per shift—a throughput increase
of 5 percent.
Highlands Diversified Services Inc.
250 Westinghouse Drive, London, KY 40741
606-878-1856
www.hds-usa.com

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40 The FABRICATOR FEBRUARY 2016

 PRODUCT HIGHLIGHTS
Multiprocess welding system provides
industrial-quality arc in compact package
ESAB has introduced the
Rebel™ EMP 215ic, a 120-
to 230-V, CC/CV welding
system that offers true
multiprocess arc perfor-
mance and portability. A
sMIG (smart MIG) func-
tion enables users to be-
gin GMAW with a stable
arc by setting metal thickness and wire diameter. There is no need to enter
information for shielding gas mix.
The unit provides an industrial-quality arc for GMAW, FCAW, lift GTAW, and
SMAW and delivers excellent performance with E6010 electrodes, states the
company.
The machine has basic and advanced operating modes. The operator inter-
face combines traditional weld parameter adjustments with the functionality
of a smartphone.
ESAB Welding & Cutting Products
411 S. Ebenezer Road, Florence, SC 29501
800-372-2123
www.esabna.com
Don’t settle
for less cuts
than what you
should be getting.
Don’t be fooled by cheap imitation cut-off
blades from other suppliers that under-
perform and can ruin your production runs.
For over 70 years, Steelcraft Tool Company
has revolutionized cut-off blades for the
tube and pipe industry. Count on Steelcraft
Tool Company for the best products, with
the best service, at the best value.
We’ve been making cut-off blades
better and longer than any one
Proudly Made in USA else in the industry.
call 734.522.7130 fax 734.522.1134
email STCTOOL@aol.com
42 The FABRICATOR FEBRUARY 2016
2-D laser cutting machine available
with 8-kW laser
TRUMPF offers the TruLaser
5030 fiber, the first 2-D laser
cutting machine available
with an 8-kW TruDisk laser.
The machine can process
complex contours and thin
sheets; the BrightLine fiber,
CoolLine, and PierceLine func-
tions allow processing of thicker materials as well. This results in greater ma-
terial tolerance while enabling more intricate material contours and tighter
layout of parts, states the company.
The Smart Collision Prevention feature helps minimize the risk of collisions
during laser cutting. The function analyzes the cutting process to determine
where cut parts are likely to tip and adjusts the processing strategy. This can
most often be achieved without adding microjoints to the part.
The Drop&Cut feature enables operators to use part skeletons for additional
production. Operators are provided with a live image of the machine’s interior
on the control unit’s interface. From the control unit, the operator clicks or
taps the screen to drag the programmed contour to the desired location on
the projected sheet and initiates the cut.
TRUMPF Inc.
111 Hyde Road, Farmington, CT 06032
860-255-6104
www.us.trumpf.com
Band saw cuts metal tube
in upward direction
Kasto Inc. has introduced the KASTOwin
tube A 5.0, a fully automatic band saw de-
signed for cutting tubular material. The
blade cuts from the bottom of the tube in
an upward direction as opposed to cutting
from the top of the workpiece downward.
The upward travel of the blade helps re-
duce blade wear and prevent damage to
the blade teeth than can occur when a blade travels downward into chips that
have accumulated inside the tube, the company reports.
Downward travel makes it difficult to use carbide-tipped blades for sawing
tubes, as the delicate teeth can be damaged easily, making a bimetal blade
typically the only option. According to the manufacturer, this saw is intended
to use carbide-tipped band saw blades to achieve higher production rates.
Cutting capacity is 20 in. dia. on round tube, and the shortest cutting length
is 0.40 in. The frequency-controlled drive can achieve variable cutting speeds
from 40 to 490 SFPM. The upward travel of the saw head is equipped with zero-
play linear guides, while a precision ball screw helps ensure controlled cutting
feed rates.
The intelligent touchscreen SmartControl sawing machine controller con-
tains all the material data and automatically sets all the necessary sawing
parameters. The KASTOrespond system developed for this machine continu-
ously records the cutting forces at the blade and uses an intelligent algorithm
to convert them into optimized saw feed rates, the manufacturer states.
KASTO Inc.
3002 Venture Court, Export, PA 15632
724-325-5600
www.kasto.com
 PRODUCT HIGHLIGHTS
One-step polish process achieves Automated robotic bending cell handles
#8 mirror finish small, complex parts
Walter Surface Technologies Amada’s EG 6013 AR automated robotic
has announced new innova- bending cell combines a servo-electric press
tions to its portfolio of stain- brake with an advanced bending robot. The
less steel polishing products. high-speed system is suitable for small,
The Instant Polish Line is complex parts, eliminating the need for hu-
available in three formats: man operation and the associated risk of
preapplied on the Quick Step dealing with difficult-to-handle small parts.
Instant Polish Disc and the In- The compact cell is engineered for the unattended production of any lot size
stant Polish Belt, and as a stand-alone paste. or part mix. Equipped with what the company says is the world’s first twin
The products combine the strength of the company’s white and blue polish- servo-electric drive system, the cell offers high-speed and -accuracy bending
ing pastes into a one-step process that achieves a #8 mirror finish. The prod- with lower power usage, says the manufacturer.
ucts eliminate the need to clean in between polishing steps and reduce the Features include automatic angle measuring, offline programming, multi-
frequency of consumable changeover. ple part load/unload stations, and an automatic tool changer. The 6-axis robot
Walter Surface Technologies travels along the ground in front of the press brake. Loading can be performed
810 Day Hill Road, Windsor, CT 06095 from a variety of positions, offering a large capacity for raw materials. Several
860-298-1100
unloading options also are available. Completed parts can be stacked by the
www.walter.com
robot, placed in boxes, or placed on a synchronized conveyor belt.

Tube cutting system employs Amada America Inc.

7025 Firestone Blvd., Buena Park, CA 90621
direct-diode laser 877-262-3287
www.amada.com
Mazak Optonics Corp. has de-
veloped the Versatile Compact
Laser (VCL) Tube-100 laser
cutting system, designed for
low-volume tube and bar com-
ponents up to 4 in. dia. (3 in.
square) and lengths up to 25 ft.
The machine uses a direct-diode laser. It includes a fiber delivery system,
and the generator has similar cut performance to fiber generators in mild and
stainless steel. According to the company, direct-diode cuts aluminum fast-
er than fiber generators while remaining more energy-efficient and offering
modular flexibility.
Mazak Optonics Corp.
2725 Galvin Court, Elgin, IL 60124
847-252-4500
www.mazakoptonics.com

Abrasive wheels designed for removal

of laser brazes
Rex-Cut has created the Type 1 Laser
Braze finishing wheel, constructed with
the measurements needed to remove la-
ser brazes in automotive manufacturing.
According to the manufacturer, the cotton
fiber wheels complete braze finishing in
half the time it takes using the standard
unitized Type 1 wheels.
The wheels’ layered construction cre-
ates a durable, dense wheel that stays straight when removing laser brazes.
This eliminates side deflection, in which the wheels bend slightly, causing
them to hit the base metal instead of just the braze.
Rex-Cut Products Inc.
960 Airport Road, Fall River, MA 02720
800-225-8182
www.rexcut.com/laser

FEBRUARY 2016 The FABRICATOR 43

 PRODUCT NEWS
Automatic crowning system
Gasparini has intro-
duced the X-Press press
brake with ACSG active
crowning. A sensor in
the ram detects bow-
ing. Cylinders in the table raise the die,
while another sensor measures the
height. When the two values are equal,
punch and die are at the same distance,
and the profile has a constant angle
across its length.
The tailor-made press brake is built
entirely by the manufacturer, including
the frame and hydraulic circuit.
Gasparini
39-0422-8355
www.gasparini.it/en
Metal Market Advertising Showcase
Autodarkening filter
3M™ has introduced
the Speedglas™ auto-
darkening filter (ADF)
kit 9100XXi. The op-
tics provide detail, contrast, and natu-
ral-looking color for welders.
An external grinding feature enables
welders to switch into a grinding mode.
They can access two preset welding
modes by pushing the button on the hel-
met’s front panel, without having to re-
move their safety gloves or helmet. The
grab-and-go feature automatically turns
the welding filter on to the last setting.
3M
800-328-1667
www.3m.com/ppesafety
Parts supplier E-book
Precision Metal Industries (PMI) has
published an e-book titled Save Money
and Improve Quality on Your Complex
Sheet Metal Assembly AT THE SAME TIME.
The e-book is designed to help com-
panies that are deciding to manufacture
parts from sheet metal to choose the
best manufacturer. The e-book explains
how to conduct a careful evaluation of
the manufacturing company and which
factors to consider. Topics include dif-
ficulties in sheet metal manufacturing
processes, repeatable production, and
short-term savings.
Precision Metal Industries
954-942-6303
www.pmiquality.com
Weld shaver
Heck Industries has
added a new hand-
held weld shaver
to its line of fabri-
cating equipment.
The weld shaver uses standard carbide
inserts in a milling cutter to shave weld
beads flush to a workpiece.
Used for cleaning butt welds and cor-
ner welds, the unit removes only the
weld without damaging surrounding
materials such as conventional grind-
ing of joints. The 2-HP model WS-625
removes welds at 6 to 8 FPM.
Heck Industries
800-886-5418
www.heckind.net

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en•gaged
adj \in-'gājd, en-\
definition: involved
in activity
The FABRICATOR’s

Your message
belongs here.

is an official Web site of the Fabricators

& Manufacturers Association, Intl.®

44 The FABRICATOR FEBRUARY 2016

 PRODUCT NEWS
Punch/fiber laser Compact welding machines package and the low spatter control and pulse multicontrol
combination machine Fronius has introduced the TPS 270i processes developed for TPS/i are available as options.
C Pulse and TPS 320i C Pulse with in- Features include drive rollers color-coded according to the
tegrated wire-feed unit. Designed for wire diameter, a viewing window that helps the user check
welding currents of up to 270 amps quickly how much wire is left, and a straightforward user in-
and 320 amps, respectively, the com- terface.
pact welding machines are suitable for Options and accessories include gas or water cooling, re-
GMAW, GTAW, and electrode welding. mote control, and a PullMig welding torch.
In addition to the pulse welding Fronius USA LLC
The LC 2515 C1 AJ punch/laser combi- package included as standard, the standard Fronius welding 219-734-5701
nation machine from Amada America www.fronius.com
Inc. features a 2-kW fiber laser that pro-
vides up to 70 percent electrical savings
when compared to a CO2 system, the
company reports. The fiber laser can
cut reflective materials such as copper,
brass, and titanium.
The laser head moves in the Y axis
via a direct-drive servomechanism. It
is isolated from punching vibration to
help maintain beam integrity and cut
quality. A gap near the laser axis is engi-
neered to allow cutting gas and slag to
escape without affecting processing. A
cartridge-type lens provides for simple,
fast lens changes. In addition, the use
of noncontact sensor technology helps
ensure that the laser beam remains fo-
cused on the sheet.
The system features a 49-station
Multi-Purpose Turret (MPT), which in-
cludes four tapping tool stations and
three die lift stations. The die stations
lift automatically to facilitate upward
forms while reducing material scratches
and preventing downward forms from
hitting the forming dies during sheet
movements. A brush table automati-
cally lifts to support the material and
provide scratch-free processing to elim-
inate the need for secondary finishing.
Amada America Inc.
714-739-2111
www.amada.com

Electric press brake

SafanDarley has introduced the 44-ton

E-brake Ergonomic portable, high-
speed electric press brake. It offers a
working length of 5 ft., an open height
of 23 in. standard, and a 12-in. stroke
standard for bending small parts.
Rapid acceleration and deceleration
of the electrical servo-driven ram deliv-
ers approach speeds up to 430 IPM. The
machine has a compact footprint of 101
by 69 in.
Safan B.V.
41-573-222-222
www.safandarley.com

FEBRUARY 2016 The FABRICATOR 45

 PRODUCT NEWS
Edge-rounding line add automated cutting and material handling capabilities. Saw blade performance
HGG Profiling Equipment has The line includes a conveyor for in-and-out material feed, monitoring
introduced an edge-rounding aligning rollers to position and guide material, and an edge-
rounding unit to stabilize and round the bottom and then
line, which imparts a smooth,
top flanges. The line also includes a handling conveyor for
rounded surface edge on I/H-
outfeed to a revolver, which revolves material so that the top
beams, T’s, and flat bars to
flanges can be rounded in turn once bottom flanges have
prevent corrosion and elimi-
been rounded.
nate the need for grinding.
HGG Profiling Equipment
The line is available as a stand-alone machine, or it can be 330-461-6855
integrated with the company’s robotic profile cutting line to www.hgg-group.com Cosen Saws has introduced MechaLogix
Cosen Predictive Computing, a cloud-
based system with a feature that moni-
tors the performance of a blade and can
accurately forecast the number of re-
maining cutting hours left before a saw
blade dulls and is no longer cutting with
precision, or a complete breakage.
It’s your world. The system reports issues such as

Shape it as you please. excessive vibration, overheating, and

changes in fluid line pressure in real
time. The technology can be custom-
In the hands of skilled craftsmen,
our steel becomes the parts, components and ized by the user, and adjustable alert
products that make the world turn. For over notification settings work seamlessly
65 years, fabricators and manufacturers big and with the mobile app, according to the
small have trusted Admiral Steel to help them manufacturer.
leave their mark on the world. For any size order
Cosen Saws
from 10 lbs. or 10,000, you get first-class quality, on-time
877-729-4641
delivery, and personalized service from Admiral. Contact
www.mechalogix.com
us for a quote today!
Fiber laser
™
JMT has introduced the HDFL fiber la-
ser, which incorporates a high-power
Admiralsteel.com
ISO 9001 REGISTERED fiber delivery system from IPG Photon-
ics and a ProCutter head from Precitec.
4152 West 123rd Street Alsip, Illinois 60803-1869
Ph: 800-323-7055 Fax: 708-388-9317 email: sales@admiralsteel.com The dustproof head protects the
Admiral is a registered trademark of Admiral Steel LLC. Alsip, Illinois. beam path from contamination. Its fully
Reg. No. 2430959. All rights reserved. integrated sensor system monitors the
cutting process and provides the user
with relevant information via machine
controls, head-mounted LEDs, and a
Bluetooth® system that interfaces with
the operator’s smart device.
The system features a Lantek Expert
Cut CAD/CAM system with automatic
nesting.
JMT USA
855-773-7727
www.jmtusa.com

Degreaser
WD-40 Co. has introduced WD-40® Spe-
cialist® industrial-strength degreaser.
Featuring PowerSolve Technology™, a
solvent that breaks down grease, oil,
and dirt quickly, the degreaser works on
a variety of surfaces.
The product’s Smart Straw® sprays as
a pinpoint stream when flipped up or as
a wide spray when flipped down. The
degreaser formula is VOC-compliant in
all 50 states.
WD-40 Co.
888-324-7596
www.wd40specialist.com

46 The FABRICATOR FEBRUARY 2016

 PRODUCT NEWS
Press brake tooling Magnetic drill with automatic feed and other metals. Additional capabilities include twist drilling
Wilson Tool CS Unitec’s MAB 825 V portable magnetic drill and reaming up to 1¼ in. dia., tapping up to 1⅛ in. dia., and
International® features an automatic feed mechanism with countersinking up to 2 in.
has intro- power retraction, which makes it suitable for The unit has a quick-change keyless cutter system for ¾-in.
duced the LVD production applications. Weldon shanks. Among its integrated sensors are magnet
style line of The 16-amp, double-insulated reversible overheating protection, visual magnet adhesion indication,
press brake motor has a 4-speed oil bath gearbox (40-110, and an electronic safety shutoff sensor that shuts down the
tooling. The punches and dies are laser- 65-175, 140-360, 220-600 RPM) for applica- drill motor if the magnet loses contact with the material.
hardened, and dies are Nitrex®-treated. tions requiring high power. CS Unitec Inc.
They feature LVD’s patented STONE® With infinitely variable torque control and full-wave elec- 800-700-5919
radius die design to help ensure accu- tronics, the drill cuts holes up to 4 in. dia. in structural steel www.csunitec.com
rate bend angles along the full length of
the bend and reduce friction between
material and die, the company says. Die
Your Solutions Partner!

youtube.com/user/rexcutabrasives | linkedin.com/company/rex-cut-abrasives | twitter.com/RexCut

heights are designed to work with LVD’s
Easy-Form® system.
Wilson Tool International
866-752-6531
www.wilsontool.com
Apex Machine Group offers
Press brakes high-quality production
sanding machines for
processing steel, stainless

Reaching New Heights in Production!

steel, aluminum, alloys and

NEW
composites.

QUICK CHANGE DISC Deburring Machines • Edge Radius Machines • Slag Grinders • Finish Sanders
Brush Sanders • Top / Bottom Sanders • Machines widths from 13” to 82”

MAX
Aluminum • Mild Steel
Stainless Steel • Nickel
The TruBend Series 3000 press brake Alloys • Kevlar • Brass
from TRUMPF Inc. features a closed- This versatile disc outlasts We produce
frame design that provides high rigidity coated quick change discs 5:1 the most
for improved precision. The backgauges Want to see for yourself? adjustable and
effective line of
can move across the entire length of the Request a sample by visiting brush sanders on
machine bed, enabling unrestricted use www.rexcut.com/qcdmax the market.
when bending at the ends of the ma-
chine. Automatic CNC crowning allows
constant angles. www.rexcut.com
products@rexcut.com Toll-Free: (855) 500-2739
As the fastest machine in its class, the 1-800-225-8182 Time Saving Solutions www.apexmachinegroup.com | info@apexmachinegroup.com
TruBend 3100 also features a press force
of 110 tons and a bending length of 118
in., the company states. The machine
comes standard with a 2-axis back-
gauge, with the option to expand to a
4- or 5-axis backgauge. Suitable for en-
try into precision bending, the machine
allows the operator to draw and pro-
gram parts graphically with multitouch
control. The exact bending parameters
are calculated automatically based on
data that the manufacturer has derived
from decades of experience in precision
bending. Pre-existing programs are im-
ported via a USB interface or a network
connection.
Third-party tools can be used with-
out an adapter to upgrade bending ca-
pabilities to the 3000 series. The user
selects from a number of different tool
clamping concepts. Manual clamping
comes standard, with the upper and
lower tools secured with Allen screws.
The quick-clamp option facilitates rapid
clamping of the upper tools with a lever.
TRUMPF Inc.
860-255-6104
www.us.trumpf.com

FEBRUARY 2016 The FABRICATOR 47

 PRODUCT NEWS
Lifting device This freestanding, plug-and-play system incorporates G-
Gorbel has announced the avail- Force® Intelligent Lifting technology with the body of an ergo-
ability of its new Easy Arm® 660 lift- nomic articulating jib crane.
ing device. With spans up to 14 ft., the system handles pick-and-place
With load capacity up to 660 lbs., operations. The unit can reach lifting speeds up to 45 FPM for
the unit addresses a variety of ap- high-production environments.
plication needs from placement of
Gorbel
automobile engines to loading of 800-821-0086
large plates in CNC machines. www.gorbel.com
Deburring
Precision Edge Rounding
Deslagging
& Finishing Edge Rounding
Laser Oxide Removal
Surface Finishing
WEBER PT
Perfect metal machining at its best
 Up to 4 stations
 43", 53" and 63" widths
 New generation Weber
"i-Touch" screen control
 Variable grinding belt length
 CBF technology for a perfect surface finish
 Easy accessibility for maintenance
 Modular design for flexible station arrangement
 Optional top/bottom machining
 MRB brush system for perfect edge deburring
Hans Weber Sales & Service
P 913.254.1611 • F 913.254.1582
sales@weberamerica.com • www.weberamerica.com
PT_halfpg.indd 1
48 The FABRICATOR FEBRUARY 2016
Wet scrubbers
A new line of
Handte Vortex wet
scrubbers from
Camfil Air Pollution
Control (APC) offer
wet dust collection
with plug-and-play
operation and low
maintenance, the
company reports.
The units are suitable for capture of
very sticky dusts and fibers, for process-
es with high fire loads and flying sparks,
and for filtration of highly explosive
dusts—particularly for applications in
which NFPA standards state that dry dust
collection systems are not appropriate.
Because they provide wetting of com-
bustible dusts, the scrubbers can elimi-
nate the need for ancillary explosion
protection devices.
The scrubbers use combined princi-
ples of water swirl and disintegration to
provide two levels of separation of dust
particles traveling through the system.
The scrubbers work best with medium-
to large-grain emissions and provide 99
percent removal efficiency on particles
of 3.0 micron and larger. Moist, clean air
is exhausted through a central air outlet.
The water level is automatically con-
trolled, feeding in fresh water as needed
to ensure that the concentration of dust
particles in the scrubbing fluid is kept
below required thresholds.
Camfil APC
800-479-6801
www.camfilapc.com
Applications laboratories
Amada Miyachi America Inc., Monrovia,
Calif., offers a range of fully equipped
applications laboratories focused on
developing and enhancing produc-
tion processes for manufacturability.
Customers send their samples to the
laboratory for a free process develop-
ment consultation, and the company’s
engineers determine the most suitable
equipment and methods to address
specific needs.
Applications engineering staff can
provide assistance with eight different
process technologies: resistance weld-
ing, reflow soldering/bonding, resis-
tance seam sealing, projection welding,
and process monitoring, as well as laser
welding, cutting, micromachining, and
marking. In-house experts can also pro-
vide consultation on part design, mate-
rial selection, and manufacturability.
Amada Miyachi America Inc.
626-303-5676
www.amadamiyachi.com
1/19/2016 3:49:11 PM

Plasma cutting electrodes
Hypertherm has introduced SilverPlus®
electrodes for its HySpeed® HSD130
plasma cutting systems. In the com-
pany’s laboratory testing, the electrode
has been shown to last more than twice
as long as a standard copper-tipped
electrode. According to the manufac-
turer, the electrode delivers 4 and 5 cut
quality consistently throughout its life.
The electrodes are created by fusing
a solid silver tip onto a copper electrode
base and then inserting a hafnium pin
into the tip. This helps slow the elec-
trode’s wear rate, as the silver disperses
the heat better than copper, says the
company.
The bond between the hafnium and
silver allows for consistent wear rates,
deep pits, and robustness to ramp
down errors and hard failures.
Hypertherm
800-643-0030
www.hypertherm.com/silverplus
CMM tube inspection software
Hexagon Metrology has announced
the release of its TubeShaper software
for the portable Romer Absolute Arm
CMM tube inspection system. The new
software is designed to apply the CMM’s
measurement capabilities to tube pro-
duction, tube and pipe inspection, re-
verse engineering of tubes and tube as-
semblies, and tube gauging.
TubeShaper is based on an intuitive
GUI with two operator access profiles.
Measurement plans can be created
automatically in first-part inspection
or set up offline before measurement.
The CAD engine enables the import and
export of tube data in various formats,
as well as the inspection of full tube as-
semblies, including welded brackets,
hangers, and flanges.
The software can interface directly
with one or more CNC tube benders. As
a result, correctional data can be calcu-
lated and applied within the production
cycle, which streamlines operations and
almost completely eliminates scrap, the
company states.
Hexagon Metrology
855-443-9638
www.hexagonmetrology.us
FEBRUARY 2016 The FABRICATOR 49
PRODUCT NEWS
Lift magnets
11th
ANNUAL
Techniks offers EZ-Lift magnets for load-
ing and unloading ferrous stock, includ-
ing plate, block, and round steel and
press molds. The user centers the mag-
net on the metal to be lifted and turns Feb. 24-26, 2016
the lever to engage the magnet.
Paradise Point Resort & Spa
The units feature rare-earth mag- San Diego, Calif.
nets rated to lift up to 6,600 lbs. Using
spreader bars increases capacity up to
13,500 lbs. According to the manufac-
turer, lifting magnets improve safety,
ease of use, and speed compared to
BLM GROUP USA Corporation Invites
sling and strap systems.
Techniks YOU to the 2016 Technology Update
800-597-3921
www.techniksusa.com
during The FABRICATOR ®’s
Leadership Summit
Multistack tube cold
bending machine Join Lindley Searles, North American
Schwarze-Robitec offers the CNC 220 Product Manager, Benders, End
HD MW heavy-duty multistack tube cold Finishing & Cutting (pictured), and
bending machine. It processes tubes fellow machine tool suppliers as
with a maximum diameter of 8.63 in.
they discuss equipment advances
available to improve production
and up to 19.7 ft. long.
and increase the bottom line during
Offering quick setup time, the bend-
The FABRICATOR ®’s 11th Annual
er processes materials such as steel,
Leadership Summit on Thursday,
copper-nickel-iron alloys, and stainless Feb. 25 in San Diego, Calif.
steel. It can bend thin- and thick-walled
tubes with different diameters at the The experts on the panel will
same time. showcase their cutting edge
The tube is clamped in the index head solutions allowing you to compare
and positioned in space by means of and contrast processes. Mark
your calendar for this popular, open
the transport unit and index head. Af-
exchange to get your questions
ter the first bend, the tube is removed
answered about opportunities
and turned if necessary, creating 3-D
available in today’s fabrication
tube systems without an excess of weld
market—you’re sure to be on the
seams.
road to excellence with a clear
Schwarze-Robitec America Inc. sense of emerging trends for
231-598-9125 2016 and beyond.
www.schwarze-robitec.com
REGISTER TODAY!
Waterjet cutting machines
Semyx offers standard and custom wa-
terjet cutting machines for a variety of
cutting applications in the aerospace,
automotive, marine, and military/
Conference Fees:
defense industries. $945 FMA members / $1,195 General
Each series of waterjet cutting ma-
chines is customizable. Users can pick
Visit fmanet.org/annualmeeting
features that are most suitable for their
applications, such as tank or pit instal- or call toll-free 888-394-4362.
lation, hydraulic lifting arms, combina-
tion cutting heads, dual cutting heads, Platinum Sponsor:
dual Z-axis, and multiple gantries.
Semyx LLC Mention this BLM GROUP
877-787-3699 USA Corporation ad and your
www.semyx.com registration could be free!
www.blmgroup.com
 PRODUCT NEWS

Oval suction cups Rotary draw tube bender Degreaser Optics for high-power
Fipa Inc. has intro- The Ercolina Top Bender 050 Plus mod- Bio-Circle, a di- fiber lasers
duced two new se- el rotary draw tube and pipe bender vision of Walter Mate Laser Technologies has introduced
ries of oval suction simplifies programming and allows the Surface Tech- 1 Micron Optics for high-power fiber la-
cups for sheet metal operator to store and produce the de- nologies, has in- sers. The products include lenses, pro-
handling. The SM- sired bend angle in seconds. troduced Alustar tective windows, and nozzles for several
OF (flat) and SM-OB The new color-coded control displays 100 for cleaning laser system brands.
(bellows) series pro- machine position and all current func- and degreasing The optics feature extremely low-
vide slip-free han- tions on one screen. Bend angle can be aluminum and absorption, fused-silica substrates. The
dling of dry and oily adjusted accurately by degree anytime nonferrous al- low-absorption, antireflective coat-
metal sheets in a variety of automotive, throughout the bending cycle. The ma- loys in automated and ultrasonic parts ings on the lenses and windows have a
metal processing, and mechanical and chine stops at the desired bend angle au- washers. high laser damage threshold. The low-
plant engineering applications. tomatically to end the cycle. The operator The mild alkaline cleaner contains absorption feature helps ensure high
Suitable for use in constricted spaces, can use the control panel or foot pedal to built-in foam- and corrosion-inhibitor cutting quality without thermal lensing
the suction cups are designed with mul- activate bend and return functions. packages. and focus shift, the company states.
tipart, antislip cleats and antislip sup- The machine offers a capacity of 0.25- It is formulated with low-energy sur- The fiber optics are suitable for use
porting ribs that provide slip resistance, to 2.5-in. tube or 2-in. Sch. 40 pipe. The factant, which can clean and degrease in 1-micron applications from 1,030
absorb shear forces, and prevent thin- tooling installs quickly, and the swing- in hot parts washers at lower tempera- to 1,080 Nm with absorption of less
sheet deformation. away counter bend die vise simplifies tures, generating energy savings. than 50 PPM at 1.03 to 1.08 microns, a
According to the company, oval cups workpiece loading and unloading. The Free of VOCs and phosphates, the pinpoint focal length tolerance of ±0.5
deliver greater suction force than round three-phase drive motor operates from product can be used for sensitive ma- percent, and laser damage threshold
cups of equal width. any 220-V, single-phase power source. terials. higher than 10 J.
Fipa Inc. CML USA Ercolina Inc. Bio-Circle Mate Precision Tooling
919-651-9888 563-391-7700 860-298-1100 800-328-4492
www.fipa.com www.ercolina-usa.com www.biocircle.com www.mate.com

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50 The FABRICATOR FEBRUARY 2016


Automatic crowning system
Gasparini has introduced the X-Press
press brake with ACSG active crowning.
A sensor in the ram detects bowing. Cyl-
inders in the table raise the die, while
another sensor measures the height.
When the two values are equal, punch
and die are at the same distance, and
the profile has a constant angle across
its length.
The tailor-made press brake is built
entirely by the manufacturer, including
the frame and hydraulic circuit.
Gasparini
39-0422-8355
www.gasparini.it/en
40-ton electric press brake
Cincinnati Incorporated has introduced
the all-electric Goform 40-ton press
brake for small parts up to 0.25 in. thick
and less than 50 lbs. It offers a 10-in.
stroke and 17-in. open height for jobs
requiring tall tools and adapters. The
6-axis backgauge is suitable for basic
and complex parts.
Featuring a heavy-duty, stress-re-
lieved frame, the machine is designed
for full tonnage with minimal deflec-
tion. The drive system uses satellite
roller screw actuators that reduce heat
and wear.
With its small footprint and operation
without being anchored to the floor, the
machine can be moved with a forklift or
overhead crane to adapt to changing
plant layouts and work flows.
The press brake can be configured
to use the three major tooling styles—
American, WT/New Standard, and Eu-
ropean—and Express Clamp systems
from Wilson Tool provide fast setup,
self-seating, and low maintenance with
leak-free mechanical clamps, the com-
pany reports.
Cincinnati Incorporated
513-367-7100
www.e-ci.com
PRODUCT NEWS
Gantry-style fiber Flap disc
laser cutting machine Weiler Corp. has launched the Tiger® X flap disc. It features
the company’s X3 technology, which combines a triple split
coat grain anchoring system, dual flap design, and engineered
abrasive cloth backing with intermixed ceramic alumina and
zirconia alumina materials. The triple split coat material helps
ensure consistent cut rate throughout the life of the disc without the need to apply
more pressure. The ceramic and zirconia alumina material blend allows for high ini-
Koike Aronson offers the Fibergraph, a tial cut rates and consistent grinding, the manufacturer reports.
gantry-style cutting machine that uses Weiler Corp.
fiber laser technology. The machine de- 800-835-9999
livers excellent cut quality on mild steel www.weilercorp.com
while using one-third of the electricity
of a CO2 laser at the same cutting speed,
the manufacturer states.
Two sizes are available: the 2-kW
model cuts mild steel from 1⁄8 to ¾ in.
thick, while the 5-kW model cuts thick-
nesses up to 1 in. Standard safety fea-
tures include a torch cover and machine
enclosure. The shielding wall around GET THE LISSMAC EDGE!
the machine can be customized.
Koike Aronson Inc./Ransome
585-492-2400
www.koike.com
SMW 123 – the lean alternative
Waterjet cutting machine for wet deburring, edge rounding,
TECHNI Water-
jet™ offers the
and surface finishing
TJ3000-X3® (5-
by 10-ft.) wa-
terjet cutting machine. It incorporates
linear scale feedback to help ensure
high accuracy of motion.
By mapping the entire cutting area
with a laser-calibrated digital encoder, R T
the motion system can deliver posi-
tional accuracy of 0.0005 in. and cutting
speeds up to 1,000 IPM.
TECHNI Waterjet
888-832-4643
www.techniwaterjet.com
R B
Ball rail systems
Rexroth has introduced BSHP ball run- SMW 123 RT for deburring /edge rounding - SMW 123 RB for surface finishing
ner blocks. Their patented entry zone
helps improve travel accuracy and
workpiece quality while increasing . Compact and highly versatile
load capacities and service life, says the
company.
. 2 head machine with wide belt
The runner blocks are available in aggregate and interchangeable
most sizes, versions, and accuracy barrel brush/top brush aggregate
.
classes. They are 100 percent inter-
changeable with existing profiled rail Made in Germany
applications using the same part num-
ber as before.
. Very competitively priced
The runner blocks reduce pulsation
when placed under a load. Dynamic
load capacities have been increased
CONTACT US TODAY!
by about 26 percent, with static load
capacities improving by as much as 50 LISSMAC Corporation
356 Hudson River Road
percent, the manufacturer reports. Waterford, NY
Phone +1 518 326 9094
Bosch Rexroth sales@lissmac-corporation.com
www.lissmac-usa.com
800-739-7684
www.boschrexroth-us.com
FEBRUARY 2016 The FABRICATOR 51
SMW123_117,455x247,65_fabricator_final_qr.indd 1 11.12.2015 14:47:42
 PRODUCT NEWS

Fiber laser cutting machine Welding robot teaching system

11th
ANNUAL

The 2015 Salvagnini L5 fiber laser cut-

Feb. 24-26, 2016
Paradise Point Resort & Spa
San Diego, Calif.
Attend the
ERP Software Panel Discussion
during The FABRICATOR ®’s
Leadership Summit
Join experts from Exact JobBoss, ECi M1, and
Global Shop Solutions for an interactive discussion
on Enterprise Resource Planning (ERP) solutions in the
fabrication market during The FABRICATOR ®’s 11th
Annual Leadership Summit on Thursday, Feb. 25
in San Diego, Calif.
Panel experts will discuss cloud computing, scheduling
on-time deliveries, as well as customer successes
and solutions to challenges. Get a better understanding
of how software can help your company make better
decisions, improve customer satisfaction, lean out
operations, and allow employees to work more
efficiently.
ting machine incorporates the patented,
rotary motor-driven compass head po-
sitioner. According to the manufactur-
er, the positioner allows for improved
speed, accuracy, reliability, energy con-
servation, and performance.
Available in 2-, 3-, and 4-kW versions,
the machine comes fitted with a new,
all-electric pallet changer. The pro-
cessed piece always passes beneath the
worktable, eliminating any risk of cut
parts or scrap falling onto the incoming
blank.
An automation package is available
that includes the manufacturer’s MCL
automated Cartesian sorter/manipula-
tor for laser cutting systems. This floor-
mounted gantry uses a single suction
cup gripper to pick up parts as small as
8 by 4 in. and uses two grippers to pick
up parts as large as 157 in. and weighing
as much as 286 lbs.
Guided by a software program that
automatically positions the sorter over
parts to be retrieved and runs an effi-
cient unloading and placement cycle,
the system can extend kit production
and single-piece part flow to automated
laser cutting.
Salvagnini America Inc.
513-874-8284
www.salvagnini.com
Electrohydraulic press brake
Robotiq, in partnership with Yaskawa
Motoman, offers Kinetiq Teaching™, a
product that allows operators to task
robotic welding machines without re-
quiring in-depth programming knowl-
edge.
The product enables operators to
move the robotic welding machine
with their hands and program welding
paths intuitively by using a dedicated
teach pendant interface. No in-depth
programming knowledge is required.
According to the company, the product
opens the door to robotic welding at
small and medium-sized manufacturers
with high-mix and low-volume welding.
Once the welding point is reached,
the welder determines the welding
parameters through a touchscreen
interface. Once all the points are re-
corded, the welder can play back the
programmed trajectory and modify it
on-the-fly.
Robotiq
888-762-6847
www.robotiq.com/welding
Welding power source data
analysis system
Fronius has
developed
the WeldCube
documen-
tation and

REGISTER TODAY!
Accurpress offers the Accell electrohy-
draulic hybrid press brake. The com-
pact, closed design uses no oil lines,
Conference Fees: making it clean and leak-free to oper-
ate. All components, including the tank
$945 FMA members / $1,195 General system, are integrated in the machine.
The press brake translates the electri-
cal input from the machine controller
(CNC) into mechanical linear motion. To
Visit fmanet.org/annualmeeting accomplish this, the machine controller
data analysis
system. It can connect up to 50 power
sources, enabling continuous data
monitoring.
The unit is based on an industrial PC
with integrated software. It is compat-
ible with all digital Fronius series, with
the DeltaSpot resistance spot welding
system, and with the TPS/I intelligent
welding device platform. This enables

or call toll-free 888-394-4362.
Presenters:
www.exactjobboss.com
www.ecisolutions.com
communicates with the axis controller
and subsequently with the motor con-
troller. The synchronized actuators fol-
low preselected profiles, comprising a
working motion or a rapid motion and
working motion, using controlled trac-
ing. The drive controls the position of
the bending tool, and its force during
stamping, with a speed-variable motor-
pump unit.
Accurpress
605-718-2550
www.accurpress.com
users to record and analyze data includ-
ing welding current, voltage, wire feed
speed, welding speed and time, arc
length and dynamic correct, job num-
bers for manual and robotic welding,
and consumption data.
The data is viewed from a standard
web browser, allowing users to view
the documentation and graph the data
from their computer or mobile device.
Fronius
877-376-6487
www.fronius.com

www.globalshopsolutions.com
52 The FABRICATOR FEBRUARY 2016

Abrasive waterjet
accessory head
OMAX® Corp.
offers the wa-
ter-resistant
Rotary Axis
head for com-
plex 3-D parts
production as
an accessory
for its JetMachining® Centers. The head
expands an OMAX machine’s capabili-
ties to cut in up to 6 axes when used in
conjunction with the A-Jet® software-
controlled, multiaxis cutting head.
Precise indexed rotations make the
head suitable for pipe and tube cut-
ting and simplify challenging projects
such as intersecting pipe fittings. The
accessory’s drive head also allows for
customized fixtures, and a versatile at-
tachment design lets users position the
head in various locations within a ma-
chine’s work tank.
Fully submersible and powered by
common table controls, the accessory
requires no additional power supply.
It features a built-in water drip sensor
with warning lights and automatic shut-
down, as well as external grease fittings
for simplified maintenance.
OMAX Corp.
800-838-0343
www.omax.com
High-speed press brake
Bystronic has
introduced the
Xpert 40 com-
pact, portable,
high-speed
press brake.
It is suitable
for applica-
tions with lim-
ited space and
varying capacities.
With its integrated tool storage, the
press brake combines the entire setup
and production from one station, help-
ing to reduce nonproductive bending
times. Its backgauge and ram speeds
help the machine keep up with high-
speed fiber laser cutting machines.
According to the company, the ma-
chine produces 1,028 bends per hour. It
offers press capacity of up to 44 tons for
applications with both thin and thicker
materials. The backgauge system has
up to 6 axes to allow production of com-
plex sheet metal shapes.
Bystronic Inc.
847-214-0300
www.bystronicusa.com
FEBRUARY 2016 The FABRICATOR 53
PRODUCT NEWS
Hand-held dot peen
marking system
Equipment Sales Co., the sales and
distribution subsidiary of Rocklin Mfg.
Co., offers the FlyMarker® Mini battery-
operated, hand-held dot peen marking
system. Housed in an ergonomically
designed, compact, 6-lb. unit, the tool
requires no power or air cables.
The unit marks such materials as alu-
minum and steel, as well as round parts,
with automatic height compensation
up to 0.19 in.
Marking files can be programmed via
self-explanatory software on the unit
itself, or they can be programmed with
optional PC software and then trans-
ferred to the tool using its built-in USB
interface. Several hundred files can be
stored.
Optional accessories include logos,
data matrix codes, bar code scanners,
and a solid-column frame for conver-
sion to a tabletop unit.
Equipment Sales Co.
800-255-6046
www.equipmentsalesco.net
Dimensioning system
Rice Lake Weighing Systems offers the
iDimension™ 100 for calculating NTEP-
certified dimensions of boxes, flats,
polybags, and tubes.
The dimensioning system’s multiple
patented sensing technology and 3-D
imaging work together to help optimize
time and throughput, says the com-
pany. In 0.2 second, NTEP-certified di-
mensions are calculated with 0.2-in. ac-
curacy; on irregularly shaped packages,
accuracy is 0.5 in.
The system is ready to function as
soon as it is connected to a power
source, and all necessary tools and
components are included for assembly.
The operator display is attached direct-
ly, with no PC interface required.
When connected to a network via
DHCP or static IP, the embedded firm-
ware provides access to additional
screens and configuration parameters
without additional software.
Rice Lake Weighing Systems
800-472-6703
www.ricelake.com/idimension100
 PRODUCT NEWS
Aluminum extrusions
Eastern Metal Supply (EMS)
offers custom and standard
aluminum extrusions and
miscellaneous aluminum
sheet items. The firm also
maintains large private inven-
tories for stocking customers’
proprietary profiles to assist with JIT production needs. EMS
often fabricates or machines these profiles to enable them to
go immediately to the end-use product assembly.
Custom REPRINts
RepRints aRe ideal foR:
n New Product Announcements n Sales Aid For Your Field Force
n Conferences & Speaking Engagements n Direct Mail Enclosures
n Customer & Prospect Communications/Presentations
n Trade Shows/Promotional Events n PR Materials & Media Kits
n Recruitment & Training Packages
For additional information, please contact Foster Printing Service, the
official reprint provider for The Fabricator.
Call 866.879.9144 or
sales@fosterprinting.com
54 The FABRICATOR FEBRUARY 2016
The company makes parts for lighting, patio/restaurant fur-
niture, architectural sunshades, marine, sporting equipment,
railings, hurricane/decorative shutter, sound equipment, elec-
tronics, and signage.
Machining and fabrication capabilities include milling,
shearing, cutting, punching, finishing, drilling, tapping, as-
sembly/welding, roll forming, bending, anodizing, beveling/
chamfering, powder coating, and design assistance.
EMS
800-432-2204
www.easternmetal.com
use this logo
backgroundsThe software also allows for com-
use this logo on black or darker
backgrounds.
Service 41-43-444-61-61
Universal dot peen controller
Au to m a -
tor Ameri-
ca has re-
leased the
AC500-3.0
universal
dot peen
controller for its line of pneumatic, elec-
tric, and scribe marking systems.
The new release of the controller
features increased flash memory, a
faster and cooler processor, software
enhancements, and expanded capabil-
ity to operate and communicate with
outside equipment. This release also
extends the list of marking heads from
other manufacturers that can be oper-
ated by the controller.
Programming upgrades allow for
deeper marks through multiple dot rep-
etition. Standard programming allows
the user to mark alphanumeric, sym-
bols, logos, and bar codes through the
touchscreen.
Automator America
740-983-0157
www.automator.com
Hemming planning software
AutoForm Eng. GmbH offers AutoForm-
HemPlannerplus software, fully integrat-
ed in the AutoFormplus R6 version. The
software enables users to define and
optimize the hemming operation.
In combination with AutoForm-Solv-
erplus, this software offers efficient plan-
ning of hemming processes to meet
quality and cost requirements, effective
implementation for early feasibility and
final validation studies, rapid identifica-
tion of typical hemming defects, predic-
tion of full assembly springback after
hemming, and simplified data exchange
internally between different depart-
ments and externally between OEMs
andonsuppliers.
white or lighter
pensation of inner and outer parts, as
well as any adjustments of the hem-
ming equipment. It supports AutoForm-
HemPlannerplus supports roll, conven-
tional die, and tabletop hemming.
AutoForm
Eng. GmbH
The Printing
is in white.
www.autoform.com
 PRODUCT NEWS
Flexible automation Membrane dryer liquids whenever an ounce or more is present. It is fully auto-
for punch presses The WNA AMD- matic with no continuous air loss. The third and fourth stages
035 membrane remove any remaining particles to 0.01 micron and absorb re-
maining moisture and oil vapors.
dryer from Wal-
The membrane dryer vents humidity into the surrounding
mec North Amer-
atmosphere.
ica has a four-
A flexible input hose assembly eliminates the hazards of
stage prefiltration, a flow rating of 35 SCFM, and maximum
damage from vibrations in piped compressed-air systems and
working pressure of 150 PSI.
LVD Strippit has introduced Flexible Au- allows the unit to be installed in any position.
The first- and second-stage filters remove moisture, liquids,
tomation for Punching (FA-P). It offers Walmec North America
dust, rust, and scale to 5 microns. An automatic float drain 866-764-8377
dynamic load/unload capacity, smart
under the second-stage filter opens and expels all collected www.walmecna.com
part picking, and a large area for stack-
ing punched parts directly onto desig-
nated pallets. The technology now is
available on the Strippit-PX punch press.
The system loads sheets up to 120
by 60 in. and material thicknesses up
to 0.16 in. from two shuttle tables with
a maximum capacity of 6,600 lbs. It can
handle punched parts down to 8 by 4 in.
Two independent gripper arms are
positioned automatically to pick the
part. The suction cups are activated
following the nesting configuration
calculated by the CADMAN®-P offline
software module. Small, closely spaced
suction cups are used to pick small
parts, while larger suction cups are ac-
tivated for picking larger parts and load-
ing full-size sheets.
A laser distance sensor measures the
pallet height and stacked parts. Follow-
ing this measurement, the suction cups
stack parts on top of one another.
LVD Strippit
716-542-4511
www.lvdgroup.com

Self-clinching
threaded fasteners
Pe n n E n - oxyfUeL Psma Warjet
gineer-
ing® offers
variations

QUALITY & VERSATILITY

of PEM®
s e l f -
clinching
nuts, studs, and standoffs designed to Optimize time, quality, and production costs with oxyfuel, plasma, and water jet cutting tools
allow for close-to-edge placement in that are economically priced, yet deliver superior cutting performance and capabilities.
thin metal assemblies without compro-
mising the host sheet or fastener. Their
engineering reduces the standard mini-
mum distance for hole-centerline-to-
edge required for successful clinching.
Upon installation, the metal fastener
threads accept mating hardware to
complete the attachment process. The LineaTech NOVA offers cutting
solutions from simple oxyfuel The Plasma RED is a complete Combine plasma and water jet
They will withstand repeated dis- cutting to the most complex plug-and-play solution cutting technologies affordably
assembly and reattachment of com- operations and machining. for quality plasma cutting. with the DUALine.

ponents without affecting fastener or

thread integrity, reliability, and perfor-
mance. NORTH AMERICA OFFICE: CONTACT:

PennEngineering
76 Eisenhower Ln N (843) 409-2350 SOITAAB.COM
Lombard, IL 60148 sales@soitaab.us
800-237-4736
www.pemnet.com

FEBRUARY 2016 The FABRICATOR 55

 BIZ TALK
Read more from Tim Heston at www.thefabricator.com/author/tim-heston
The story of
26 Commerce Road
The narrative tells a lot about life
for the small U.S. manufacturer
This 36,000-square-foot structure has a winding story that says a lot about the life of a small business in America.
By Tim Heston, Senior Editor
D
rive along the nation’s highways and you
can see thousands of anonymous-looking
buildings. But if you dig a little deeper, you
find that these buildings have a story—and each
can tell us a lot about life for the small manufac-
turer in the U.S. economy.
Consider one building in Pittston, Pa., just off the
Pennsylvania Turnpike’s northeast extension, be-
tween Wilkes-Barre and Scranton, at 26 Commerce
Road. The building has a story of multiple strands,
one of evolving technology, of business closures, of
crime, of unexpected disasters, and of unexpected
opportunities.
For years a company called Penox Technologies
occupied 26 Commerce Road. Penox fabricated
stainless steel liquid oxygen systems for the home
healthcare business. Oxygen units like ones from
Penox allowed people to leave the hospital and re-
cover in the comfort of home.
In 1987 a diversified manufacturer called Essex In-
dustries purchased Penox, including the building it
occupied at 26 Commerce. Through the years Penox
operated pretty much independently, but tumultu-
ous times were ahead. Portable oxygen concentra-
tors, a newer technology, began taking more of the
market. This, combined with changes in Medicare
reimbursements, forced Essex to close the Penox
facility in 2008.
“The one thing I was most proud of is that every
one of our employees found a job if they wanted it,”
said Mickey Waldman, president of Essex, a multi-
generational family business in St Louis.
Winding down the operations, employees came
across inventory of stainless steel left in the building.
Instead of selling it, Essex moved it all to St. Louis.
“Several of our maintenance and shipping individuals
were really big into home brewing, and they had the
idea of fabricating fermenters out of that material,”
56 The FABRICATOR FEBRUARY 2016
Waldman said. “So we turned that idea into a little
business until we sold all the inventory.”
That little business was called Brewhemoth.
Google it and you’ll find videos of home brewers
unpacking their newly acquired stainless steel fer-
menters. That business halted once the stainless
steel inventory ran out, but for a time the venture
was a serendipitous opportunity that connected
home brewers to that anonymous-looking building
at 26 Commerce.
Another strand of the story involves GT Fabrica-
tion Inc., a shop run by a Pittston family who pur-
chased a building 20 yards from the Susquehanna
River in the early 1990s. Back then the last major
flood had occurred in 1972, and meteorologists at
the time called it a once-in-a-century event. Just to
be safe, the Tighes added on a second building that
was 4 feet higher, an elevation where no flood on re-
cord had reached—at least at the time.
But that was about to change. GT Fabrication’s
plant flooded four times over the ensuing years.
Before the latest flood, in September 2011, employ-
ees removed all the equipment they could, but not
some of the largest machines.
“With millions of dollars of equipment left in the
building … we could receive only $500,000 in con-
tents and $500,000 on building FEMA insurance. We
knew we were in trouble.”
So said Gino Tighe, GT Fabrication’s chief operat-
ing officer, in testimony given to the House Small
Business Committee in Washington. The family ap-
plied for an Economic Injury Disaster Loan from the
Small Business Administration but was unsuccessful
because the SBA kept requesting documents, includ-
ing sales records, that were destroyed by the flood.
“I felt like we were pawns in some kind of game,”
Tighe said. “We were going through all of this trou-
ble and aggravation for a 6 percent loan.”
Eventually a loan provided by the Luzerne County
Flood Recovery Program gave the company the
cash it needed to get back on its feet.
A year later the Tighes finally were in a position to
start looking for new property. It was then they vis-
ited 26 Commerce, at the time still owned by Essex
Industries. It was on high ground. It was next to the
highway. To the Tighes, it was perfect.
Unfortunately, just after placing a bid, the facility
was leased to a sign-making company from Georgia.
The company had limited success in Pennsylvania
and stayed only for a short time before closing shop
and moving back south. As Waldman put it, “They
ran into the economics of our country, and they de-
cided not to buy the building.”
So 26 Commerce came on the market again, and
this time the Tighes were ready with an offer. Wald-
man flew up to Pennsylvania to meet Gino, his fa-
ther (and company president) Gene Tighe, and the
rest of the family.
“What a nice family they are,” Waldman said, who
added that he tried to meet people directly rather
than rely on a middleman (the realtor, in this case).
“I like to meet people so that they know me. Meet-
ing them, you either trust somebody, or you think
they’re full of you-know-what.”
Before the deal closed, Waldman and the Tighes
visited the now vacant structure, only to find that all
the copper wiring was gone—thousands of pounds of
it, in fact. This wasn’t done by some guy in a pickup
truck. The police (who never caught the perpetrator)
said it was probably a professional who came in with
a fork truck, took the wire, and then drove to the Port
of New Jersey to exchange the copper wire for cash.
Waldman recalled the moment. “I looked at Gene
and I said, ‘Whatever it is, we’re going to take care of
it. You find the contractor you want, and we’ll put it
together exactly how you want it.’”
It turned out that the wiring GT Fabrication need-
ed wasn’t quite as extensive as the original wiring,
so the Tighes ended up saving Waldman a little
money. After all this, the deal closed in late 2014,
and GT Fabrication completed its move to higher
ground in 2015. At this writing the company has 20
employees and has plans for significant growth over
the next few years.
The narrative at 26 Commerce is a slice of the suc-
cesses, serendipities, failures, and struggles that
make the U.S. economy what it is. People like to talk
about how technology has transformed business,
and in many ways it certainly has. But what really
keeps the economy going are connections between
trusted people. That trust has allowed the story at
26 Commerce to continue on its winding path.
Senior Editor Tim Heston can be reached at timh@the
fabricator.com.
Image provided by GT Fabrication Inc., Grimes Industrial
Park, 26 Commerce Road, Pittston, PA 18640, 570-883-
0775, www.gtfabinc.com.
Essex Industries, 7700 Gravois Road, St. Louis, MO 63123,
314-832-4500, www.essexindustries.com
 AROUND WASHINGTON
Read more from Stephen Barlas at www.thefabricator.com/author/stephen-barlas
New law enhances
manufacturers’ tax benefits
Expensing deduction and bonus depreciation laws
get permanent approval
By Stephen Barlas, Contributing Writer
M
anufacturers got a Christmas present from
Washington, D.C., in December.
Congress passed the Protecting Ameri-
cans from Tax Hikes (PATH) Act of 2015 and Presi-
dent Obama signed it into law. The legislation in-
cludes two significant provisions affecting small
and medium-sized manufacturers.
The Section 179 expensing deduction and bonus
depreciation laws, which have been up for grabs
in previous tax bills, have been put into place per-
manently. The 179 expensing law had been dra-
matically tightened for the 2015 tax year, dropping
down to $25,000 from the $500,000 allowed in 2014.
The PATH Act restored the $500,000 deduction limit
starting in 2016 and continuing in ensuing years.
For businesses that spend a total of $2 million for
qualifying equipment, the Section 179 deduction
will phase out dollar-for-dollar and be completely
eliminated above $2.5 million.
As a bonus, Congress allowed the $500,000 and
$2 million amounts to be indexed for inflation go-
Andersening forward, which was 1not
WP360-Jan2016_Layout the case in
12/14/2015 thePM
4:58 past.
PageThe1
IRS will index the depreciation amount in $10,000
WELDPRO 360 Slashes Non-Arc Time
Productivity increases of 15-30% are being realized with
the revolutionary WELDPRO 360. Not your Grandfather’s
weld boom–this is a modern state-of-the-art welding
center. Every tool the weld operator needs is placed at
their fingertips.
With the flip of a switch, this double-articulated boom
rotates into position, anywhere within a 56 ft. diameter
weld zone. Unlimited rotation around the center-support
column, along with a secondary boom arm that pivots
Andersen Industries, Inc. - 17079 Muskrat Ave, Adelanto, CA 92301 USA Ph. 760.246.8766
58 The FABRICATOR FEBRUARY 2016
increments in future years. The agency has yet to
announce this figure.
Further plumping up Section 179, legislators
permanently defined off-the-shelf computer soft-
ware as qualifying property. (Software was always
included on a temporary basis in the past.) Air-con-
ditioning and heating units were even included as
qualifying property. The provision also makes per-
manent the treatment of qualified real property as
eligible under Section 179.
The PATH Act also dresses up bonus deprecia-
tion rules while slimming them down a bit as well.
The most noteworthy change is a reduction in the
current 50 percent rate that companies have been
eligible to take in additional depreciation in the first
year an asset is placed in service. That will be re-
duced by 10 percent per calendar year, dropping to
40 percent in 2018 and 30 percent in 2019.
On the positive side, additional first-year depre-
ciation will be allowed for qualified improvements
to property without regard to whether the improve-
ments are to property subject to a lease. Plus, the
requirement that the improvement must be placed
in service more than three years after the date the
building was first placed in service is jettisoned.
back towards the center column–in either direction,
delivers total coverage of the welding zone. No
dead spots. No cables to drag. No wasted mo-
tion. Arc on-time soars.
If you are looking to slash your welding costs
in a significant way, then you’re ready for the
revolutionary WELDPRO 360 welding center.
Let us show you how you can take control of
weld productivity, improve product quality, and
enhance operator safety with a WELDPRO 360
welding center.
www.weldpro360.com
Additionally, the provision modifies and extends
the election to increase the alternative minimum
tax (AMT) credit limitation in lieu of bonus deprecia-
tion for five years to property placed in service be-
fore January 1, 2020.
For more details about all the provisions in the
PATH Act, see www.jct.gov/publications.html?func=
startdown&id=4861.
Further plumping up Section 179,
legislators permanently defined
off-the-shelf computer software as
qualifying property. Air-condition-
ing and heating units were even
included as qualifying property.
OSHA Upgrading Health
and Safety Guidance
The Occupational Safety and Health Administration
(OSHA) is updating its safety and health program
management guidelines, last changed in 1989.
These guidelines provide a framework for man-
agement, particularly in small and medium-size
workplaces, to analyze possible health or safety
shortcomings and address them. As guidelines,
they are not legally enforceable by the agency but
ostensibly help companies reduce direct injury and
illness costs and workers’ compen-
sation claims by getting ahead of
potential problems. The indirect
costs that can accrue, such as from
work stoppage related to having to
replace injured workers and the loss
of material and property, can be 2.7
times the direct costs.
The next OSHA-sponsored meet-
ing on the draft guidelines is sched-
uled for March. David Michaels, the
OSHA administrator, said he hopes
to have the final version out by this
summer.
The draft is broken down into sev-
en core elements, including man-
agement leadership, worker partici-
pation, hazard identification, and
hazard prevention. The 1989 ver-
sion has just three core elements.
Each core element has action items.
Occupational Safety and Health Admin-
istration, www.osha.gov
 IMPROVEMENT INSIGHTS
Read more from Dick Kallage at www.thefabricator.com/author/dick-kallage

actional processes tend to drift—in how the process

Do as the accountants do
How the process audit
prevents the unexpected
By Dick Kallage, Contributing Writer
is done, who does it, and the tools employed—and
for processes done by us humans, they are inher-
ently susceptible to variation. If this is true (and it
is) for transactional processes like filling out paper-
work, then it is also true for the processes involved
in actually making the product.
ISO 9001 is often described by a deceptively simple
phrase: State and document what you do and then
While most of the readers of this column have par-
faithfully do what you stated. But even without an

T
ticipated in one or more of these inventory counts,
he word audit rarely drives anyone to party relatively few know exactly why we go through this ISO discipline, company leaders often assume that
in the streets—unless, of course, you hap- process. Most think, correctly, that it brings invento- things are being done in certain defined ways. Those
pen to be the auditor who is chomping at methods are conveyed to the people performing the
ry counts that we think we have to the levels that we
the bit to bring the cringing audited to heel. If the process through training, usually of the on-the-job
actually have. Fair enough. That alone would make
word is preceded by “IRS,” well, it can be positively variety. Documentation can range from a formal pro-
this rather tedious process well worth it, especially
frightening. cess document to a handwritten instruction taped
if you’re not the one stuck with actually doing the
If you stuck around through that opening para- on a machine. So far, so good—though the handwrit-
counts.
graph, be assured that this column has nothing to ten, taped-on thing is definitely suspect.
do with the IRS. You have enough to worry about. Then unexpected things happen, and off we go
It has a lot to do with calibrating what a company Too many companies perform a process trying to figure out what went wrong. After a lot of
actually does in the conduct of its business. It also audit only when the pain of poor looking, we inevitably find out that one of three
has a lot to do with improvement. performance becomes unsustainable. things occurred:
Most of you who have spent time in operations And they do it once and move on, 1. The process wasn’t done like we thought it was
are familiar with the annual inventory count. This is only to see the pain return later. to be done. It had somehow changed or was never
the time of year when operations are stopped while implemented properly in the first place.
raw, work-in-process (WIP), and finished-goods
But the highly orchestrated inventory count is 2. The process, even when performed correctly,
inventories are counted by part number or some
actually part of a broader and extremely important was inherently incapable of providing the quality
other identifier. The counts usually are recorded on
process: the financial audit, which has the sole pur- of output or the consistency required. Basically, its
some standard form. Normal production resumes
Cpk (process capability index) was insufficient for the
only after the counts have been officially recorded pose of assuring any interested party that the finan-
task.
by someone associated with the accounting func- cial books are substantially correct. It essentially
tion. In many cases, the counts themselves are sam- checks the soundness of the transactional process- 3. The process was capable, usually done properly
pled by someone other than the person doing the es necessary to ensure that the company is under and as expected, but a random error occurred.
original count, just to check the soundness of the sufficient financial control. The third of these is difficult or perhaps impos-
counting process itself. (This sampling is a form of The periodic inventory count is critical to this, sible to prevent entirely, especially if people are
an audit, by the way.) as are examinations of other key accounts such involved. But in the scheme of things, this cause is
OLQtrPgFeb16Fab_TheFabricator 1/11/16 10:46 AM Page 1
as payroll, receipts usually small potatoes compared to the first two.
from and payments This begs the question, Why do we too often find
Your Single Source For to vendors, and other that either the process wasn’t being done as pre-
fundamental trans- scribed, or that the process itself wasn’t capable of
Tube, Sheet & Plate actions. I won’t bore producing the necessary results? And why do we
Parts & Assemblies you with the financial seem to find out only when something really bad
audit process, but has happened?
Ohio Laser is just-in-time rest assured that it is The answers are simple: We never checked; or we
focused. Combined with
our vendor managed necessary. It helps a checked it out and verified it once when the pro-
inventory and wide array company avoid a lot cess was commissioned, but never again. We have
of cutting equipment for
tube and flat laser of unpleasantness, no way of detecting unfavorable process drift until
processing, including including an IRS audit something unexpected (usually bad) occurs. This is
Trumpf® flat and tube laser
cutting machines, and and, even worse, run- a pretty costly way of verifying process integrity.
value-added welding ning out of cash. In some cases process drift is actually favorable.
and fabrication
For example, an operator may perform minor chang-
capabilites, including
press brake, forming, Everything es for convenience, like rearranging his workstation
and robotics, count on Changes or using better fixturing. (Although, even in the cases
us for all your parts
and assembly needs. If everyone who puts of positive attempts to improve, the law of unintend-
Call: 1-614-873-7030 together the financial ed consequences can raise its head.) Sadly, most
Web: www.ohiolaser.com statements is honest, drift is not favorable simply because there are far
ISO 9001: 2008 Certified
true, and trained, do more ways for a change to be negative than positive.
we really need the au- So, as you can surmise, the situation is crying out
dit? The answer is yes, for a means to ensure processes stay stable and un-
and here’s why: Trans- der control. This is the role of the process audit.
Regional Name. National Coverage
60 The FABRICATOR FEBRUARY 2016
 IMPROVEMENT INSIGHTS

Process Audits • That the process uptime is generally consistent with the quires something to compare to, which means the process
Readers of this column know that I data in those systems. reference point has to be documented. That is a key reason
often cite best practices employed • That there is a means for detecting and correcting prob- for the documentation requirements in ISO and other total
by outstanding companies. They use lems in the process.
quality management (TQM) systems.
these practices for a reason: to en- • That any special considerations for an individual cus-
If you want to avoid a lot of unexpected grief in produc-
hance the overall economics of the or- tomer’s requirements are indeed being performed.
tion, do what the accountants do. Audit regularly.
ganization. One practice that I haven’t The process audit has two versions. The first is the base-
featured is the process audit. It’s sim- line where the audit is done for the first time or after a pro- Dick Kallage is principal of KDC & Associates Ltd., 522 S. Northwest High-
way, Suite UL-8, Barrington, IL 60010, 847-525-6109, www.kdcconsultants.
ply a periodic check of the methods cess change. This sets the reference point for the second
com. Kallage serves on the Management Advisory Council of the Fabrica-
and procedures employed to success- version: the integrity or maintenance audit that ensures tors & Manufacturers Association International®. For more information,
fully operate the business. that no significant process drift has occurred. This audit re- visit www.fmanet.org/training or call 888-394-4362.
For example, in production opera-
tions, a process audit entails a regu-
lar, detailed examination of the key
processes used in physically building
products. We define “key processes”
as those that are both commonly used
and whose integrity are critical to
product quality.
Great operations go one step fur-
ther and verify that the process is
also capable of the throughput and
uptime assumed in estimating and
scheduling. As I wrote in a previous
column on scheduling and on-time
delivery performance, two common
root causes for chronic poor delivery
performance (and/or excessive over-
time) is that one or more production
process has lower throughput and/or
uptime than planned.
An audit of the process can help
detect and correct these problems.
Too many companies do this only
when the pain of poor performance
becomes unsustainable. And they do
it once and move on, only to see the
pain return later.
Great companies do the audit regu-
larly before things go south. And they
do it because they believe that since
they accepted an order from a custom-
er, part of that acceptance is the prom-
ise that the processes employed in sat-
isfying that order are indeed capable.
At the very least, process audits for key
production processes should verify:
• That these procedures and meth-
ods are compatible with and reinforce
the quality of the output.
• That these procedures are capable
(in the quality sense) over the range of
products that will be produced.
• That the operators executing these
procedures are sufficiently trained
and know why these procedures are
critical.
• That the process is capable of
producing the range of throughput
expected by estimating, costing, and
scheduling.

FEBRUARY 2016 The FABRICATOR 61

 PRECISION MATTERS
Read more from Gerald Davis at www.thefabricator.com/author/gerald-davis
Shop technology and 3-D CAD:
Using 3-D geometry to create
interactive documents
Tips and tricks for preparing product illustrations
By Gerald Davis, Contributing Writer
I
n the January 2016 edition of this column, we
discussed the concept of adding value to inven-
tory for profit. The inventory in this case is 3-D
geometry—the intellectual property that 3-D CAD
software spits out.
Consider a scenario in which our job shop is pro-
ficiently using 3-D CAD to convert customers’ de-
signs into manufactured goods. We have a limited
role in product development. That job is left to our
customers.
We routinely convert CAD into CAM data. Through
the magic of CAM, our customers’ 3-D CAD ends up
controlling the motions of fabricating machinery.
Professional CAM Magic
Yes, our shop performs “CAM magic,” but not for
free.
To improve the efficiency of the CAM work flow,
we have invested in 3-D design software. This allows
for more direct extraction of product manufacturing
information (PMI) from the 3-D geometry. It also
gives us an opportunity to assist, for a fee, in the
design-for-manufacturing process.
The investment in a design tool—such as 3-D
CAD—not only helps with converting a design into
machine toolpaths, but also allows for the produc-
tion of fabrication drawings based on that 3-D ge-
ometry. The customers of our shop place value on
the quality of the drawings that we draft. Figure
1 is a screen shot of a drawing being created to in-
clude an exploded view as well as a bill of materials
(BOM) table. We are expert and efficient at produc-
ing such drawings. Drafting for dollars is an impor-
tant activity in our (hypothetical) operation.
Beyond data conversion and drawing production,
the 3-D CAD system can produce illustrations and
Figure 1
This drawing in progress includes a BOM table, bal-
loons, and an exploded view. Converting 3-D geometry
into this drawing takes mere minutes for an expert.
62 The FABRICATOR FEBRUARY 2016
Figure 2
A rendering in progress features realistic materials and
finishes. As an add-on software tool, this capability
represents an incremental investment over the base
3-D CAD.
animations for embellishing service manuals and
brochures. Figure 2 is a screen shot of a 3-D CAD
operation in the process of generating a near-real-
life image of a product. The software—and possibly
hardware—required to produce such images might
be built into the CAD workstation and thus not re-
quire specific capital investment. Grabbing a screen
shot of a nicely positioned model is, by itself, very
easy to accomplish. Getting the model into the per-
fect position is the craft of professional illustrators.
Our goal is to become helpful at least and essen-
tial at best to the team supporting the product. Our
experience in processing CAD models for manufac-
turing will be leveraged to offer services in prepar-
ing illustrations for brochures and manuals.
Doing It All
Diversification is a business decision. Too much can
lead to loss of focus; a single hen is risky to a diet of
omelets. We merely present an opportunity, not a
recommendation.
Image rendering has much in common with draft-
ing. The ability to receive, store, and retrieve 3-D
geometry in folders and files is vital. Fabricators are
accustomed to dealing with security as well as re-
vision management. Fabricators also speak “CAD”
when it comes to resolving problems between de-
sign and production. They understand materials
and finishes; they are attuned to the finest detail.
These skills come into play when resolving prob-
lems between the design and end users.
In addition to making still shots, some brands of
3-D CAD software also can be used to create anima-
tions of the model for playback as movies. Figure
3 is a screen shot of the timeline setup (in the bot-
tom half of the screen) for a motion study that will
Figure 3
The timeline shown in the bottom half of this screen
shot has event markers that control when and how ob-
jects appear in the graphics window. A wizard tool can
create an explode/collapse animation with just a few
mouse clicks.
show the parts flying into a finished assembly. This
setup took only a few mouse clicks and relied upon
the CAD work already completed to create the ex-
ploded view shown in Figure 1.
For a draftsman considering an illustrator’s task,
the main difference between creating a BOM draw-
ing, as in Figure 1, and creating a collapse anima-
tion, as in Figure 3, is the editing of timeline events
to control when something moves as opposed to
dragging the position of components and adding
balloons. Neither is hard, just different.
Services Rendered
In terms of deliverable goods, our drafting depart-
ment routinely generates drawings in PDF files. We
might also zip the native CAD files as part of the
product delivered to our customer. When it comes
to product illustrations, the deliverable file formats
include movies (AVI and MP4) and images (JPG and
PNG).
The images and movies we produce will be
merged into documents that are the manuals, bro-
chures, and other literature for the product. Several
software products are available for merging images
into documents. Website development tools, video
editors, image editors, and publication layout soft-
ware all come into play.
We might create MS Word® document files with
embedded images, as described in the January edi-
tion of this column, or we might simply deliver the
illustrations. Either way, it is likely that there will be
iteration toward a finished brochure.
The first try at rendering an image is seldom per-
fect. As professionals, we take part in each iteration
because of our skill in manipulating 3-D geometry.
Not all artists in the graphics trade are proficient
with 3-D CAD. We make a valuable contribution to
the team as we position the model and render it to
produce a beautiful result.
The Ideal Excludes the Redundant
The iterative nature of this work takes time. That
time, or delay, might create demand for a better
tool. The ideal tool would allow us to deliver a docu-
ment that our customer can refine on their own.
 Such a document would
allow them to position
the model and to other-
wise embellish, extend,
and finalize.
That document could
be used to create static
images as well as fully
interactive documents,
Figure 4 similar to website opera-
The timeline shown at the bottom of this screen shot tion.
is similar in function to the timeline in Figure 3. Skills
from 3-D CAD are quickly adapted to skills in compos- Figure 4 shows a
ing interactive documents. screen shot of a timeline
from a brand of software
that is designed for the production of interactive documents. The neat trick is
that it works with 3-D geometry from our 3-D CAD system. In fact, this document
production software imports any brand of CAD.
The concepts used in composing timeline-based animations are similar in
both Figure 3 and Figure 4. Event keys control the location and appearance of
actors in a scene.
To eliminate redundant work, the exploded view shown in Figure 5 import-
ed directly from the model used to create Figure 1. That is a nice time-saver
when authoring a document, but it has additional value in the completed inter-
active document. The person viewing it can explode or collapse the model at
his or her pleasure.
Figure 6 is an example of an interactive document with clickable buttons
for explode/collapse as well as buttons for navigation to other pages. As anoth-
er time-saver, CAD jockeys can import the information shown in the BOM table
from the 3-D CAD model. This eliminates redundant data entry.
The interactive document shown in these figures is available for download
in its native file format, SMG. With acknowledgement to Daniel Lubbe for his
YouTube™ postings on creating interactive documents, the sample document
we offer includes a BOM,
explode/collapse, and
movie clips that show
the process of removing,
exchanging, and rein-
stalling the air filter.
The native file may be
viewed with download
of a free player. Alterna-
tively, if you have access
to Windows Internet Ex-
Figure 5 plorer, you can view the
Software was used to import the exploded view from
the 3-D geometry that was used to create Figure 1. This HTML created by this
intelligent view can be used to create interactive ex- document.
plode/collapse views.
Gerald Davis uses CAD
software to design and
develop products for his
clients at www.glddesigns.
com. From 1984 to 2004 he
owned and operated a job
shop.
Gerald would love for you
to send him your com-
ments and questions. You
are not alone, and the
problems you face often
are shared by others. Share
the grief, and perhaps we
Figure 6
will all share in the joy of
This interactive document has “buttons” to collapse or
to fly-out the model. Other buttons switch you to other finding answers. Please
pages. The BOM table highlights the corresponding send your questions and
component. The model can be rotated in space with comments to dand@the
the right mouse button. fabricator.com.

FEBRUARY 2016 The FABRICATOR 63

 BENDING BASICS
Read more from Steve Benson at www.thefabricator.com/author/steve-benson
Press brake bending and notching:
A symbiotic relationship
The type of square corner notch directly affects
layout dimensions and bending order
By Steve Benson, Contributing Writer
Question: I have read many of your articles over the
years. In all that time I do not remember you discuss-
ing corner notching. I lay out, notch, and form sheet
metal trays, boxes, and a few plate parts. My problem
is I do not have access to a CAD system. While I can
find quite a few books on sheet metal pattern layout,
I can find little to nothing on the topic of precision cor-
ner notching for sheet metal.
Can you offer any guidance or help me locate refer-
ence materials?
Answer: If you want to build high-quality sheet met-
al parts, you are not just required to ensure the final
forming and dimensions are correct and held to tol-
erance. To produce the various parts a job shop re-
quires, you need to know about notches, why they
are necessary, their various kinds, and which is ap-
propriate to use.
This begins by calculating the correct bend deduc-
tion (BD)—for a review of this, see previous Bending
Basics articles archived on thefabricator.com. If you
have calculated those numbers accurately, based
on the actual inside radius that will be produced,
you will be able to accurately lay out a corner notch
style of your choice, one that will close tightly, or at
least to the required dimension, without binding or
pinching. This too is greatly affected by forming or-
der—that is, the order in which you sequence your
bends.
CAD Versus Manual Layout
Fewer and fewer people actually perform their own
notching layouts now. Even the heating and air
conditioning (HVAC) community is moving toward
computer-aided design and manufacturing. CAD/
CAM has become almost universal.
Nonetheless, learning the background of laying
out precise notching will help you to understand
what your CAD system is doing. This will assist you
with selecting the correct corner joint and assign-
ing the forming order to the work traveler or offline
program. There is no doubt this knowledge will help
you with your job, especially if you are performing
prototype work.
So Many Styles
Four basic 90-degree-corner types are the 100 per-
cent weld notch, 50 percent weld notch, closed
notch, and relieved notch. These are your straight-
64 The FABRICATOR FEBRUARY 2016
forward perpendicular corners. Each style has a
specific purpose.
The 100 and 50 percent notches are similar, the
differences being the strength of the corner weld.
While the forming order isn’t an issue with a 100
percent weld notch, the forming order is an issue
with the 50 percent weld notch.
The relieved notch offers clearance in the corner,
and it’s often designed into a part so that the corner
itself can mate on the inside of another square cor-
ner—to a shelf, for example.
The Mold Line
First, you need to make sure you’re using the right
mold line. The area between the mold lines rep-
resents where the part radius will be. If your BD
and calculated radius match the actual radius you
achieve in the workpiece, the area defined by the
mold lines will be accurate.
To find the mold line locations, we begin with the
outside dimension for the outside mold line (OML).
Say you have a workpiece that’s 2 in. long and the
outside flange dimension is 1.000 in. So here the
OML would be at 1 in., as shown in Figure 1. We
find the inside mold line (IML) by removing the BD.
In Figure 1, the BD is 0.100 in., so the IML is located
at 0.900 in. (1.000 – 0.100).
Technically, any change in the bend radius area
would occur toward the IML location. In the real
world of press brake operation, however, the op-
erator will center the bend line to split the error be-
tween the two planes, using the tolerance of a given
feature.
If you calculate your inside radius incorrectly or
you fail to achieve the inside radius as planned, the
1.900
1.000 OML
0.900 IML
0 one bend to pass freely by the previously formed
0 1.000
1.000
Bend Deduction 0.100
Figure 1
The area between outside mold line (OML) and inside
mold line (IML) represents where the radius will form.
The yellow lines represent the same bend but with a
larger radius and, therefore, a larger area between the
mold lines.
0.710 0.710
0.060
100% of Mt
0.650
0.750
0.100
0.750
Figure 2
This shows a 100 percent weld notch calculated in
0.060-in.-thick material with a 0.750-in. outside flange
dimension and a bend deduction of 0.100 in.: (0.750 –
0.100) + 0.060 = 0.710 in.
area defined by the mold lines will also change. This
in turn may mean that some features will be near or
within the bend radius itself, which can cause dis-
tortion. For instance, as shown by the yellow lines
in Figure 1, increasing the radius increases the area
between the mold lines; this in turn causes holes to
become located on the radius. Feature distortion
will be the result.
The 100 Percent Weld Notch
The simplest form of notch to lay out, the 100 per-
cent weld notch is also the strongest and most com-
mon. It’s where the two inside corners on the mate-
rial meet at right angles; if welded, the notch would
be filled to 100 percent of the material thickness. To
calculate this, we subtract the bend deduction from
the outside flange dimension, then add the material
thickness (see Figure 2).
The 100 percent notch is often defaulted to in
CAD/CAM programs, and it requires no special form-
ing order. It’s just that simple. This is because, after
overbending slightly to account for springback, ei-
ther flange will freely pass by the previously formed
flange.
The 50 Percent Weld Notch
The 50 percent notch is similar to the 100 percent
notch, except that it’s only half of the material thick-
ness (see Figure 3). You need to determine which
axis, or flange, will be on the outside.
To calculate the 50 percent weld notch for one
axis, subtract the BD from the outside flange dimen-
sion and add the material thickness, as before. For
the second axis, you also subtract the BD from the
outside flange dimension, but this time you add
only half the material thickness.
The 50 percent notch requires some forethought
about springback and the clearance necessary for
flange. Forming order makes a difference, as the
flange with the smaller notch dimension will need
to be formed first. If it’s formed second, it will collide
with the adjacent flange.
The Closed Notch
The closed notch is illustrated in Figure 4. To cal-
culate the closed notch for the first axis, you sub-
tract the BD from the outside flange dimension and
 BENDING BASICS

Try to use a hole diameter that is between the material thickness and the BD
values—the closer to the material thickness, the better. Please note that wheth-
er you are using a CAD system or laying out and punching by hand, be sure to
0
drill or punch the relief hole into location before the notch is added. This keeps
0 50% Weld Notch
the die and punch from side loading and damaging the punch or the part.

Conclusion
A
With a little practice you will be able to lay out, notch, and form square cor-
ner notches. Whether you are a press brake technician or are programming in
CAD, an understanding of the notching will lead to better products and a more
efficient operation. As for reference material, I would recommend my latest
2.000
First Axis 2.000 Second Axis textbook, The Art of Press Brake, the details of which are given at the end of
(flange on outside) (flange on inside) the article.
Figure 3 Next month we’ll delve deeper into notching and forming order and take a
Calculate the dimensions of the 50 percent weld notch as follows: First axis = (Out-
side flange length – BD) + Material thickness; Second axis = (Outside flange length brief look at more advanced layout concepts, including perpendicular flanging,
– BD) + (Material thickness/2). double bends, compound corners, and internal corner flanging.
Steve Benson is a member and former chair of the Precision Sheet Metal Technology Council of
the Fabricators & Manufacturers Association International®. He is the president of ASMA LLC, 2952
Doaks Ferry Road NW, Salem, OR 97301, steve@theartofpressbrake.com. Benson also conducts
FMA’s Precision Press Brake Certificate Program, which is held at locations across the country. For
more information, visit www.fmanet.org/training, or call 888-394-4362. For more information on
bending, check out Benson’s book, The Art of Press Brake: the Digital Handbook for Precision Sheet
0 Metal Fabrication, © 2014, available at www.theartofpressbrake.com.
Closed Notch
0

A join the best: 4-8 April 2016

Düsseldorf, Germany I www.tube.de

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First Axis 2.000 2.000 Second Axis

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You can calculate the dimensions of the closed weld notch as follows: First axis =
(Outside flange length – BD) + Material thickness; Second axis = Outside flange
length – BD.

add the material thickness. For the second axis, just subtract the BD from the
outside flange dimension.
Forming order makes a difference here, too, as the flange with the smaller
notch dimension will need to be formed first to avoid a collision with the other
flange. In other words, the flange that goes to the inside forms last.

The Relieved Notch

This type of notch builds clearance into the corner, such as what you might find
in the corner of a shelf where a sharp square corner could cause mounting prob-
lems (see Figure 5). In this notch, the flanges never touch. Calculating this is
International Tube and Pipe Trade Fair
the same as for calculating the 100
percent weld notch, except that you
add the dimension of the relief.
0
0 0.125 Radius Relieving the Corners
Except for the relieved notch, the
A other three notch styles may require
a relief hole to stop the material
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01.09.15 13:58
 CHIEF CONCERNS
1947 1948 1949 1950 1951 1952 1953 1954 1955 1956 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 1975
Managing metal fabrication
through the generations
Experience shapes perception, and each generation has different experiences
By Tim Heston, Senior Editor
A
welding technician in his early 20s fixtures
a subassembly in a robot welding cell, and
yet he calls up the wrong welding pro-
gram. The young tech plugs along without notic-
ing, welds the batch, then goes on to the next job.
Quality control flags the error before (thankfully)
the job ships, and the boss (in his 50s) calls him
into his office. The drama ensues, and the boss just
shakes his head. What was the kid thinking?
A manager in his 50s holds a meeting with cus-
tomer service, sales, and engineering personnel.
A deadline for a large industrial fabrication was
pushed up, so now the entire project is behind
schedule. Everyone will need to double down. An
engineer in his late 30s heads back to his cubicle
and shakes his head. His boss already sent him an e-
mail about the problem. He even updated the proj-
ect management software with the new schedule.
Why did he waste time calling the meeting, espe-
cially now that the project is so behind? What was
the guy thinking?
A supervisor in his 40s approaches a press brake
operator. In his early 70s, the operator is still work-
ing simply because he
enjoys his job. The super-
visor talks to him about
Diane Thielfoldt, co-founder
of The Learning Café, spoke
at the FMA Annual Meeting
in 2014 about how fab shop
business leaders can work
with their multigeneration-
al workforce.
66 The FABRICATOR FEBRUARY 2016
upcoming changes: new bending software, an im-
provement initiative that will include new organiza-
tion practices (5S) and the like. Debate ensues. The
veteran has seen this before, and the shop has noth-
ing to show for it. Sales seems to go up and down
with the economy, no matter how organized or dis-
organized his workstation appears to be. The super-
visor leaves and shakes his head. Doesn’t he see how
inefficient everything is? What is he thinking?
Most people in this business can relate to these sto-
ries, which imply a broader narrative to the skilled-
labor crisis. Hard skills are important, but they can
be taught. Shadow a press brake veteran, and he can
show you the ropes. But connecting with co-workers
is another story, and to do that requires empathy.
Diane Thielfoldt has experience with this. As co-
founder of The Learning Café, Daniel Island, S.C.,
she has helped employees at various companies,
including manufacturers, relate to one another. In
2014 she spoke at the Fabricators & Manufacturers
Association Annual Meeting on the topic, and in late
2015 The FABRICATOR spoke with her about how
metal fabricators can work with their multigenera-
tional workforce.
Empathy starts with knowing where people
are coming from, and this, Thielfoldt explained, is
where the study of generations plays an important
role. Family, friends, teachers, and others play big
roles in shaping one’s behavior, but so do shared
experiences like war, terrorist attacks, economic de-
pressions and recessions, music, and popular cul-
ture. Those shared experiences shape a generation.
Thielfoldt conceded that the study of generations
by its nature involves generalizations, and the years
dividing them are only approximations. “We com-
pare generational differences and similarities,” she
said. “It’s our belief that this is not an exact science.
It is in fact a social science, and it is probably one
of the most intriguing and informative ways to view
the people you work with.”
Silent Generation: Work First
Born between about 1933 and 1945, the silent gen-
eration grew up with the Great Depression followed
by war. The youngest of this generation is still in the
workforce, either out of necessity or for the enjoy-
ment of it. The latter, Thielfoldt said, is probably
more likely, considering this generation’s good sav-
ing habits.
Their experience of their childhood has shaped
their life views. They put the group (company and
family) first. They exhibit loyalty to a company, and
they know how to work within a defined system.
“The ‘silents’ put personal desires and goals aside
to do their best for their families and their compa-
nies,” Thielfoldt said. “Their willingness to defer
gratification is a hallmark.”
She added that their desire to put the group in-
terests ahead of their own makes them natural
corporate leaders. They’re also cautious and con-
servative, excelling in situations that require care-
ful thinking before taking action. The Learning Café
calls this the “work first” generation. They value
workplace loyalty and job security.
These attributes certainly fit the metal fabrica-
tion shop of their youth. This generation started in a
world before the CNC, of calculating flat layouts by
hand. They learned G-code, and when they reached
the middle of their careers, they worked with early
numerical controls, reviewing code line by line.
 CHIEF CONCERNS
Baby Boomers: Live to Work tunities they have. Those opportunities may be with their current employer, an-
“Between 8,000 and 10,000 baby boomers turn 65 every day,” Thielfoldt said. other company, or at a company they launch themselves.
“There’s a tremendous amount of organizational knowledge making its way out They see the workplace as a community, and they embrace teamwork—if, in
the door.” their view, it helps them get the job done better and faster. Work is distinct from
Like the silent generation before them, boomers aren’t all retiring the mo- the rest of their lives, which is why The Learning Café calls them the “work to
ment they turn 65, but their organizational knowledge is unique. Born between live” generation.
1946 and 1964, this generation grew up with Woodstock, the Beatles, and bell At thousands of metal fabrication businesses, the oldest Gen Xers are now in
bottoms. Their predecessors, the silent generation, grew up just after the Great positions of authority. They started work at a fab shop dominated by the CNC,
Depression and became great savers. The boomers, growing up during a post- though they may
22854 Thehave learned
Fabricator the ropes
Vertical FEB.aion 1a few old-school
1/11/16 11:16 machines.
AM They
war economic expansion, became great spenders. also saw the expanded use of software in not just machine control, but also
Boomers grew up during a time of tremendous change led by historic, char- shop management. They view new technology, like everything else, through a
ismatic figures. They experienced the fear of the Cuban missile crisis and the pragmatic lens.
excitement of the moon landing. They lived through the civil rights movement
and experienced women’s liberation. Many went to war in Southeast Asia.
“Boomers put their personal hallmark on work,” Thielfoldt said, adding that
they view people and projects in their environment from a broad perspective.
They value collaboration and teamwork, and put in long hours to make their
mark. “They support the value of coming together for the common good.”
In the process they became savvy navigators of the corporate hierarchy. As
Thielfoldt put it, “For many boomers, there is one way to move in an organiza-
tion, and that’s up.” The Learning Café calls them the “live to work” generation.
“The baby boomer generation added one full month to the work year.”
Underlying all this hard work is an optimism unfaltering in the face of high
inflation in the 1970s and globalization in the 1980s and after. They entered the
metal fabrication business as high-volume stampings were moving offshore and
the flexible and soft tooling of punch presses and laser cutting began to trans-
form the fab shop.
Many began their working years learning manual layout and programming
from their silent generation peers. They then saw software and CNCs utterly
change metal fabrication forever, and some boomers adopted that change with
gusto. The possibilities seemed enormous.
The boomers’ optimism took root during their formative years, when they
had a fair amount of time on their own to explore and play with friends. “They
came home from school, hopped on their bikes, and took off until their parents
called them or the streetlights came on,” Thielfoldt said, adding that this experi-
ence starkly contrasts with the experience of their children—and this in turn has
created some friction in the fab shop.

Gen X: Work to Live

When this generation walked home from school or the bus stop, they carried
house keys with them. The oldest of this generation, born between 1965 and
1979, remember their parents enduring times of high unemployment, high in-
terest rates, and sky-high inflation. Although some were too young to really un-
derstand what globalization really was, they saw its effects as their parents lost
their jobs.
“This was a dark time to be a kid,” Thielfoldt said. “The divorce rate doubled,
and we had a distinct drop in the population. If you analyze the events that in-
fluenced this generation, they were less than positive.”
During their early working years, they experienced the optimism of the 1990s
tech boom, the ensuing bust, and the terror of 9/11. All this has made many as-
sume that Gen Xers don’t trust employers and, hence, lack loyalty. But as Thiel-
foldt explained, this isn’t entirely true. “Gen Xers are highly committed to good
bosses,” she said. “They are also committed to the work and the team they are
a part of.”
Still, they do take a pragmatic approach to the workplace, they look at the
world with a critical eye, and they don’t mind breaking the status quo if that
helps them get the job done better and faster. Doing so, they add to their “por-
table” skill set.
Unlike boomers, they may not see a career as a straight-upward ladder but
rather a lattice. The more skills across the lattice they acquire, the more oppor-

FEBRUARY 2016 The FABRICATOR 67

1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004

Millennials: Live, Then Work
This latest generation to enter the workforce, born between 1980 and 2000,
can’t imagine a life without technology. They can’t remember a time when a
home didn’t have a computer, and the youngest of them can’t remember a time
when they didn’t have e-mail or the Internet.
They grew up during a time when kids no longer got on their bikes and rode
away until dinnertime. They grew up with arranged playdates. They also grew
up in a world in which multitasking was just how people lived their lives. They
did homework and checked e-mails on the way to or from soccer practice or
dance classes.
As Thielfoldt put it, “Millennials are the most wanted, most focused on, and
doted on generation that has appeared on this planet.” They grew up with
adults—parents, teachers, and others— who acted more like coaches and less
like army generals. They lived not by carrying out orders but by practicing and
performing a task, all the while receiving continual feedback from others.
Only some of them may remember the Gulf War and the fall of the Berlin Wall,
but all of them remember Columbine, and they all remember Sept. 11, 2001. A
half dozen years after the Great Recession ended, many remain unemployed or
underemployed; some moved back home.
These events, among others, buttressed a need to be connected with peers,
and it instilled a deep sense of civic duty and morality. They work for the greater
good, not just for money and financial security. To them, it’s not about “working
to live” or “living to work,” it’s about combining the two: live, then work. Many
don’t have a “work life” or “personal life.” They live a life in which work, leisure,
and play intertwine.
As Thielfoldt explained, “If you happen to be a Gen X manager who is manag-
ing millennials, here’s a coaching tip: It takes about two to three times more
time to manage, coach, and mentor them, and to get them started, than it did
when you were managing folks in other generations.”
Such coaching doesn’t sound at all positive, and it gives credence to common
complaints about millennials being an entitled generation. In a world of lean
staffs and cutthroat competition, who can devote so much time to training and
coaching people?
Thielfoldt responded this way: “Older workers and millennials have a differ-
ent view about work. [Older workers] think that [millennials] just don’t work
as hard as they do. And the millennial generation does not disagree. They ac-
knowledge that the baby boomers have a different work ethic than they do. Are
they lazy? I would bust that myth and say that they are multitaskers. Often, if
your millennials are engaged in multiple projects at the same time, that variety
challenges and stimulates them in the workplace.”
Managing the Generations
Adults have always complained about “these kids today.” To the same extent,
youth have always complained about the older generations, saying they’re
stuck in their ways. It’s not a new story, but as Thielfoldt explained, the current
situation has a new wrinkle.
The silent generation works hard for the greater good of an organization. Al-
though they have a different perspective, millennials work for the greater good
as well, which may be one reason, Thielfoldt said, for the fact that millennials
and the silent generation tend to get along well.
In manufacturing, the silent-millennial pairing—say, in a veteran and appren-

THE BEST GOT EVEN BETTER

tice relationship—may be particularly valuable. Using computer technology is
innate to millennials, but they didn’t grow up with the same hands-on experi-
ence as their grandparents. Today’s fab shop needs people comfortable with
both technology and hands-on work.
ALL NEW And what about having to be coached continually, the constant feedback, and

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shop and today’s manufacturer in general.
HMD904 The millennials work in a fab shop where part designs change often, assem-

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When people think of job flexibility, many think of technology workers
spending time in front of a laptop at the coffee shop, in the park, or wherever.
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Of course, manufacturing occurs at a plant and in specified shifts. A shop can
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this “multitasking” experience, millennials may bring a holistic perspective to
any improvement initiative.
Admittedly, sometimes there is no way to get around the fact that some op-
erations require repetitive work that demands prolonged concentration. One
careless move—say, fixturing a part incorrectly—and a day’s worth of work is
More features for safer, wasted. In these cases, Thielfoldt suggested engaging millennials in improve-
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68 The FABRICATOR FEBRUARY 2016

Hou-725-FAB-half.indd 1 1/7/16 1:53 PM
4 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 203

Communicating
Improvement
Say a fab shop wants to implement a
continuous improvement initiative.
Each generation may view that initia-
tive in a different light. An employee
who belongs to the silent generation
may view it from a financial sense.
Revenue and margins are what mat-
ter, and he knows that labor is the sin-
gle largest expense on a balance sheet
besides material costs. How secure is
to-day operations may leave more time for charities and vol-
unteering, be it sponsored by the company or on their own.
Back to Fundamentals
Thielfoldt emphasized that just knowing the character-
istics of a specific generation is a tool, but it won’t solve
underlying organizational problems on its own. Processes,
procedures, and best practices need to be agreed upon,
documented, and measured. Workers want to be appre-
ciated and their voices heard. They need some level of
training on the company’s procedures and processes. And
there needs to be some level of trust. As Thielfoldt put it, “If
organizations are not loyal to employees, we can’t expect
employees to be loyal to our organizations.”
Regardless, it’s never a bad thing to know where people
are coming from. Although the study of generations is an
inexact social science, it may help company leaders em-
pathize, minimize conflict, and get everyone on the same
page.
Senior Editor Tim Heston can be reached at timh@thefabricator.
com. For more on the Fabricators & Manufacturers Association
Annual Meeting, slated for Feb. 24-26 in San Diego, visit annual
meeting.fmanet.org.
The Learning Café, 843-471-2374, www.thelearningcafe.net

his job—really?
In this case, the manager might
make this argument: This lean initia-
tive will help us grow and compete. It
will make each person more produc-
tive and more valuable. And key to this
change is the technical knowledge
that the silent generation possesses.
Baby boomers may view the same
initiative as a personal offense. After
all, they helped build the company
into what it is today. In this case, the
manager might make the collabora-
tive argument: The lean initiative will

UNCAGED
involve everyone, from top managers
to the front lines. It will require every-
body to pull together. Being company
veterans, they personally connect
with a lot of workers in the plant, and
as the initiative commences, that
professional connection will be even
more important to sustain the effort.
Gen Xers may view the initiative

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They can imagine the extra hours
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describe a time-saving idea, such as
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inspection protocol, or a new tooling
technology that will reduce errors at
the press brake. The change itself may
require extra hours, but the result will
help make life more predictable and
manageable. For a Gen Xer who sepa-
rates work life from home life, that’s a
very good thing.
A millennial might think an im-
provement initiative is more of the
same. People don’t communicate
with him, and he doesn’t seem to be
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 TECHNOLOGY SPOTLIGHT
three-stage, 5-micron filtration system cleans the
Waterjet cutting is totally enclosed water for recirculation; the unit doesn’t need to be
hooked up to a water supply or a drain. The pump
No drain required
and motor are located at the base of the unit. The
machines can be designed with pumps that deliver
up to 40,000 PSI, Sarmiento said.
The unit does not require a power source. It is de-
signed to run off 230-volt, single-phase power.
“You can literally put this in your garage,” Sarmien-
to said. “We’ve had guys tell us that they are going to
pull out their dryer and put this in its place.”
The waterjet, which sits on casters, operates
like other waterjet cutting machines. A 19-in.,
Windows®-based touchscreen control is used to
program jobs, and a familiar-looking 3-axis waterjet
handles the cutting (see Figure 2). It can handle
a variety of materials, from metals to composites,
with positioning accuracy down to 0.0005 in.

The waterjet cutting system is

unlike other systems in that it
has a fully integrated water
recirculation system and an
Figure 1
The HSB24 abrasive machining center is designed for fabricating operations that require this type of high-toler- onboard pump and motor.
ance cutting capability, but do not have to contend with high-volume production pressures.

By Dan Davis, Editor-in-Chief system with a 24- by 24-inch X-Y cutting envelope.
At FABTECH, Sarmiento was demonstrating how

D
The equipment’s tank and guards are made from
an Sarmiento spent several years of his the waterjet could cut several metals, including
10-gauge stainless steel. The frame is constructed of
working life designing high-speed packag- 0.25-in. steel, using only 15,000 PSI.
2- by 2-in. stainless steel tube. The panels to see into
ing lines for the pharmaceutical industry. “You can compensate for less pressure by using
the cutting chamber are made of 3⁄8-in. clear Lexan™.
He invested a lot of time in developing fast-paced more abrasive,” he added. “Typically something like
“There is nothing on this machine that will ever
systems for a fast-growing industry. this, we would be running 1.25 to 1.50 lbs. of abra-
rust,” he said.
To get parts for these systems made, he worked sive per minute.”
The waterjet cutting system is unlike other sys-
Hydren Systems LLC, 1900 N. La Canada Drive, #70027,
with several fabrication shops. Most of the parts re- tems in that it has a fully integrated water recircula- Oro Valley, AZ 85737, 941-448-7837, www.hydrensys
quired waterjet cutting, which delivered very high tion system and an onboard pump and motor. The tems.com
tolerances and did not create a heat-affected zone
in the metal while cutting.
With each shop visit, however, Sarmiento’s nega-
tive image of the waterjet cutting process was rein-
forced. He couldn’t get the unorganized and dirty
scenes of the fabricating areas out of his mind.
“I didn’t like the fact that you could walk into a
waterjet shop and that within a 60-foot radius of the
machine, garnet was everywhere. I didn’t like the
fact that after five or six years the waterjet machines
were complete rust buckets because they make the
waterjets out of mild steel and then paint them,”
Sarmiento said.
That led him to create his own waterjet cutting
machine. The HSB24 from Hydren Systems made its
formal industry debut at FABTECH® 2015 in Chicago
last fall (see Figure 1).
The waterjet cutting system is not designed for
the typical fabricating job shop. Targeted users are
colleges, technical schools, engineering shops, and
high-tech start-ups, according to Sarmiento.
Neither is the HSB24 designed to accommodate 4- Figure 2
by 8-foot or 5- by 10-foot sheets. It’s a fully enclosed This stainless steel tubular part was cut on the portable waterjet.

70 The FABRICATOR FEBRUARY 2016

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 TECHNOLOGY SPOTLIGHT
Part marking on the move
Marking unit has desktop capabilities
in a portable design
Figure 1
The traditional handle and an upper stabilization handle on the FlyMarker® mini help the operator to securely position
the marking unit on the workpiece.
By Dan Davis, Editor-in-Chief
P
art marking isn’t something that dominates
the thoughts of many metal fabricators,
but maybe it should. After all, if a shop has
spent thousands of dollars to automate mate-
rial handling for laser cutting or punching opera-
tions, shouldn’t it be concerned about the time it
takes for a shop floor technician to walk between
a stationary part-marking unit and the operations
where the parts are located?
72 The FABRICATOR FEBRUARY 2016
That’s not time that the customer is paying for,
and that is something that fabricators can under-
stand. Waste, in this case non-value-added time, is
no one’s friend.
That’s why Equipment Sales Co., a subsidiary of
Rocklin Manufacturing Co., which is known in the
metal fabricating industry for its Rocklinizer car-
bide application equipment, is excited about its
latest generation of dot peen marking technology
(see Figure 1). The FlyMarker® mini weighs 5 lbs.
15 oz. (2.7 kg) and is encased in a plastic housing
that is designed to be more durable than traditional
die-cast aluminum housings. The unit, which has
a marking area of 2.56 in. (65 mm) by 1.19 in. (30
mm), can not only mark metals such as aluminum,
stainless steel, and hardened steel, but also plastic
(actually, any material up to 62 Rockwell). Because
the marking force and subsequent marking depth
can be adjusted, the markings the unit creates can
stand up to activities such as sandblasting and coat-
ing and still remain visible, according to company
officials.
“This is for anywhere that a product has to be
identified,” said Ross Rocklin, the company’s vice
president. “It can be used to keep track of heat num-
bers, job numbers, and part numbers.”
Rocklin described a situation in which sheet
metal is loaded onto a laser cutting machine, and
the original identification tag that accompanies the
sheet is located in one corner. When the cutting be-
gins, the sheet is transformed into several individu-
al parts with no identification and no history. This is
where the FlyMarker mini can make a big difference:
It allows the machine operator to quickly mark the
parts so that downstream operations know what
they are handling.
The unit’s software is designed to be easy to fol-
low, so much so that a nontechnical person can
handle programming, Rocklin said. A numeric key-
board is integrated into the user interface to assist
with programming; users can type the numbers di-
rectly from the keyboard without having to worry
about venturing into the software. They are able to
view the picture of the marking file in the color dis-
play before the marking process begins.
If the fabricator chooses to upload the file to the
unit, it can handle that as well. The internal mem-
ory can store about 800 files, according to Rocklin.
USB interfaces on both sides of the
marking tool can handle importing of
marking files. Additionally, a device
such as a bar code scanner can be
connected directly via the interfaces.
For nonflat surfaces, the marker
has features that help to ensure con-
sistent marking. Height controls com-
pensate for changes up to 0.20 in. (5
mm) to deliver consistent marking
depth on wavy surfaces. Two prisms
on the positioning plate help to mark
round workpieces radially and axially.
“The other thing that it does is con-
vert to a tabletop unit, if you want
something stationary,” Rocklin said.
In today’s lean manufacturing
world, it’s always good to have the
possibility of portability.
Equipment Sales Co., a subsidiary of
Rocklin Manufacturing Co., 118 South
Jennings St., Sioux City, IA 51101, 800-
255-6046, www.flymarker.us
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 Being better
while being bigger
Mayville Engineering Co. is proving that metal fabrication can be the
basis for big business. Through multiple acquisitions and internal growth,
the fabricator has tripled its revenues since 2010. This robust expansion
is one of the main reasons The FABRICATOR has named MEC
the winner of its 2016 Industry Award.
74 The FABRICATOR FEBRUARY 2016
By Dan Davis, Editor-in-Chief
A
cquisitions are always difficult to pull off.
First, the financial transaction has to meet
the requirements of both the buyer and
seller. If that can be accomplished, the acquiring
company has to begin the process of integrating
the new organization into the family—surveying
manufacturing capabilities, getting to know em-
ployees and customers, and taking a critical look at
incoming work processes and IT systems. It takes
time and plenty of focus to pull off successfully.
Now imagine that during such a transaction, a
metal fabricator finds an opportunity to add some
new manufacturing space and expand its capabili-
ties. It has to take into account new facility layouts
and incorporation of new fabricating technology
on the shop floor without interrupting service to
existing customers. That’s a major administrative
challenge for any fab shop, but to attempt to do
something like that in the face of ongoing acquisi-
tions and an uncertain economy might make some
industry observers scratch their heads.
Mayville Engineering Co. (MEC) accomplished
both of those feats over the past three years. At
the end of 2012, the Mayville, Wis., fabricator had
completed a deal to acquire Center Manufacturing
of Byron Center, Mich.—a company that was 80 per-
cent of MEC’s size. The acquisition gave MEC new
fabricating capabilities, such as complex frame as-
semblies for the power sports market, and access
to a manufacturing-rich regional market. In the fall
of 2014, MEC added to its Virginia operations with
a new 148,000-square-foot, state-of-the-art manu-
facturing facility in Atkins, Va. The move solidified
its presence in southwest Virginia, and the new
capacity actually opened the door to some much-
welcomed internal growth opportunities.
In 2015 the heavy lifting associated with these
expansion efforts had evolved into everyday com-
pany operations. Human resource policies are now
consistent. Manufacturing capabilities have been
fully cataloged, and best practices are being shared
among MEC’s seven Wisconsin locations; two plants
in Virginia; and the former Center Manufacturing lo-
cations in Michigan, Mississippi, and South Carolina.
The tube business systems have been converted to
MEC’s homegrown production planning system to
support commonality, speed, and flexibility, while
a remaining legacy system is refined to be effective
in a high-volume, low-mix manufacturing and plan-
ning environment.
Reflecting its growth—and trying to formalize the
idea of it being one entity with several manufactur-
Figure 1
Robert Kamphuis, MEC’s chairman, president, and
CEO, is surrouned by some of the company’s manager
and front office and shop floor workers, who also hap-
pen to be shareholders in the fabricating business.
MEC is one of the nation’s largest employee-owned
companies in the U.S. (Photos courtesy of Artist Group
Photography and Video).
Figure 2
Robotic press brakes not only increase part bending efficiency, but also help operators avoid the potential of
strained backs caused by the manipulatin of large and heavy parts.
ing talents instead of a holding company with sev-
eral manufacturing businesses—the company has
spent the last several years rebranding itself as MEC
(which rhymes with “tech”). For example, it’s no lon-
ger called Mayville Engineering or Center Manufac-
turing, but MEC Fabrication. Fabricating Specialists
of Neillsville, Wis., is now MEC Tube, and Phoenix
Coaters in Beaver Dam, Wis., is now MEC Coatings.
Even the shotshell-reloading business, one of the
company’s original product lines, dating back to the
mid-1950s, is now known as MEC Shooting Sports.
To be specific, MEC’s revenue was $335 million
in 2014, which put it at the top of The FABRICATOR’s
FAB 40 list for the fifth year in a row. It expects to
generate sales in the range of $350 million this year,
even faced with declining markets in agriculture
and mining; new markets that came with recent
business acquisitions have helped to balance out
the dips in the other markets.
“I think the story here is tying a fragmented mar-
ketplace together,” said Robert Kamphuis, MEC’s
chairman, president, and CEO. “There are a lot of
smaller shops out there. What we do is look to ag-
gregate or consolidate that.”
Maintaining this type of dramatic growth is typi-
cally the realm of venture capitalists, who buy dis-
tressed businesses, build them up, and then sell
them off for healthy profits. Kamphuis said that’s
not MEC’s motivation. It wants to build a big fab-
ricating business that is responsive to customer
needs, is supportive of the local communities in
which it operates, and is profitable for the compa-
ny’s shareholders (see Figure 1).
In recognition of the creation of this huge fabri-
cating business, The FABRICATOR has named MEC as
the winner of its 2016 Industry Award. The compa-
ny, with approximately 2,000 employees and 17 lo-
cations, is building its fortune the same way a small
shop might go about it, and it’s having great success
doing it that way.
Diversify or Die
Diversification has not only been good for growing
MEC’s customer base, but also for creating consis-
tency in production levels, helping the company to
avoid the major peaks and valleys that might oc-
cur with only a few major customers. The blue-chip
manufacturing companies like the idea of doing
business with a fabricator that has the foundation
to sustain in uncertain economic times.
MEC knows the dangers of relying on one or two
industries for most of its business. In the late 1990s,
the company had a major aerial scissor lift business
that propelled it to purchase a 163,000-sq.-ft. facil-
ity to handle the expanding manufacturing activity.
By 2001 a competitor had introduced an articulat-
ed boom-type product that totally changed what
people could do with a lift, and MEC had to shut
down production in its new Beaver Dam, Wis., facil-
ity shortly thereafter. Also around that time, one of
its large customers in the electronics area shifted its
production to overseas sources.
Those lessons were never to be forgotten and
were a key motivation to seek out new opportuni-
ties, in this case Center Manufacturing. The acqui-
sition got MEC into complex, tube-intensive frame
structures for performance sports, and it’s proved
beneficial while agriculture and mining, or “earth-
connected” industries as Kamphuis describes them,
await for the global economy to rebound.
Not only does this diversification help to provide
a safety net from the ups and downs of volatile in-
dustry segments, but it also has provided a valuable
manufacturing perspective. The individuals who
were part of the Center Manufacturing deal came
with a lot of automotive experience, which makes
sense given their proximity to the Motor City, and
they are very familiar with sophisticated tube frame
designs that rely on automated welding.
FEBRUARY 2016 The FABRICATOR 75
Save the Date
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are excited to present a two-part
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Figure 3
MEC has the capability to laser-cut metal up to 0.625 in. thick while maintaining tol-
erances to 0.002 in. at speeds up to 1,300 inches per minute.
“[With that experience] they are then able to take what they know in automo-
tive, combine that with the experience and interaction of the high-mix and low-
volume environment, and tailor some nice solutions that provide a competitive
advantage on cost,” said Chad Mitts, MEC’s executive vice president.
As an example, Mitts said the folks with MEC Fabrication understand how to
cost-effectively design for low-volume, prototype, and aftermarket manufac-
turing without the need for hard tooling, using their knowledge of fabrication
efficiencies, such as modular welding fixturing. Simultaneously, engineers at
MEC Performance Structures, which evolved from the Center Manufacturing
purchase, have a lot of experience with dedicated equipment, fixtures, and
processes for high-volume, repetitive products. The result of such mind-melds
of these parties is a fabricating scenario in which turnarounds are measured in
days, not weeks.
“Our diversification is probably the best in the marketplace of the companies
that do the type of work that we do,” Kamphuis said.
MEC Requires Tech
Opportunities to pursue potential acquisition targets and grab market share
from other fabricators that are unable to meet the requirements of large OEMs
can occur only if MEC has capacity. That’s why it needs flexibility on the shop
floor to absorb spikes in job orders.
“Being able to move quickly is key,” Kamphuis said. MEC spends about 150 to
200 percent of the company’s annual depreciation on capital equipment pur-
chases.
Eric Welak, MEC’s vice president of operations, cited two TRUMPF robotic
press brake cells (see Figure 2) as examples of recent equipment investments
that can take on additional work without supervisors having to scramble to find
additional human operators.
“Most parts that run through there would have taken two or three people to
move the part around to position it in the press brake,” Welak said. “Now the
robot is doing that, and it’s doing it faster and with better quality.”
Capital expenditures are focused on growth areas, as MEC works to fill current
footprint capacities. Kamphuis said the company is always ready to take a look
at potential investment as new opportunities come along. New opportunities
that require additional equipment trigger quick discussions about availability
of the new fabricating equipment, the possible implementation window, and
the deadline for having the new capacity available.
When capacity utilization hits 80 percent for a certain fabricating operation,
MEC starts looking at potential relief alternatives. To offset what might be a tem-
porary peak in production, company officials may elect to outsource the extra
work. If it continues, of course, discussions about capital equipment invest-
ments begin.
76 The FABRICATOR FEBRUARY 2016
 Across its many facilities, MEC has a facturer making the same few widgets every day, it’s easier fed into a subassembly and then the final assembly. The
breadth of fabricating capabilities: to schedule. software system used had to contend with numerous lev-
• Solid-state and CO2 laser cutting “We see changes weekly, and we have to react to those. els of bills of materials.
systems (see Figure 3) Our capacity planning tools allow us to do that quickly “Our dataset back then was built around complexity. To-
• Plasma cutting machines when we are dealing with a lot of complexity and multiple
day that heritage helps us to be a lot more agile and able
• Press brakes ranging in size from parts,” Welak added. “It’s second to none and possibly the
to plan at a detailed level and with a lot of flexibility,” Kam-
35 to 400 tons best in the market.”
phuis said.
• Large-bed stamping presses from Kamphuis said the origin of the current software system
dates back to MEC’s scissor lift manufacturing days. Back How might that agility work? Responses to requests for
50 to 1,200 tons, some with in-die
then the shop floor was dealing with projects that could be quotes are detailed because they are repeat jobs or contain
measuring and sensing
a simple product or a much more complex assembly that elements of similar jobs.
• Coil processing equipment that
can handle coils up to 8,000 lbs.
• Robotic welding cells (see Figure
4)
• Milling and turning equipment
• Tube cutting and bending ma-
chines that can accommodate round
and rectangular tubes from 0.25 to 8 in.
• End forming equipment for tube
fabrications
• Powder coating and painting lines
• An electrodeposition (e-coat) line
• A two-pass chemical agent-re-
sistant coating paint line for military
markets

“Our diversification is
probably the best in
the marketplace of the
companies that do the
type of work that we do.”
—Robert Kamphuis, MEC

Planning for Capacity

Equipment to take on additional ca-
pacity is useful only if it’s in place on
time. MEC can do that because of its
investment in capacity planning tools.
The origins of this homegrown shop
management software tool date back
to MEC in the late 1970s and early 80s.
From the start, the goal of the IT sys-
tem was to use it to improve and stan-
dardize all quotation, product launch,
and production-planning activities.
Today the enterprise software sys-
tem that runs the high-mix MEC busi-
nesses has an Oracle database foun-
dation, and MEC’s IT staff maintains
the specialized applications that were
written to accommodate the variety
associated with the company’s job
shop business.
“We have the ability to manipulate
it so that it fits our business, and we
have done that for years,” Welak said.
“What keeps us nimble is our ability
to do capacity planning in a contract
manufacturing environment, which
isn’t typical. When you are a manu-

FEBRUARY 2016 The FABRICATOR 77

Figure 4
MEC can design and construct its own weld fixtures, which helps to minimize the
turnaround time for automated welding jobs.

If a purchase order is issued for a job, the quote is then fed into the produc-
tion planning system. No one is expected to re-enter the data. The information
flows through the entire organization. Machine time is scheduled, material use
is noted, and CAM programs are created in some instances. At the same time,
when the project is given the green light, future production capacity is reflected.
“This is the most efficient way to drive down your cycle time development
and to make sure you are providing the best cost solution out there,” said Ryan
Raber, MEC’s vice president of sales and marketing.
The IT systems have scaled successfully as MEC has grown larger over the past
several years. They have allowed the company to truly grasp the entire organi-
zation’s manufacturing capabilities over its many locations and distill that into
thorough and realistic quotes.
Welak said that MEC’s IT department, which is made up of software develop-
ers who have learned about fabricating and manufacturing professionals who
have jumped into coding, has had to expand its ranks by just two because of
company expansion. The software has proven to be a useful tool for all parties—
MEC veterans and new users—and the IT department hasn’t had to worry about
reinventing the system with the arrival of new manufacturing entities into the
MEC family.
MEC knows what’s coming, and it can react appropriately. Meanwhile, the
company’s software is flexible enough to accommodate the inevitable daily
production schedule changes that come with the fabricating environment. MEC
has created a valuable tool that other fabricators would find hard to duplicate.

Deliver the Value

Talk of winning quotes may lead others to believe that MEC must be pretty good
at such a task. With annual revenues above $300 million, sales personnel must
be closing a lot of deals.
That’s not the way the fabricator looks at its customer-facing efforts, however.
It has a team of sales engineers who are aligned with markets and large cus-
tomers. All of these individuals have either an engineering or a technical back-
ground. Each one of these 30 sales engineers is a face for the entire MEC organi-
zation, knowledgeable about all that the company can offer and skilled enough
to present the best approach to get a fabrication made quickly and efficiently.
“Where the value is created isn’t in a customer sending me 100 prints and me
sending 100 quotes,” Raber said. “Let’s find out what needs to happen, and let’s
have a technical conversation where we can get the intention of the part, not the
design of the part, and get that figured out. We’ll end up in the best cost position
by doing all of the other things right upfront.”
MEC puts its money where its intentions are. It has a couple of sales engineers
that actually maintain an office at the customer locations. They interact with
the customer’s engineers and work with them to ensure parts are designed for
manufacturability.

78 The FABRICATOR FEBRUARY 2016

 MEC also maintains a prototyping group for its fabricating and tube business.
They are able to test early designs, which not only helps the customer’s produc-
tion development teams, but also allows MEC to prove whether the part designs
are as easy to fabricate as planned.
Kamphuis said the company tracks the revenues and costs separately for the
prototyping activities because it’s important to know how much customers are
leaning on MEC for these services.
“The reason that we went this route is a lot of our business is about listening
to the customer and what they value,” Raber said. “Over the years, the OEMs
used to be very vertically integrated. However, you don’t see a lot of brick and
mortar investment by those guys anymore. They design, assemble, market, and
distribute the product. They are getting out of manufacturing.
“We have seen the need to be the technical experts, and for them to trust us
because we are the experts in what we do.”
The model is not just a simple commercial interaction for MEC. They are fabri-
cating experts for those companies that don’t have that expertise.

“We see changes weekly, and we have to react to those. Our

capacity planning tools allow us to do that quickly when we are
dealing with a lot of complexity and multiple parts. It’s second
to none and possibly the best in the market.”
—Eric Welak, MEC

The Path to Continued Growth

When asked if he thinks MEC is still a manufacturing company, as opposed to a
“solution provider,” “product life cycle manager,” or some other slick marketing
descriptor, Kamphuis was quick to say his company is still a contract manufac-
turer. It just happens to have a perspective that maybe other fabricators don’t.
“Whereas many shops are concerned just with getting the quote and deliv-
ering the product, MEC sees opportunity in all aspects of customers’ product
development. MEC has structured itself in such a way to be all of these things to
all of its customers,” Kamphuis said.
If a customer needs engineering assistance, the approximately 80 engineers
in the MEC ranks can assist, and the prototyping service can turn around designs
quickly without the hassles of having to navigate the shop floor. If a customer
needs to ramp up production, MEC has the capacity, technology, and manufac-
turing locations to make that a reality, whether it’s high-volume production that
requires hard tooling or a smaller run that involves laser cutting, bending, and
some welding. If a customer has to deal with legacy products and isn’t inter-
ested in handling aftermarket inventory, MEC is responsive enough to be able
to build fabrications that meet original design specifications and have them
shipped out. In the meantime, customers realize that they are dealing with a
company of a certain size and level of success, which gives them confidence that
they won’t be closing up shop because the stock market has had a bad week.
“We are in this for the long haul,” Kamphuis said. “Even though our metrics
and goals are tough, we are not waiting to hear whether or not our shareholders
like us. They all work here in our shop. We do things for the right reasons and for
the long-term return on investment.
“Our model is unique. MEC’s agility, adaptability, and alignment of perfor-
mance and value creation is in place,” he said, “and it has a long horizon to it.”
On the outskirts of Mayville’s downtown is a historical marker noting that the
town was the site of Wisconsin’s first iron smelter. In 1847 John Orr and James
White founded Wisconsin Iron Co., and two years later the company’s furnace
fired up its first molten iron. The company’s furnaces produced iron for 79 years,
but the facility shuttered in 1928 with the disappearing demand for pig iron.
Eighty-eight years later, metal is big in Mayville again. It’s not the raw mate-
rial that’s going to keep the story going, however. It’s MEC’s fabricating prowess
that will keep the company growing and, ultimately, the story might be worth a
historical marker of its own.
Editor-in-Chief Dan Davis can be reached at dand@thefabricator.com.
MEC, 715 South St., Mayville, WI 53050, 920-387-4500, www.mecinc.com

FEBRUARY 2016 The FABRICATOR 79

 Figure 1
Advanced hydraulics and intelligent drive systems are
now available to help metal formers tackle more chal-
lenging projects that involve new metal alloys that can
be difficult to form.

harmonize the target/actual position in real time

within milliseconds. The precision of the movement
solely depends on the measuring system used. In
stamping presses, hydraulic drives can reliably po-
sition axes to within a few micrometers of precision.
One way to achieve this precision is through the
use of more powerful and accurate measuring sys-
tem technology. Transducer electronics have been
dramatically improved, with digital transducers
being free of electrical noise interference present
in older analog devices. Combined with the right
digital hydraulic controller, transducer electronics

Modern hydraulics: achieve and sustain a much higher level of control

over motion sequence parameters such as speed,
velocity, and force. This equals much greater con-
trol over the quality and precision of the part being
Six advanced capabilities for stamping presses produced.

The need to form more complex shapes and to work with high-strength Compact and Powerful
materials drives stampers to adopt advanced technology
It is often difficult to place electromechanical
drives with sufficient performance in tight machine
spaces. Unlike hydraulic drives, they also generate
significant heat. This is one of the key advantages
that hydraulics continues to provide for stamping
By Jeffrey Grube and Jens Schmitt Advanced hydraulics and intelligent drive sys-
presses. Because power generation is decentralized

B
tems now are available to provide greater precision
y virtue of its speed, force, and power den- and improve stamping press productivity and prod- in the hydraulic power unit and is connected to the
sity, hydraulics technology has long been uct quality. Some of the capabilities of this versatile actuator via lines or pipes, machines can generate
used as a core drive system in stamping drive technology may come as a surprise. great forces even with minimal construction space
presses. Yet stamping press manufacturers are un- (see Figure 2).
der pressure to deliver more sophisticated perfor- Micrometer Precision Even for older-model stamping presses, dramatic
mance. Electrohydraulic axis controllers close the control improvements in power density can be achieved
Operators need presses that can provide greater loop decentrally, similar to electric servo drives, and by retrofitting them with modern electrohydraulic
precision; produce more complex shapes and parts;
and operate with increased productivity, cost con-
trol, and energy efficiency. Many machine designers
may not be aware how the latest electrohydraulic
control technology has significantly advanced the
performance and intelligence of modern hydraulics
to achieve those objectives.
Two areas in particular are driving the demand
for better hydraulics technology in stamping press-
es. One is the need to improve precision for increas-
ingly complex shapes stamping presses produce.
For example, in the automotive industry, doors,
quarter panels, fenders, and other components fea-
ture complex, rounded surfaces that require sophis-
ticated hydraulics and controls to achieve accurate
and high-volume fabrication.
The industry also is seeing a movement to greater
use of higher grades of steel, steel alloys, and alumi-
num to fabricate parts (see Figure 1). These mate-
rials react differently to forming processes, which in
Figure 2
turn require better hydraulic control to handle the This amount of space can accommodate electrohydraulics that can deliver high levels of pressure in a stamping
formability challenges. press.

80 The FABRICATOR FEBRUARY 2016


Figure 3
Today’s advanced controllers help hydraulic presses to deliver smooth transitions between position and force,
generate smooth motion trajectories, and synchronize multiaxis movement.
technology, which is compact yet delivers hydraulic
pressure up to 5,000 pounds per square inch.
This kind of retrofitting also can add a level of
sophistication to stamping press cushioning func-
tions. Synchronization of the speed, velocity, and
force parameters of the cylinders driving the cush-
ioning axis now can be more sophisticated for shap-
ing an asymmetrical part, enabling older presses
retrofitted with the latest hydraulics to produce
higher-quality, higher-value products.
On-demand Energy Efficiency
Some of the most important advances in hydraulic
stamping presses involve technologies that operate
more intelligently, such as variable-speed hydraulic
pump drives. In these systems, software combines
the best characteristics from electronic and hydrau-
lic products. The decentralized intelligence in the
electronic control device coordinates the rotational
speed of the hydraulic pump drive on demand as
the stamping press requires power, or reduces it to
zero to save energy in idle mode.
In comparison to traditional constant-speed drive
systems, energy consumption of hydraulic power
units is reduced by up to 80 percent. This can offer
significant savings for older facilities and stamping
presses, extending their service life while reducing
energy consumption. Those savings can help justify
the investment in a hydraulic system controls up-
grade.
Balanced Drive Physics
Fluid technology is not always inherently linear.
Drive software for hydraulic actuators takes these
characteristics into consideration and harmonizes
them automatically. Pre-programmed hydraulic
function blocks, like synchronization and position-
dependent braking, provide the software founda-
tion for efficient hydraulic controller programming.
Hydraulic motion control components have been
specifically engineered to take full advantage of
modern electrohydraulics and variable-speed pump
drives. They provide intelligent, high-performance
control for these pump systems as well as systems
controlled with traditional proportional valves.
They typically feature advanced control software
packages tailored to the unique demands of hydrau-
lic system properties (see Figure 3). For example,
the software compensates for factors such as fluid
compressibility and nonlinear system dynamics.
Hydraulic-specific algorithms for proportional valve
and variable-speed pump drives allow for smooth
transitions between position control and force con-
trol, the generation of smooth motion trajectories,
Figure 4
Ready-to-install servo-hydraulic axes are designed to
transform an old hydraulic press into a modern metal
forming tool in a short time frame.
and multiaxis synchronization. These features re-
duce system shock and impact on tooling, provide
improved dynamics and accuracy, and boost ener-
gy efficiency and press productivity.
Open and Easily Integrated
Real-time Ethernet protocols are used more and
more in modern machines to integrate all actuators
and peripherals together. This trend also includes
stamping press operations.
One key driver in this area is quality control and
process data capture for both diagnostic purposes
and to document quality processes for end-user
parts customers. Hydraulic controls platforms not
only need to tell a valve what to do, they also need
to capture data such as valve position and cylinder
delivery force and then communicate that informa-
tion from the press to higher-level management
and quality control systems.
Modern motion controls for hydraulic drives sup-
port all common protocols such as Sercos, EtherCAT,
Ethernet IP, PROFINET RT, Powerlink, and VARAN.
Their software is also based on open standards in-
cluding IEC 61131-3 and PLCopen. With this sup-
port, they are an ideal match for the increasingly in-
tegrated and technology-overlapping infrastructure
of modern production environments and provide
stamping press operators with competitive advan-
tages as they work with customers who need “smart
factory” machine-to-machine communication and
data sharing. This is especially important as ma-
chines incorporate Industrial Internet of Things and
Industry 4.0 concepts.
Plug-and-Play Modularity
Ready-to-install servo-hydraulic axes have an inte-
grated fluid loop and are driven by the same elec-
tric servo drives as electromechanical versions (see
Figure 4). Many hydraulic axes are now available
as complete self-contained systems, to which engi-
neers can simply connect power and communica-
tion cables for assembly and start-up. Everything
else (for example, the parameterization values de-
termined from simulations) is already stored in the
drive software and supports the plug-and-play phi-
losophy.
For stamping press operations, a modular, self-
contained hydraulic axis—comprising cylinder,
motor, pump, and manifold—could provide an ef-
ficient, easily integrated way to upgrade second-
ary systems, such as tooling used to punch holes
on parts that are being simultaneously formed. It
also could be a cost-effective method for handling
systems that move source metal into presses or re-
move finished parts.
Jeffrey Grube is press group manager and Jens Schmitt
is manager, stamping presses, Bosch Rexroth Corp.,
2315 City Line Road, Bethlehem, PA 18017, 610-694-
8300, www.boschrexroth-us.com.
FEBRUARY 2016 The FABRICATOR 81
Considerations for designing parts for
By Kevin Fradette
Y
ou might have noticed some co-workers
with gray hair. It’s not surprising because
baby boomers, the generation born between
1946 and 1964, have been a large part of the manu-
facturing landscape for most of the last 20 years.
That’s changing, however. As the oldest of the
boomers are heading for retirement, a new genera-
tion of employees are joining the metal fabricating
field, and they probably are having to learn as much
as they can from the shop veterans before they
make their final exit. Unfortunately, the industrial
technology courses that helped to shape a genera-
tion of tinkerers and gearheads simply don’t exist
today.
That’s why it’s important to revisit some basics of
part design. In this case, the focus is on laser cut-
ting. Even though laser cutting has been an integral
part of metal fabricating for the last 20 years, it still
might be new to novice sheet metal and plate fab-
ricators. These design tips can help get them up to
speed.
No. 1: The Laser Changes the Material
Anyone who uses a laser to process parts must real-
ize that a high-intensity light source used to gener-
ate a laser beam is so hot that it melts metal in a
millisecond. Therefore, any part processed with
a laser is exposed to extreme heat and will have a
heat-affected zone (HAZ) along the edge of the cut.
For almost all fabricators, this HAZ is a nonissue,
but in certain fields, such as aeronautics, it can be a
serious issue. Critical parts for these industries often
82 The FABRICATOR FEBRUARY 2016
laser cutting
Edge requirements, pierce points, and material thickness
are just some of the factors to examine
are not laser-cut because the design engineers can- Figure 1
not take the risk that the metal will form microfis- Piercing during laser cutting is a much more controlled
process than it used to be, often leaving a clean sur-
sures that could pose a problem in the future. face. Older laser cutting technology delivered an ex-
plosion of molten metal that often left the surface area
No. 2: Watch for the Taper covered in splatter.
All laser-processed parts have a taper of some de-
ly, which results in dross forming on the relief edge.
gree because the focused laser beam is not perfect-
That dross gets in the way of the bend. The part
ly straight, but rather is shaped like an hourglass. In
thin material the taper is so minimal that it is not an must be redrawn so that the laser can process it cor-
issue. The taper starts to show in material 0.50 in. rectly.
and thicker.
No. 4: Put the Pierce in Its Place
Fabricators concerned about taper should be
Piercing through material with a laser has greatly im-
aware that machine tool builders have developed
proved compared to how it worked in the early years
new technology that improves the cut quality and
speed, while reducing the amount of taper in thick- (see Figure 1). Fabricators now can use various
er material. For example, a new nozzle technology is piercing methods to process their parts. These in-
being used to funnel the cutting gas to the cut itself clude fast piercing; slow, gentle piercing; and multi-
rather than allowing it to spread over the material. stage piercing. The gentle and multistage pierces
Also, beam modulation is being used to improve the are designed to minimize the amount of splatter
cut edge quality. that can land on what will be a finished part.
No. 3: Be Aware of Bend Reliefs
One of the best advantages of using a laser to process
sheet metal is that it can create just about any shape
required. The only limitation is part size, although it
is amazing how small laser-cut parts can be.
One consistent part design error is improper bend
reliefs drawn into parts. Often in thin-gauge mate-
rial, these reliefs are simply too thin to achieve a
good cut straight off the laser. The problem occurs
because the assist gas travels the path of least resis-
tance, which is the first segment of the path the laser Figure 2
The part that was cut with oxygen as the laser cutting
takes. As the laser travels back up the other side of assist gas is marked by a black edge. The clean part
the relief, the melted material is not ejected proper- was cut with nitrogen.
 Optical sensors are also being used to determine the moment that the laser No. 7: The Part Shape Affects Cutting Efficiency
has penetrated the material so that the cutting can begin. This feature helps to Solid-state laser cutting technology has increased the machines’ cutting speeds
reduce the production time of parts. and reliability, but it has not changed the way people think about designing
Because a finished part’s appearance is often important, a laser programmer parts. Whether cutting with a traditional CO2 laser or a solid-state laser, a fabri-
has to place the pierce point in an ideal location. One of the best places to put the cator should take the same considerations into account to increase the reliabil-
pierce is in the middle of a small slug of material. Placing it there greatly reduces ity of the cutting process and to get the best end result.
the risk of pierce splatter and the heat effect in thicker material. For example, if a part is engineered with 90-degree corners, the cut time can
What happens when the pierce is in the wrong place? Consider a pierce that is increase and the part quality decrease. Because the laser cutting head has to
placed 1⁄4 in. away from what will be the hole edge in 1⁄2-in. mild steel. If the pierce decelerate as it takes the sharp corner, it can overburn the corners, causing
point is placed close to the edge that will be cut, heat or splatter from the pierce dross to form. It might even burn away the corners entirely. Generally, the larger
could affect the quality of the cut or even cause the cut to be lost. By moving the the radius a design engineer is able to allow, the better. This enables a fabricator
pierce point away from the edge, the design engineer circumvents those issues. to increase the cutting speed and part quality.
Kevin Fradette is a laser applications engineer, TRUMPF Inc., Farmington Industrial
Park, Farmington, CT 06032, 860-255-6000, www.us.trumpf.com.
No. 5: Will the Parts Be Powder-Coated?
If a part is to be powder-coated, a fabricator has to keep a few things in mind.
The most important issue is what assist gas should be used to cut. If oxygen is
used, a secondary process such as tumbling or an acid bath will be required to
remove the oxide layer that forms on the edge of the part during laser cutting.
Quality & Performance
If that oxide is not removed prior to powder coating, the cured powder finish Backed By Decades Of Experience
eventually will flake off because it is attached to the oxide layer and not the
metal itself.
To eliminate the need to remove the oxide layer, fabricators can cut with ni-
trogen as the assist gas because it yields a clean cut (see Figure 2). With nitro-
gen gas cutting, the more power the laser has, the thicker the material that it
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Depending on the laser power, a fabricator also needs to consider the ma-
chine’s ability to process a material with the desired end results. If, for example, Mandrel & Non-Mandrel
a company wants to purchase a laser to clean-cut 0.1875-in. steel that will be Manual/Automatic
powder-coated, the company would want to analyze the differences in the fin-
ished part when using a 3-kW laser cutting machine as opposed to 4-kW equip- Solid Steel Frame
ment. The greater power level of the 4-kW machine may give them the results Programmable
they want to achieve without nitrogen. The 3-kW machine may require the use
of oxygen as the laser assist gas to obtain a dross-free part. Steel Tooling
Quick Release
No. 6: Material Thickness May Not Matter Anymore
Flat sheet laser cutting machines are really making strides in their ability to pro- Heavy Duty ETM-90
cess materials. Today’s solid-state laser cutting technology processes thin mate-
rial very quickly. For instance, an 8-kW solid-state laser cutting machine can cut
0.039-in.-thick steel at a speed in excess of 2,000 inches per minute (IPM).
Even for thick plate, fabricating technology developers continue to increase
the speed at which fabricators can cut. Using the latest solid-state cutting tech-
nology, fabricators can cut 1-in. mild steel at speeds greater than 35 IPM. For
3000 Series
Double Pinch
that material especially, the speed has improved compared to what was pos-
sible even just a few years ago. The cut edge quality also is improved greatly.
The latest laser cutting technology also can process up to 1-in. aluminum and Roll Bending
2-in. stainless steel (see Figure 3). For reflective material such as brass and & Coiling Solutions
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cut up to 0.38 in. thick Variable Pitch and
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FEBRUARY 2016 The FABRICATOR 83
 Figure 1
At Metcam, a custom fabricator in Alpharetta, Ga., as-
semblers slide parts across a series of table brushes for
scratch-free production.

the part becomes stuck before being sent down the

chute.
Seeing this, the team asks the obvious question:
Why wouldn’t similar brushes work in assembly,
where workers handle cosmetically critical parts all
day?
Richard Uber, quality manager at Metcam, told
this story during a tour the Alpharetta, Ga.-based
fabricator gave for Manufacturing Day 2015. To pre-
vent part scratches, the shop installed table brush-
es—rectangular sections that have a PVC base, or
block, with stapled brush bristles—at certain as-
sembly areas (see Figure 1).
Because Metcam has some unique applications,
including intricate parts, managers decided not to
buy table brushes off-the-shelf but instead go with
a custom system. Assembly is late in the process
chain, after a lot of value has already been added to
the part. The later the error occurs, the more expen-
sive rework and scrap can become.

First Questions
Uber worked with Rickey Bates, lead technician
at Brush Design & Manufacturing, a small custom
brush shop in Fayetteville, Ga., south of Atlanta. As
Bates explained, numerous variables go into a table
brush design.
The first question to ask is, What bristle material
do I need? “If a brush is going to be touching any
food, then you’ll need to stay with nylons that are
antibacterial,” Bates said, adding that nylon brush-
es may be needed in high-heat applications too.
Regardless, for the vast majority of metal fabri-
cation applications, Bates said that less expensive

Brushing up assembly
polypropylene bristles should suffice. (Metcam
went with polypropylene material.)
The next question: How heavy will the workpieces
be? The answer will determine how stiff the brushes

Table brushes support cosmetically critical parts need to be. “This ensures that when you’re slid-
ing a product across [a table brush], the brush is
without a scratch robust enough to support the product without the
fibers bending over.” Bending or wobbling brush
fibers opens the door for potential scratching, and
By Tim Heston, Senior Editor it makes it difficult for parts to slide across without

A
getting caught on the bristles.
job goes through punching, forming, hardware insertion, inspection, and now it’s at the assembly
station, after which an employee notices something. The cosmetically critical parts aren’t accept-
Stiffness Variables
able. They’re scratched.
Determining how stiff a table brush will be involves
What happened? A kaizen event commences, people start asking questions, and they find that the parts several factors, the first being the diameter of the
were scratched in the assembly stations. It really was no one’s fault. Parts move across carpeted tables, and individual bristle fibers. “We can work with bristles
those tables sometimes have tiny metal parts or debris stuck on them. So how do they avoid this? from 0.012 in. all the way up to 0.120 in. diameter,”
Diligently cleaning the carpeted tables is one solution, but it’s still easy to miss a spot. Is there a way to Bates said.
“engineer out” the problem? The kaizen team then turns to another machine in which parts slide across the Other factors that influence stiffness are the brush
surface: the punch press. To protect parts against scratches or other cosmetic defects, these punch presses pattern, density, and length. The more bristle fibers
have brush tables. They even have bristles high enough, and arranged in such a fashion, to account for forms you pack into each staple hole (that is, the hole in
like downward protruding louvers and flanges fabricated with form tools. The flange bends downward in the PVC base the bristles are stapled into), the stiffer
between groupings of bristles so that the part remains stable; yet the bristles aren’t packed so tightly that the brush will be.

84 The FABRICATOR FEBRUARY 2016


Figure 2
Metcam chose a straight bristle pattern, which allows
pieces that may have short protrusions sticking out
underneath to slide easily from one station to the next.
Figure 3
Staggered brush bristle patterns like this are found on
some modern punch presses.
Bristle length has the most obvious effect. The
longer the bristle is, the more give it has and the less
stiff it becomes. Bates said that the bristle length in
industrial brushes varies widely, from 0.375 in. up to
about 12 in. A 12-in. brush will have significant give,
even with thick bristle diameters, while 0.375 in. will
be extremely stiff, even with very thin bristles.
Many table brushes don’t have more than 1 to
2 in. of bristle length, if that, though Bates added
that it does depend on the application. If you have
a brush with short bristles packed tightly, even the
thinnest fibers can hold up a heavy part.
“Many assume that if they have heavy pieces,
they really need a heavy fiber to hold them up,”
Bates said. “But if you take a piece of 0.120-in.-di-
ameter fiber and cut it to 1⁄2 in. long, it’s almost like a
piece of steel. It’s very rigid. It’s rough on the hands,
too, and it’s difficult for us to trim and repunch it.
Although it’s really stiff, it won’t scratch your parts,
but it may be overkill.”
This is why many choose a brush that is only as
stiff as it needs to be for the operation, but no stiffer,
especially in a manual operation where workers
handle parts directly.
Pattern Considerations
Workers may need to slide parts that have small
protruding forms. Or they may need to reach into
the bristles to grab small parts. Or they may want to
avoid losing small parts among the bristles.
The right brush pattern and bristle density can a brush,” Bates said. “Eventually, though, you do get
address these concerns. Bristles can be so tightly to the point where the staple will not hold, especial-
packed that the brush looks and feels like a door- ly if you have a thinner table brush [with a thin PVC
mat, or they can be spaced out and staggered, base]. If you have a thicker table, you’ll get more re-
similar to how they appear on many modern punch punches out of it.”
presses. If assemblers work with small parts that The humble table brush on the assembly table
can get caught, a tight brush pattern might not be exemplifies how the little things really do make a
ideal. In a tight, doormat-like brush, a small part can difference in the fab shop. Scrapping a part is never
be difficult to remove. Bristles that are too far apart a good thing, but repeatedly scrapping cosmetically
can open the door again for scratching and make it critical parts in assembly, so late in the production
difficult to slide the part. process, can add up to serious costs.
Some applications call for a straight-grid table Senior Editor Tim Heston can be reached at timh@the
fabricator.com.
brush, Bates said, often because of the part ge-
Brush Design & Manufacturing Inc., 135 Bethea Road,
ometry. An assembly worker may need to slide a Ste. 506, Fayetteville, GA 30214, 770-461-3137, www.
brushdesignmfg.com
part with a shallow flange along the table, and the
Metcam Inc., 305 Tidwell Circle, Alpharetta, GA 30004,
straight pattern of bristles allows space for the part 770-475-9633, www.metcam.com
to slide easily from one station to the next (see Fig-
ure 2).
There’s a trade-off, though. A straight grid pat-
tern requires more bristles to cover a specific area
to maintain adequate bristle stiffness. As Bates ex-
plained, this is why some choose a staggered brush
pattern (see Figure 3). “A staggered pattern will
allow you to fill more space without using so much
material,” Bates said.
The ideal table brush pattern should prevent
parts from scratching and be gentle enough for as-
semblers (or anyone one else) to work with without
scratching or pinching themselves. At the same
time, table brushes should be robust enough so the
bristles don’t wobble and bend. With all the vari-
ables tuned correctly, a good table brush can last
for months of rigorous use.
Figure 4
Restapling the Brush Nylon fibers (for a food industry application) emerge
But they don’t last forever. Still, when the brush bris- from a brush stapling machine at Brush Design & Man-
ufacturing. Instead of buying a new custom brush ev-
tles wear or flatten, they needn’t be thrown away.
ery time bristles wear, many companies send brushes
They instead can be restapled (see Figure 4). out to brush manufacturers for restapling.
Aside from certain brushes, in which every strand
is individually glued, Bates said that most industrial
polypropylene brushes use what’s known as a “mul-
tistrand staple set.” A brush-making machine pulls
a fiber through a die, and a staple is inserted into a
hole drilled in the PVC base.
When brushes wear, fibers can be pulled out and
new fibers can be stapled in their place. In Metcam’s
case, the company sends certain table brushes to
Brush Design & Manufacturing for restapling every
six to eight months. And the fabricator has a few
extra table brushes on hand, so that assembly isn’t
interrupted while the brushes are out for restapling.
This, Bates said, can be much more cost-effective
than having to order a custom table brush every
time an old brush wears out.
The longer the brush lasts between restapling,
the better. This brings up yet another variable: the
thickness of the table brush’s PVC base, or block Figure 5
(see Figure 5). A table brush’s PVC base of significant thickness (0.375
in. and up, depending on the application) should be
“As long as the core of the block isn’t mangled or able to be restapled numerous times before the staples
otherwise damaged, you can repunch and rebristle won’t hold or the tufts won’t stand up straight.
FEBRUARY 2016 The FABRICATOR 85

Precise fabrication shortens modular building
erection to mere hours
By Tim Heston, Senior Editor
O
ne morning during the last week of No-
vember 2015, in the coil inventory yard of
JMC Steel Group’s Atlas Tube mill in Har-
row, Ont., a team erected a modular four-story
building frame of steel hollow structural sections,
or HSS. They finished by early afternoon.
This wasn’t a typical construction project. The
team was from Vector Praxis, which used a crane
from Connexio Building Systems Inc., a module out-
fitter and erector launched last year by a partnership
between JMC Steel Group and Amico Affiliates, a
construction firm in Windsor, Ont. To construct the
building, the team used Vector Praxis’ VectorBloc
system. Connexio now is the first licensee of that
technology.
86 The FABRICATOR FEBRUARY 2016
Julian Bowron, Vector Praxis’ founder and presi-
dent, hopes this technology will overcome the chal-
lenges of modular building with HSS. According to
Bowron, the system provides a way to connect HSS
quickly and accurately in the fab shop (see Figure
1). This, he said, is what allowed the team to build a
four-story steel frame in four hours.
A Connection Challenge
From a purely physics perspective, hollow structur-
al sections have numerous advantages, one being
strength. By moving the material away from the cen-
ter of the section (as with a typical hot-rolled beam)
toward the periphery, HSS have a high strength-to-
weight ratio.
But from an engineering perspective, wide-flange
beams have had one main advantage: They’re easy
Figure 1
This “test stack,” built in November 2015 in the yard
of JMC Steel Group’s Atlas Tube mill in Harrow, Ont.,
showed how quick modular construction can be. Two
interconnected stacks of four chassis, all made of HSS,
were erected in four hours.
to connect. To assemble angles and beams, an erec-
tor simply bolts through two adjacent flanges, or he
bolts through a clip into a web section.
“Do that, and you get the slip-critical connection
everybody wants,” Bowron said. “But connecting
to HSS can be challenging. How do you attach a
nut? If you try to fabricate connection points out of
pieces of plate, then you’re going back more than a
century,” back before the wide-flange beam was in
common use, when individual plates were riveted
together to make structural beams.
This is where steel cast connections fill a need.
Several North American companies have developed
connection systems for HSS, including ConXtech in
California and CastConnex in Ontario. Vector Praxis
has focused its connection system on the modular
building market.
Challenges of Modular Construction
“Having been in structural engineering for a num-
ber of years, I knew that ‘modular construction’ was
a buzzword that had been around for a long time,”
said Brad Fletcher, sales engineer at JMC Steel’s At-

Figure 2
A worker welds a hollow structural section to a VectorBloc machined cast connection.
Atlas Tube. “But there have always been stumbling
blocks. The execution was always a tough nut to
crack. But when I looked at [Bowron’s] concept, I
couldn’t poke any holes in it.”
Modular construction often entails outfitting
certain elements of the building like bathrooms—
installing the plumbing, electrical, toilets, and the
rest—on a shop floor, then trucking these pods to
the construction site. There, the pods are hoisted
into place within a steel frame.
But according to Fletcher, the nature of the Vec-
torBloc system, including the tight-tolerance fab-
rication involved, may expand the possibilities of
modular construction. Instead of constructing pods
and sliding them into a frame built on-site, the steel
frame itself is broken up into chassis, or cubical (or
rectangular prism) steel frames, which can be fab-
ricated in the controlled shop environment. Each
chassis then is outfitted into a complete module
with flooring, electrical, HVAC, sprinkler systems,
tiles, and even drywall and the building façade.
“That’s the pipe dream,” Fletcher said. “You stack
these, and you end up with a completed building
that’s plug-and-play. We think VectorBloc will give
someone the opportunity to achieve that pipe
dream.”
About Accuracy
The idea for the Vector Praxis system came in part
from connection systems used on container ships.
Containers aren’t simply placed on top of each
other without a secure connection (lest a lot of con-
tainers fall overboard). Instead, they have steel cast
connectors on each corner. To join these container
corners requires access from the outside, which
doesn’t make them practical for modular construc-
tion, especially if façade panels are already in place.
“Still, [the containers] don’t touch anywhere
else,” Bowron said. “If you look at an oceanic freight
stacks of modules,” he said. “Obviously, that’s unac-
ceptable.”
So erectors have resorted to various work-
arounds. They often shim and adjust the modules
as they stack them. And they sometimes put a layer
of concrete between the modules to hide the posi-
tioning errors.
“We have a backlog of a little
more than 500 modules at this
point. A lot of people were
waiting for the test stack, our
proof of concept, to be completed.
We expect a lot of new interest in
the first quarter [of 2016.]”
—Julian Bowron, Vector Praxis Inc.
container, all the forces get transmitted through
those corners. That really was the inspiration.”
The weld prep on the end of the VectorBloc fits
into the end of the HSS, and a weld secures the con-
nection (see Figure 2). In the plant, fabricators
weld and assemble the HSS into a chassis, a steel
frame that is then outfitted into complete modules,
ready to be transported to the construction site and
hoisted onto the structure. Workers stack modules
at the connectors located at the corners as well as at
intermediate points if loading conditions require it
(see Figures 3 and 4). It’s a little like building with
LEGO® blocks, just on a massive scale.
What makes LEGO such a fun and successful toy
isn’t just the design of the blocks themselves. It’s
the fact that all snap together precisely, with little
fuss. The same holds true for the cast connections
for HSS.
“What if you started to build a wall of LEGOs, and
yet you found all the bricks were slightly different,”
Bowron said. “It wouldn’t be a fun toy anymore …
Similarly, imagine if a production line worker at
General Motors placed a door in an opening, then
had to take the door off and grind it down to size so
it can fit satisfactorily. The entire industry would fall
apart. And yet it’s widely accepted to this day in the
structural steel industry that the building is beaten
into shape as you go. There’s a constant swarm of
surveyors on every project.”
Accuracy is critical in modular construction. A
small positioning error on the bottom of a building
can turn into a major error dozens of stories in the
air. Bowron gave an example of a 10-story apart-
ment building. If the bottom module is short just 1⁄16
inch, by the 10th story this error adds up to 10⁄16, or
a little less than ¾ in. The adjacent stack has a bot-
tom module that’s 1⁄16 in. too tall. By the 10th floor,
Figure 3
the module is almost ¾ in. too tall. “Now you’ve got Cranes lift modular chassis into place, and workers po-
a 1.5-in. bump in the floor between the adjacent sition the connection points at the corners.
FEBRUARY 2016 The FABRICATOR 87
Figure 4
This cutaway of a VectorBloc connection shows how
the cast components bolt the HSS together, sandwich-
ing a gusset plate in between the upper and lower
blocks. The weld prep on the end of the block fits into
the end of the HSS, and a weld secures the connection.
“All this negates the principal benefit of modu-
lar building,” Bowron said. Why fabricate modular
components if workers need to spend a lot of time
shimming and adjusting on the job site?
He added that GM and other assembly OEMs avoid
this simply by using go/no-go gauges. If a door or any
other component doesn’t fit the gauge, it doesn’t
make it to the assembly line in its current condition.
The same concept now has been carried over to
the structural fabrication of modules of HSS, using
what Vector Praxis calls the VectorJig (see Figures
5 and 6). Think of it as a giant go/no-go gauge,
large enough to hold an entire chassis. It’s built us-
ing laser measuring systems to ensure the entire
chassis assembly stays well within tolerance.
“The chassis locating features are ±-0.015 in.,
while our connection plates, or gusset plates, al-
low for ±0.030 in.,” Bowron said. “That is about the
thickness of two business cards.”
The jig also makes structural fabrication automa-
tion a lot easier to integrate. Some of the latest sys-
tems use touch probes and other sensing systems
to account for positioning variability. The jig reduc-
es that variability and, in turn, the need for welding
touch probes or vision systems.
“You can only implement robotic welding if you
know where the weld is,” Bowron said. “There are
intelligent systems that allow the robot to find a
seam and lay a bead, but it’s far easier to predictive-
ly locate that weld in 3-D space.”
From Coil to Building Frame
Bowron has had a lot of exposure to the challenges
of modular building within the past five years. He
previously launched and operated a modular struc-
tural fabrication plant, which he then sold to the
Walters Group, a large architectural and structural
fabricator based in Hamilton, Ont.
88 The FABRICATOR FEBRUARY 2016
Figure 5
A chassis of HSS is fabricated within a VectorJig—essentially a giant go/no-go gauge.
In 2011 Bowron launched Vector Praxis as a high- “Now we have a backlog of a little more than 500
end architectural detailing and fabrication opera- modules at this point,” Bowron said. “A lot of people
tion, using building information modeling (BIM) were waiting for the test stack, our proof of concept,
and precision, large-scale jigs. In 2014 the company to be completed. We expect a lot of new interest in
introduced its VectorBloc concept, and in 2015 Bow- the first quarter [of 2016.]”
ron met with JMC Steel Group CEO Barry Zekelman The test structure erected in November may be a
as well as Fletcher. The company decided to buy a harbinger showing just how quickly a building can
stake in Vector Praxis, giving the organization the be constructed. Not long before, the HSS in that
cash infusion it needed for tooling and further re- four-story frame were in their raw form—as steel
search and development, including the four-story coils.
“test stack” erected that one morning in November. Senior Editor Tim Heston can be reached at timh@the
fabricator.com.
During the following weeks, workers began tearing
Images provided by Vector Praxis Inc., 220 Humbercrest
the test stack apart, pulling it, pushing it, compress- Blvd., Toronto, ON M6S 4L3 Canada, 416-766-9018, www.
ing it, and subjecting it to all manner of destructive vectorpraxis.com.
Amico Affiliates, 519-737-1577, www.amicoaffiliates.
testing.
com
The chassis was fabricated by VectorBloc staff Atlas Tube, JMC Steel Group, 800-733-5683, www.atlas
in Atlas Tube’s mill in Harrow, Ont., near Windsor. tube.com
According to a Vector Praxis presentation, “Atlas Connexio Building Systems Inc., 519-800-0010, www.
connexiobuilding.com
Tube’s Harrow mill is the only place in the world
where steel coil is converted into volumetric modu-
lar building chassis under one roof.”
For the test stack, Atlas Tube’s Harrow plant start-
ed with the coil material (see Figure 7), which was
leveled, formed, welded, and cut into HSS of the
appropriate shape and length. A team from Vector
Praxis then fabricated the HSS into eight chassis.
They were then sent to the Harrow plant’s inventory
yard, where a Vector Praxis crew erected the steel Figure 6
frames within hours. Workers weld connection points of a chassis, assem-
bled entirely within a precision jig to ensure accuracy.
After this, the team turned the responsibility of
chassis fabrication over to a new business entity
called VectorBloc Fabricating (VBF), co-located with
the Atlas Tube mill in Harrow. VBF is a joint venture
between Vector Praxis’ VectorBloc Corp. (the legal
entity that owns the intellectual property behind
the VectorBloc) and JMC Steel’s Atlas Tube.
In December, VBF started the work on the chas- Figure 7
sis for a 140-unit retirement home. Chassis will be Coil at Atlas Tube’s mill in Harrow, Ont., is staged for
production. This coil will be formed, welded, and cut
shipped to the Connexio plant in Windsor for out- into HSS, then fabricated into chassis—all under one
fitting before being sent to the job site for erection. roof.

By Tim Heston, Senior Editor
T
om Rich knows what it’s like to own a com-
mercial lawn care company. He ran one
himself in the 1990s. He knows about the
long hours, and he knows what makes those hours
so long. Spring is fertilizing season, and for com-
mercial lawn care companies managing acres and
acres of grass, the labor hours can skyrocket.
In the late 1990s Rich had the idea to build a ride-
along sprayer system powerful enough for a worker
to cover a lot of acreage in short order, yet small
enough so it could be maneuvered into the nooks
and crannies of manicured landscapes. From this
idea sprang Lebanon, Ind.-based L.T. Rich Products,
which Rich launched 16 years ago out of his garage.
During its early days the company outsourced all
fabrication and only assembled in-house. If the firm
followed the traditional growth path of niche lawn
care equipment production, it probably would have
remained strictly an assembler. But L.T. Rich Prod-
ucts isn’t a typical commercial lawn care OEM.
Going Direct
Through most of its history, the company has sold
directly to customers—that is, the owners and man-
agers of commercial lawn care companies—circum-
venting the distributor and dealer network. This,
Rich said, has given his company a direct path of
communication to customers.
90 The FABRICATOR FEBRUARY 2016
Better flow, better planning,
less chaos
Lawn care OEM launches a lean initiative and prepares for the future
Through conversations at tradeshows and else-
where, Rich and his engineers have talked with cus-
tomers about what they want in their products that
would make their jobs easier. Years ago one new
product included a ride-along aerator machine.
Commercial lawn services often use tractor attach-
ments to aerate lawns, but aerating acres this way
ties up a tractor for a long time. Whence came L.T.
Rich’s aerator line, which also comes with attach-
ments like a fertilizer sprayer and snow plow, giving
the product year-round use.
If Rich or his engineers talk with customers at a
tradeshow, they may come up with an idea or prod-
uct option on the ride home. Within days they adapt
a new product design and send it to engineering,
prototyping, and testing—and bam!, they’re pro-
ducing a new product. The OEM also customizes
equipment based on customer requests.
All this makes for a fast-changing operation, and
it also makes it difficult to coordinate with a net-
work of suppliers. “So with our initial growth in
the [early] 2000s, we brought everything we could
in-house, from laser cutting the stainless steel to
shipping our product out the door,” Rich said. “We
change designs on-the-fly, build it, and test it. It’s
not the cheapest way to do it, and it’s actually a risk-
ier way to do it. But in the end it affords us so much
versatility. We can dream up whatever we want and
then build it.”
Figure 1
A line of commercial lawn sprayers are assembled at
L.T. Rich Products’ plant outside Indianapolis. In its pri-
or facility, products were batch-fabricated and batch-
assembled. Today batch sizes have been reduced dra-
matically.
Rich isn’t one for meetings or bureaucracy, and
his company lacked both during the early days. Be-
cause its products were big hits, the company grew
by double digits during the early 2000s.
Then in 2012 the company struck a deal with
John Deere Landscapes (which has since changed
its name to SiteOne Landscape Supply) to sell its
sprayers and aerators through its more than 450
branches nationwide. Sales skyrocketed, jumping
40 percent in 2012 and another 40 percent in 2013.
Rich’s people just couldn’t design and build ma-
chines fast enough.
“In our old facility, we didn’t utilize an assembly
line,” Rich said. “We batch-cut and batch-assembled
them. We were constantly losing stuff, constantly
overproducing stuff, and our batch sizes were way
out of whack.”
All that batching created a lot of work-in-process
(WIP) and tied up a lot of cash, especially consider-
ing the kind of sheet metal the company processes.
Spray fertilizer is very corrosive, so about 90 per-
cent of the metal on these machines needs to be
stainless steel.
 Launching Into Lean At the same time the laser operator also some-
“Before, the mentality was, ‘We need to keep the times processes a nest of tiny parts common to
machines running. We need to continue welding most product lines.
and grinding and making sparks. If we cut batch siz- This may be enough parts for several months’
es, we won’t be making as much and won’t be doing worth of products, but cutting ahead and storing
it as fast.’ Regardless, I said, ‘Let’s cut the batch sizes the inventory just makes sense. If these small parts
in half.’ They looked at me as if I had three eyes and were nested with the larger parts, they could easily
four heads. But they went along with it. And then get lost in the shuffle. A little extra small-part inven-
we cut them again. Now batch sizes are small, but tory is less expensive than having to recut lost parts
Figure 2 it creates a part flow velocity that allows them to be time and again.
All the parts of a certain gauge and grade for a batch
more responsive to customers, and have less WIP.” Press brakes and the welding cells now have tools
of six units are cut on the laser. The company recently
installed its second laser and, as of early January, had So said Jeff Sipes, principal at Back2Basics LLC, organized so that operators can change over as
plans to install an automated material handling tower. a lean consultancy in Indianapolis that has worked quickly as possible. If those changeovers become
with L.T. Rich Products for about two years. When
even faster, the operation may consider making
Sipes arrived, he initiated basic 5S, flow, and visual
batch sizes even smaller.
management.
For now the batch is large enough so that the
Soon after he dove into batch sizes (see Figure
machines don’t have an excessive number of set-
1). At the time the laser, press brake, and robot
ups during the day. The batch is also not so large as
welding cells produced batches of parts for 16 units,
to overproduce and flood the floor with WIP. After
on average. So if each sprayer needs two panels, 32
fabrication, carbon steel parts (and a few stainless
panels (2×16) would be nested on the laser. Now the
parts, for reasons described later) are sent to a near-
fabrication department produces enough parts for
about six units. by custom powder coater, which turns products
Figure 3
As Sipes explained, the operation is in one sense around quickly.
Along with manual welding operations, the company
has two robot welding cells. a hybrid of batch and kit part flow. Technicians pro- From here parts go to a staging area adjacent to
gram the laser so that most flat parts of the same the company’s two assembly lines, one dedicated
Despite the chaotic nature of design and produc-
gauge for the batch are cut. This ensures certain com- to sprayers and another dedicated to aerators (see
tion and despite the excessive WIP, Rich said that
ponents can move on to subsequent forming and Figure 4) and a new product—snow plows (see
the company remained debt-free and in good shape
financially. Still, he saw the writing on the wall. welding as soon as possible (see Figures 2 and 3). Figure 5).
Lead times for some machines stretched out eight
to 12 weeks. Rich knew what it was like to run a lawn
care company. “If it’s spring and the weeds are pop-
ping up, eight to 12 weeks is just not acceptable.”
He knew things had to change, but how? Then in
2013 he visited a Douglas Dynamics plant in Wiscon-
sin. The large company is known for, among other
products, its FISHER® snow plows. The FISHER prod-
uct dominates the U.S. truck plow business, a sector
with extraordinarily stringent delivery demands.
“They’ve got it even worse than we do,” Rich said. Figure 4
“When you need a plow, you need a plow today. LT Rich Products’ manufactures several lines of ride-along sprayers (yellow vehicles on the right) as well as a line
of aerators (black vehicle on left).
“To increase profits, [Douglas Dynamics] had to
do it internally, because there wasn’t a whole lot the
company could do marketwise,” Rich continued.
“When I visited, people at the plant had lean manu-
facturing down to an absolute science.”
Besides 5S, visual management, and other lean
tools, the Douglas Dynamics plant borrowed ideas
from the theory of constraints. At the plant’s center
was powder coating, the constraint process that
set the pace for throughput. The company’s lasers,
press brakes, and other machines were all paced
around powder coating. “There was a purpose be-
hind everything they were doing,” Rich said.
Driving home to Indiana, Rich knew that eight
to 12 weeks of lead time was just too long. A two-
week lead time would be ideal, but things needed
to change. It was a good time to make changes,
considering Rich’s company was just about to move
into a newly built facility. The only question left was, Figure 5
where to start? L.T. Rich’s new snow plow product line shares the same assembly line with its aerator product.

FEBRUARY 2016 The FABRICATOR 91

A Seasonal Business
To develop its new snow plow line, the people at L.T. Rich put themselves in
customers’ shoes. Many lawn care customers run snow plow operations in the
winter, and a time-consuming part of that is removing snow from sidewalks and
walkways.
L.T. Rich’s small plow machine fills this need. The company already had ex-
perience building similarly designed products. Press brake operators had even
made plows before, bump-bending the stainless steel sheet. A plow attach-
ment to the aerator line had been available for years. (Interestingly, the stain-
less plows are powder-coated orange, just because the orange is more visible
in snow.) And the machines, as with other products the company produces, are
built with modular components that simplify fabrication and planning. This
new product also happens to have an opposite demand cycle than that of the
sprayer and aerator.
Still, at this writing, the snow plow is a new product, and there’s no getting
around a fact of life for any manufacturer serving the lawn care business: It’s
seasonal, which makes planning difficult, especially when dealing with pur-
chased parts with long lead times. Engines, for instance, have a 120-day lead
time. (Due to the nature of the small-engine market, which must deal with EPA
regulations, Rich said his company has limited supplier options.)
Rich didn’t want to rely on temporary workers, and he didn’t want to add a
second shift, which for Rich has always been difficult to manage because of,
among other reasons, the lack of skilled labor.
92 The FABRICATOR FEBRUARY 2016
To remedy the situation, the company made two big changes. First, it changed
to a four 10-hour-day workweek. Until recently the only machine that ran more
than four days was the laser. (At this writing, the laser cutting operations soon
will be running on the same four-day schedule; the company recently installed
a second laser, and a material handling tower is being installed early this year.)
The four-day schedule not only makes the company attractive to work for—
people like three-day weekends—but it also gives the operation some flexibility.
If workers need to do overtime, they don’t need to stay at the factory late; they
just come in on Friday.
There’s no getting around a fact of life for any manufacturer
serving the lawn care business: It’s seasonal.
Second, the company instituted sales and operations planning (S&OP), using
customer intelligence and other data to better predict demand. This in turn has
allowed L.T. Rich to level-load its production schedule.
“Because our goal is to have a customer lead time of no more than two weeks,
we needed to consider level-loading our production,” Rich said. “We now have
a lot more structure in our forecasting. Don’t get me wrong; it’s not cheap, be-
cause you’re building a lot more inventory, but it’s really the only way you can
get through those peaks and valleys of demand. It’s been huge in helping us
figure out what we’re building, when we’re building it, and how much inventory
we’re going to hold.”
As Sipes explained, “Level-loading reduces the peaks and raises the valleys,
which allows the company to more effectively use its assets and resources
throughout the year. Instead of ramping up production to handle the spring
rush and winding down through the slow period, the range of daily output is
much narrower throughout the year.”
The company sells some during the slow times, but most goes to inventory.
Still, that inventory certainly comes in handy during the months with heavy cus-
tomer demand.
Customers may request certain options, which are added just before ship-
ping. But modifying the products in inventory is a lot easier than scrambling to
meet an unmanageable spike in orders.
More Structure, Less Chaos
Tom Rich, the get-it-done entrepreneur who has lived through 40 percent
growth for two years running, and who relied on the quick hallway meeting be-
fore running in five directions at once to put out the next fire, now has more
structure to his workday.
He and his management team hold a 15-minute production meeting every
day, just to make sure everybody is on the same page. The engineering change
process now is more structured, and new part information flows seamlessly to
manufacturing management and the shop floor. And workers now receive job
information on tablet computers. When engineering makes a change, new in-
formation is uploaded as a PDF to the server, which then distributes those PDFs
to tablets.
The lean journey isn’t complete (it never is), but it’s well underway. Rich still
talks with customers all the time, and he knows their pain. “Health care and
other costs are really out of control,” he said. “My customer now has less money
and less to work with. We need to look for new business and ways to save labor
costs for our customers.”
Rich’s company employed 25 people in 2013; today it has 50. Although the
growth may not continue so rapidly, Rich said he does see growth continuing
over the next few years. The trick will be to continue developing products that
save his customers time and money. And to compete, he knows he needs to go
to market as soon as possible. Today the shop has the structure in place to do
just that.
Photos courtesy of L.T. Rich Products, 920 Hendricks Drive, Lebanon, IN 46052, 765-482-
2040, www.z-spray.com.
Back2Basics LLC, 9250 Eagle Meadow Drive, Indianapolis, IN 46234, 317-439-7960,
www.back2basics-lean.com

Moving the family fab shop
Lessons learned from serial relocating
By Tom Brizek
I
t still might be the worst phone call I ever re-
ceived. After the initial shock and denial, I feared
for my family and the families of our employees.
This was fall of 2008 and we had just moved into
our new facility in Honey Brook, Pa., at the prod-
ding of our biggest customer. Business was boom-
ing. Customers were responding well to our new
custom fabrication services, and our new product,
an orbital stretch-wrapping machine, was getting
rave reviews.
Having barely settled into the bigger and better
facility, I certainly wasn’t expecting our multimil-
lion-dollar customer to call and say they’d built a
new facility in Mexico and our services would no
longer be needed. Thanks for taking on such a com-
mitment to serve us, now go away.
Did we move too soon? Could we have made the
tighter facility work for a little longer? Maybe we
needed to go bigger in an even larger facility and
ramp up business development? And what now?
Downsize?
As dire as the situation truly was at the time, it is
only thanks to this situation that we began to pay
very careful attention to how well we use our facil-
ity, a key step in determining whether we would stay
94 The FABRICATOR FEBRUARY 2016
put or endure yet another move. The more closely
we examined our process and envisioned the ideal
facility, the more we realized how significantly the
facility either supports the overall operation and
contributes to profitability or detracts from it and
drains profitability. We weren’t being as efficient
with our space as we could have been.
To generate positive cash flow, we quickly con-
solidated our operation and created enough square
footage to sublet to another company. We explored
lean manufacturing principles and installed more
racking to maximize use of vertical space. It soon
became clear that we didn’t have to move again, at
least not yet.
I reveal this rough road in our history because it
marked the turning point in our business and in how
we thought about when to expand or relocate (see
Figure 1). Prior to that experience, available floor
space, current sales, and prospects for sales growth
were key factors driving the decision to move. But
now that we’re in the midst of our fourth move to a
new facility in a span of nine years, we’re knee-deep
in the process again, and it seems a fine time to let
other metal fabricators know what we’ve learned
and what other factors to consider before embark-
ing on a potentially costly relocation.
Figure 1
Author and TAB Industries President Tom Brizek,
shown here with his son Andrew Brizek, director of
contract sales, has moved his growing company four
times in the past nine years.
Align Facility With Business Strategy
Shaking off the loss of our multimillion-dollar cus-
tomer, we examined our entire business strategy
and set out to diversify our customer base to reduce
the impact of any single customer on the overall
operation, yet we diversified in such a way that the
range of products and services remained related to
our core competency in metals.
We wanted to add TIG welding and plasma cut-
ting equipment, for example, and expand our logis-
tics and distribution services. We looked for growth
opportunities and then considered how much
space would be needed to pursue them effectively.
From that perspective, it was easier to envision the
ideal facility and then determine if we could set up
the existing facility to suit our business strategy, or
if we’d need to move.
By setting up the facility to maximize efficiency
and by consolidating everything into as little space
as possible, we were able to avoid moving while leav-
ing ample space for a tenant to help pay the rent. Had
our business strategy focused on scaling back and
retrenching instead of on growth, then the strategy
would have suggested downsizing to a smaller facil-
ity. Many companies can probably reorganize their
plant layouts and internal processes to better align
them with their business strategies, and avoid having
to move or at least delay the need to move.
We felt confident we could stay in our new facility
because of the success of our new product line, the
TAB Wrapper Tornado, an orbital stretch-wrapping
packaging machine that wraps plastic film 360 de-
grees around and under a palletized load to secure
the load to its pallet as a single unit. At the time,
warehousing and distribution for the building and
hardware industries represented more than half of
our business, and the real estate crash was most
definitely affecting our bottom line.
But our TAB Wrapper product line grew even dur-
ing the downturn because it helped make companies
more efficient and cut costs out of the supply chain.
We sold four the year we introduced it, then 52 the
next year, then 200, mostly to metal fabricators.
Move Only When Necessary
We started using the orbital wrapper to deliver
our products to our customers, which made our
packaging and shipping department much more
efficient and safe (see Figures 2 and 3). But the
more products we sold, the more room we needed
for manufacturing. In-process wrapping machines
quickly consumed our available space.
The loading dock became a makeshift storage
area for materials and served as a second assembly
zone. To receive deliveries and to load and dispatch
our own trucks, this production zone had to stop
working and clear the area. We were trying hard to
use all of our space without moving.
Then winter came, and despite all of our space-
saving efforts, our custom assembly, fabrication,
and machining business was also doing very well,
and there was simply nowhere inside to move the
wrapper product line production. After the Mexico
experience, and given the uncertain economy, it
was with great hesitation that I finally accepted the
growth that our wrapper product line demanded.
Over the years we’ve learned to move only when
necessary, and that time had come. We needed a
bigger facility.
Don’t Rule out Old Industrial Centers
The gigantic, multinational corporations can in-
vest millions in the site selection process. They hire
consultants and have the luxury of considering lo-
cations throughout the world, even if it means lay-
ing off or relocating large numbers of workers. By
contrast, family-owned and -operated companies
are more likely to consider staying in the same area
near their customer base and near their workers.
And, yes, as owners, we’d like to keep our commutes
as short as possible too.
As far as the need for a site selection consultant,
we’ve relocated so many times that we think we’re
our own best consultant. One of the first steps is to
determine the ideal region and then narrow it down
to the city or town. Since our roots as a family and
as a company are set in Reading, Pa., and many of
our customers are located in the mid-Atlantic states,
we initially focused on towns in southeast Pennsyl-
vania. Besides Reading, we also looked at Lancaster
and Ephrata, both about an hour’s drive west from
Philadelphia.
Figure 2
TAB Industries is a custom fabricator that also makes
and sells an orbital stretch-wrapper product line.
Figure 3
TAB Industries uses its own orbital stretch wrapper in
its packaging department.
To find out about potential incentives, we called
the Greater Reading Economic Partnership and
opened up a treasure trove of resources, support,
and expertise that cemented our decision to relo-
cate to Reading. Their team helped fund a research
study on warehousing; provided office space to im-
press overseas prospects; and put us in touch with
the key city officials and business leaders, several
of whom have become customers. It was their per-
spective that helped us re-examine some common
myths in the relocation thought process.
For example, many companies build or lease
warehouses in rural areas near an interstate high-
way exit to save on the cost of land and rent. It’s
convenient for their trucking fleets and provides a
clean site with space to expand. Since we’d been lo-
cated in semirural areas, it never really occurred to
us that we were missing out on a host of benefits
available by operating within urban centers. By sit-
ing in large population centers, companies enjoy ac-
cess to a large pool of workers with a variety of skills
and experience, and many can walk to work or use
public transportation instead of commuting by car.
In our case, the industrial mindset woven into the
Reading area with its rich history in mining and met-
als played an important role. Urban centers also of-
fer access to a variety of vendors and partners, from
banking and financial support to technology and
construction. It was as if we moved into a resurgent
neighborhood of like-minded businesspeople all
working as a community network. Certainly, mov-
ing into an older building may require a slew of up-
grades, but check with the appropriate economic
development office. It’s likely they can point out tax
breaks and incentives to offset some of the costs.
Leasing May Be a Good Option
Many of us have been raised and conditioned to
think that owning real estate marks the pinnacle
of success, that it always appreciates in value, and
that paying rent rarely delivers a greater return than
ownership. However, owning a commercial building
also brings a series of ongoing headaches, responsi-
bilities, and potential crises that divert money and
attention away from running a profitable business.
Consider property taxes, liability, and insurance;
facility maintenance and repairs; landscape main-
tenance; gas and electricity; natural disasters; and
zoning. Some people may not be prepared to man-
age these issues. We thought we were and then real-
ized it wasn’t worth the aggravation when weighed
against leasing a facility.
Warehouses and other commercial-industrial
buildings aren’t exactly liquid investments, so a
business that outgrows the space may have trouble
managing a relocation and selling the building at
the same time. Consider that investing $2 million in
a building with a 20- to 30-year mortgage restricts
how easily a company can reinvest in itself and
move, if needed. Leasing for only three to five years
helps manage the risk of running a business in a vol-
atile economy, where we need to respond quickly
to changing customer needs, implement new ideas
effectively, and launch new products and services.
Leasing costs are fixed and consistent regardless
of the weather or a sudden hole in the roof, which
helps business planning. And if growth demands
more space, then the shorter-term commitment of-
fers important flexibility.
Regardless, don’t be afraid to buy or lease in a
down market, since the costs and rates will be lower
on the available properties.
Plan Ahead for the Move
Our first move from a 2,000-sq.-ft. garage to an
8,000-sq.-ft. facility was done in a day with a single
box truck. Moving to a 30,000-sq.-ft. facility took far
more planning and coordination. Our third move
took three days. With each move, we evaluated how
well we managed the process and considered how
to improve the next time.
Consistent customer service, product quality, and
on-time deliveries simply cannot be compromised
during a move. Our current move to a 50,000-sq.-ft.
facility could cost us up to $100,000, so efficiency is
critical.
A first step is to be upfront with the workforce. An-
nouncing a move can start people looking for a new
position, especially if geography is an issue. When a
new location lengthens commuting for people, our
policy is to give raises to offset the cost and incon-
venience, then set up teams who are responsible for
specific parts of the process, such as emptying in-
ventory from racks, dismantling racks and loading
trucks, and unloading trucks at the new facility.
We hired temporary workers and held daily meet-
ings to apply resources where they were needed
most. Breaking down what needs to happen into
very mundane tasks ensures no time is wasted and
everything arrives at the new facility safely and in
an organized way, ready for setup. Planning ahead
minimizes downtime.
The Business and Facility Are One
The facility plays a central role in a company’s cost
structure, production capacity, and profitability.
Don’t bite off more than you can chew. If business
has slowed, then it may be time to consolidate op-
erations in a smaller space or consider moving to
a facility with a more forgiving cost structure that
more closely aligns with the pace of business. Mov-
ing may be the driver that helps restore profitability
or at least buys time to assess the business strategy
without the same cost pressures.
But if business is booming and it’s no longer pos-
sible to uncover or create more space from existing
square footage, then congratulations—it’s time to
start the relocation process.
Tom Brizek is president of TAB Industries LLC, 2525 N.
12th St., Reading, PA 19605, 610-921-0012, www.tab
wrapper.com.
FEBRUARY 2016 The FABRICATOR 95
By Ryan Holt and Paul Rieder
Editor’s Note: This feature first appeared in the January
2016 issue of CIM-Canadian Industrial Machinery.

Y
our company is getting more involved with
welding structural shapes or pressure ves-
sels for heavy industry. Chances are you
want to deposit metal at a rate that is impossible
to do manually—in the range of 20, 30, or even 40
lbs. per hour.
Submerged arc welding (SAW) will handle the
welding, but controlling where and how you weld
can be as important as what’s melting the wire.
Buying a SAW system without auxiliary equip-
ment like a manipulator or gantry is like buying an
engine without the rest of the car. You can turn it on
and it’ll make some smoke, but it’s not going to get Figure 1
Turning rolls and a welding positioner rotate cylindrical workpieces during submerged arc welding.
you where you need to go.

What about
Knowing your applications will help you deter-
mine what auxiliary equipment you need to ma-
nipulate the welding head and get the productivity
you want.

Describe the Joint

One of the first things to determine when selecting
SAW auxiliary equipment is the type and variety of
joints you will weld. Will there be:
• Large V-groove joints with plenty of space
for a large welding torch?
• Narrow, deep grooves to minimize the amount
of weld material to be deposited?
• Multipass welds, and if so, how many passes?
• Fillet welds?
• Cladding applications where multiple passes
need to be laid in succession?
• Straight and consistent or wavy and
inconsistent welds?
Define a Typical Project
The workpiece to be welded will also help identify
the requirements of your auxiliary equipment. The
following are good questions to ask:
• Are the joints in long and straight or round
materials?
• Are they vertical?
• How large is the workpiece, and does it need to
be positioned or rotated to access all welding
locations?
When welding a large workpiece, the time re-
quired to position it can significantly affect pro-
ductivity. Flipping a large workpiece over to reach
a weld takes time and can be dangerous for the op-
erators.
A boom-and-column manipulator is probably the
most cost-effective and versatile method of holding
a weld head above a workpiece. If the joint is long
and straight, a boom-and-column manipulator on
rails with a powered travel car can be effective. It
is important to ensure that the car’s speed can ac-
commodate rapid-traverse as well as typical weld-
ing speeds.
submerged arc welding?
Questions to answer before you invest
in SAW and its options
If the workpiece is round, like a wind tower or Find Your Automation ROI
a pressure vessel, it will need to be rotated under In some instances, the cost of automating SAW has
the torch. Turning rolls and welding positioners are long payback times. In others, the cost is quickly
justified.
commonly used for this (see Figure 1). Rolls rotate
On one hand, multipass welds are often difficult
long and often very heavy cylindrical workpieces
to automate because the placement of successive
that have a center of mass that is roughly on the beads can be very important. A well-trained SAW
workpiece centerline. Positioners rotate workpieces operator can be hard to beat.
with a center of mass that does not lie on or near the
axis of rotation.
The amount of weld wire being deposited and the
thickness of the base metal determine other equip-
ment requirements. For example, conventional
flame or induction heating equipment may be
needed to preheat thick material (see Figure 2).
Figure 2
The answers to two process questions can deter- Thicker material, as shown here, may require preheat-
ing prior to welding.
mine what kind of ancillary equipment is necessary:
• How much current is needed?
• How long do I need to weld?
If you will be welding with a lot of current for
extended periods of time, it is imperative that the
welding circuit be sized properly. If your cables
aren’t big enough on either side of the arc, you run
the risk of melting something besides the electrode.
Figure 3
Another important consideration is heat trans-
Relying on a human operator to accurately deposit hun-
fer. As current travels through welding cables, they dreds of pounds of weld metal in successive beads for
hours at a time is usually not economical, practical, or
heat up and could melt. There must be enough air
even possible. That’s why applications requiring high-
around the cables to keep them cool. deposition rates are good candidates for automation.

96 The FABRICATOR FEBRUARY 2016

 On the other hand, cladding, structural sections, heavy-wall pressure vessels,
and other processes that require high deposition rates are prime candidates for
automation (see Figure 3).
For applications such as these, a typical single-wire submerged arc process
can easily deposit 15 or 20 lbs. per hour, and a twin or tandem two-wire sub-
merged arc process can deposit upwards of 40 lbs. per hour, offering up to 10
times or 1,000 percent higher deposition rate than a typical manual shielded
metal arc welding or gas metal arc welding process.
create sound welds. It’s important to understand your applications and com-
municate your requirements to your integrator or vendor.
Asking the right questions will help you specify a system that provides the
functionality and safety you need and maximize your return on investment.
Ryan Holt is co-owner and Paul Rieder is senior engineer, LJ Welding Automation, 4747
76th Ave. NW, Edmonton, AB T6B 0A3, Canada, 780-466-6658, www.ljwelding.com.

Choose Seam Tracking

Seam tracking can make welding an irregular path on wavy joints easier. A sen-
sor or feedback from the weld is used to adjust the position of the weld head so
it stays over a predetermined location on the joint. It can improve productivity
for many applications and help less experienced operators execute good welds.
The most common tracking methods are tactile, laser, and through-arc.
Tactile seam tracking is economical. A mechanical probe rides along the
joint and sends signals to powered cross slides to follow the line of motion. It
requires a well-defined joint, and therefore is not well-suited for butt welds or
very shallow joint profiles.
Laser seam tracking projects a laser beam onto the workpiece and uses image
processing algorithms to recognize a weld joint profile. The profile is used to
precisely position the welding head. Since there is no physical contact between
the sensor and the workpiece, laser seam tracking sensors aren’t susceptible to Figure 4
What is missing from this picture? A camera provides oversight of the welding opera-
jamming or breaking. They can be used to automate multipass welds; however, tion, while allowing the technician to be in another location.
the increased functionality comes with a higher price.
Through-arc seam tracking requires oscillation of the weld head and uses real-
time voltage and current readings to locate the edges of the joint. This is typi-
cally used with GMAW systems, but can be used with SAW systems as well.
BENDING &
A combination of your technical requirements, budget allowance, and the METALWORKING
supplier or system integrator will help determine the right system to track your MACHINERY
welds.

Recover Unused Flux Angle Rolls

Large V-grooves and multipass welds typically require large spools or drums of Capacities to 4″
Sch. 40 pipe and
welding wire and properly sized flux delivery and recovery systems. As a rule of angle iron
thumb, 2 lbs. of flux are needed for every pound of wire consumed. Flux capac-
ity can be extended by using a flux recovery system: basically a vacuum that
sucks up the flux that has not turned to slag so it can be reused. Using a flux
recovery system can reduce the flux-to-wire ratio. The savings in recovered flux Rotary Draw
Benders
alone can offset the cost of a properly sized system. Capacities to 6″
Flux capacity can come with hidden costs of its own. A gravity-fed hopper
needs to be located above the welding head, which means that the weight of
the hopper plus the welding head and wire spool need to be supported. Gen-
erally speaking, the heavier the weld head, the more costly the equipment re-
quired to support it over your workpiece. Repeatable quality bends
in pipe, tube, squares,
Monitor Weld Quality solids and other profiles
Monitoring and watching the weld in progress is also important. There are a few
approaches to position an operator to observe the weld on large workpieces:
put an operator seat next to the weld head; add scaffolding or a ladder so the
operator can stand next to the weld head; or place a camera at the weld head.
Adding an operator seat effectively turns a manipulator or gantry into an el-
evator, and the additional requirements can significantly increase the system
cost. Ladders and scaffolding can be cumbersome and contribute to repetitive
stress-strain injuries if the operator maintains a less-than-comfortable position
for extended periods of time. A weld camera can keep the operator in a safe
position while providing a clear view of the weld in progress (see Figure 4).
CML USA, Inc. Ercolina® 563-391-7700
Look at the Whole Picture
Submerged arc welding relies heavily on auxiliary equipment like manipulators www.ercolina-usa.com
or gantries, seam tracking systems, cameras, and flux management systems to

FEBRUARY 2016 The FABRICATOR 97


How to crunch chronic defects
with variables search
A disciplined review of possible causal factors can lead to big quality gains
By Joseph Dunn
W
hy do we produce so much scrap? Why
does fix-it rework keep dragging on?
Why are we paying so much for second-
ary inspectors?
These are just some of the frustrating questions
routinely asked in job shops. There is an answer to
each of these questions, and simply applying the
variables search (VS) steps laid out in this article can
lead to a positive resolution.
VS is surprisingly easy to conduct, graphically
convincing to team members, and accomplished
in the fewest trials compared to other experimental
methods. Fabricators that produce any amount of
scrap, for instance, can use VS.
VS pioneer Dorian Shainin preached three prin-
ciples:
1. There’s always a Red X.
2. The fastest route to find the Red X is a progres-
sive search using the process of elimination.
3. Talk to the parts with statistically simple and
rigorous tools.
VS as a Red X statistical power tool is so simple yet
accomplishes so much. It hunts down the hostile
factor in the manufacturing process or product—the
source of your problems. Anyone who can read and
talk will reduce and finally eliminate the problems
with VS. The VS results tell you how to ease the tol-
erances on the unimportant factors to reduce costs.
If your plant suffers from high defect levels, come
hither. (Note: VS also can be used to speed product
design and lower design costs.) Let’s begin down
the VS path.
98 The FABRICATOR FEBRUARY 2016
Step 1: Choose the Process
to Improve
Choose one of the most chronic problem processes
in the shop: assembly, bending, cutting, finishing,
machining, stamping, or welding. Pick a process for
which the operator, technician, and engineer can
identify five to 20 factors that might be causing the
problem. If the process has less than five potential
factors, you may skip Step 3.
Step 2: List the Possible Factors
Once you’ve chosen the process that will be the
focus of a campaign for zero defects, call a ses-
sion to generate a list of all the factors (also known
as variables or causes) that might be causing the
problems. Assemble a small group of people with
knowledge of the process. The group should be big
enough to provide animated verbal play, yet small
enough to invite individual participation and free-
wheeling brainstorm-style inventing. The ideal
group size is five to seven people.
Check these off for your successful meeting:
4Make the meeting informal. Pick an environ-
ment that ensures that you and others can relax.
Place participants side by side facing a whiteboard,
and people will respond to the problem depicted
there.
4Ban criticism of suggested causes. Don’t allow
the discussion to drift into a debate about any par-
ticular possibility. Just write the possibility on the
board and prompt for more ideas.
4Take the group on a walk-around where the
process actually takes place. This will jog memo-
ries, encourage understanding, and inspire ideas.
Their thorough input is necessary to be properly
prepared for the testing phase of this process.
4As a group, put the list of factors in a new se-
quence: List them alphabetically in order of their
perceived effect on the output. The team’s ranking
may be right or wrong; that’s OK. You’re just trying to
expose and leverage the existing knowledge. Include
all of the suspect factors. You may be surprised.
Step 3: Find the Cause
The root of the problem is called the origin or
source. The purpose of this step is to identify the im-
portant factors that are ruining your shop’s control
and creating inefficiencies on the shop floor.
a. Designate two levels for each factor: “good,”
which you think will contribute to good results, and
“bad,” which you think will contribute to worse re-
sults. (If you think wrong, don’t worry.) Put a b sub-
script by each factor’s bad level (i.e., Ab, Bb, Cb), and
use a g to represent the good factors (i.e., Ag, Bg, Cg).
b. Run six experiments, three with all factors
at good levels, the other three with all bad levels.
Scramble the sequence. Don’t do all goods then all
bads. Record the six outcome readings.
c. Establish D, the difference between the two
median (middle value) results. In other words,
D = (Median of the three good level readings) —
(Median of the three bad level readings)
d. Establish davg (the average nonrepeatability
range of the other four experiments). Here’s how:
Y Plot 1
Vertical Scatter
Note: The ramp should not be perfectly horizontal,
but otherwise the slope of the ramp is not important.
C
Plot 2
Y
Vertical Scatter
C
Y Plot 3 ary
Line
und
r Bo
Up p e
Line
Upper Cen
ter
nda
ry L
ine
Spec
Limit Low
e r Bou
Lower
Spec
Limit
C
Figure 1
These plots are used to reveal the factor or factors that
are important in trying to find the root of a production
problem.
Call the numerical difference between the two nonmedian values of the good
level experiments dg, and call the difference between the two nonmedian values
of the bad level experiments db.
davg = (dg– db)/2
e. If D/davg > 1.25 (ignore negative signs), and all three good levels are better
than all three bad levels, continue to f. If either of these conditions fail, switch
bad and good for one or two factors that you’re not sure of, then return to b. Re-
peat until D/davg > 1.25 and all three good levels are better than all three bad lev-
els. If success doesn’t come the second time around, you probably have failed to
list an important factor. Brainstorm again and then start at b again.
f. Calculate the control limits for the good three as follows:
Median of the good level readings ± 2.776 (davg/1.81)
Calculate the control limits for the bad three:
Median of the bad level readings ± 2.776 (davg/1.81)
g. Run a test with A bad (Ab) and all other factors good (Rg). Then run a test
with Ag and Rb. (When speaking, you can call these “A good, the rest bad” and “A
bad, the rest good.”) If the results of both AbRg and AgRb are inside the bad three
and good three control limits, respectively, factor A is unimportant. Go on to h. If
there’s a complete reversal (AbRg inside the good three control limits, AgRb inside
the bad three control limits), factor A is the sole important factor. Step 3 is over.
If either test shows results outside the control limits, A is part of the problem
along with other factors. Go on to h.
h. If there wasn’t a complete reversal in the previous action, repeat g for the
next factor B. (Run a BbRg test and BgRb test, and apply the same “if-then” logic to
determine B’s importance. If B is unimportant, run the same pair of tests with C,
then D, etc.) You eventually will find either a factor that shows a complete rever-
sal or a couple of factors with results outside the control limits. Reversal means
you’re done. You’ve found the important factor. However, if two factors, say A
and K, display a partial reversal (readings outside the control limits), go to i.
i. Run a AbKbRg and a AgKgRb test to see if R—the rest of the factors—can be
eliminated. If reversal is still not complete (a rare case), continue to search for a
third contributing factor by running a AbKbXbRg and a AgKgXgRb test. By now (and
probably long before this) you’ve identified your important factors.
Step 4: Establish the Best Tolerance
In Step 3 we assigned “good” and “bad” to each factor. But what is the unmis-
takably best level for the important factors? Suppose in Step 3 you discover that
factor C shows significant contribution to the problem. What is now needed to
establish tolerance on that factor?
One way is via scatter plots, a graphical method formally called realistic toler-
ance parallelograms. Here’s how to do that:
a. Plot the important customer characteristic (the result that you’ve been
measuring, such as part width or number of flaws) and call it Y (see Figure 1).
Designate a value range of factor C that you feel confident will fine-tune Y and
encompass the customer’s desired range of Y (i.e., the spec range, the fewest
flaws, etc.). Run 30 experiments in that range of C, and record and plot the corre-
sponding Y values. If the graphics plot is a ramp with only a small vertical scatter
(see Plot 1), this verifies again that C is an important factor. (If the plot is not a
ramp or if it is a wide ellipse as in Plot 2, the factor is unimportant.)
b. Draw a center line through the 30 plots. Draw a parallel line on each side
of the center so as to enclose all but one and a half of the 30 points (see Plot 3).
(Note: The vertical width of this parallelogram is the variation in Y due to all fac-
tors other than the factor you are testing. If the parallelogram is wide, the factor
you are testing is not the only important factor. Recall the partial reversal in g
and h of Step 3.)
c. Mark the customer specification limit points on the Y axis. Draw a line par-
allel to the C axis from the upper spec limit to the upper boundary line of the
scatter, and draw a like line from the lower spec limit to the lower boundary line
of the scatter (see Plot 3). Finally, drop a line from each of the two boundary-
intersection points straight down to the C axis.
d. Those two lines you just dropped will intersect with the C axis at the maxi-
mum tolerances allowed, specifying a minimum Cpk of 2.0 (a tight tolerance for
zero-defect quality). Divide the span into four equal parts and designate the
middle half as the tolerance for the important factor. Your new bull’s eye value
for the important factor is at the center of this range between the “dropped”
lines. Are you surprised by the result?
e. Compare this realistic bull’s eye and tolerance with the bull’s eye and toler-
ance that have been used in the shop until now. Make the change to ensure zero
defects!
More Good News
The typical cost of poor quality in a U.S. company is from 10 to 25 cents per
dollar of sales. And that doesn’t even include the cost of lost sales, equipment
downtime, supplier poor quality, and longer design times.
The truth is that few manufacturers use balanced testing to eliminate scrap
and rework, and still fewer are aware of VS. Many organizations perceive de-
signed experiments as complex, abstract, and expensive, and they’re usually
right. The design of experiment tools many corporate practitioners promote are
complicated, tangled, and costly. They also are mostly closed test designs.
But now you’ve been introduced to a powerful, simple, and accurate quality
tool. Put it to good use.
Joseph Dunn, a certified manager of quality/organizational excellence, designat-
ed by American Society for Quality, can be reached at joe.dunn537@gmail.com.
Putting Variables Search to Use
A metal fabricator was
generating a lot of scrap in
its automated welding cell. 
Weld burn-through and cold
lapping, where a lack of fu-
sion exists between the weld
metal and the metal surface,
were eating at the cell’s bot-
tom line. The team mem-
bers on both shifts were very
This chart shows the data collection results from experienced, so the fact that
the investigation of possible causes of setup they were not able to nail
scrap in the automated welding cell. The box
in the top right-hand corner lists the possible down the real problems was
causes that were eliminated and those factors baffling. 
that influenced the creation of the scrap. Everyone who knew any-
thing about the cell were
interviewed, both individually and in small groups, to capture the suspect vari-
ables. This included operators, maintenance, the machine vendor, weld lab
techs, team leaders, supervisors, and weld engineers.  Every theory was cata-
loged and crossed off the list only if sound logic or evidence eliminated it as a
suspect.
The next step involved setting up a test pattern and showing management
how the investigation was going to proceed. The cycle time was close to a min-
ute, so the search required a fair amount of machine and operator time to con-
duct all the trials and changeovers needed to complete the test pattern.
As the data emerged point by point, the team plotted each result on the chart.
The shop was excited to see the results as they were made public. No one pre-
dicted the outcome correctly, and no one could argue with the data because
they participated in the test plan. At each step, they adjusted the variables to the
plan. They knew what they were seeing was real.
In the end, the fabricator discovered that it needed to address torch place-
ment, travel speed, and wire feed speed. Elimination of the setup scrap led to
significant savings for the fabricator.
FEBRUARY 2016 The FABRICATOR 99

Keeping pace with technology
Wisconsin job shop has relied on cutting-edge equipment
to stay on top of increased customer demands
By Dan Davis, Editor-in-Chief
F
or being only 46, Jim Sjoberg talks like some-
one who has seen just about everything in
metal fabricating. That’s not hard to believe,
however, considering that he started receiving a
paycheck when he was 12.
“I helped put in the yard when they built the shop,”
he said, referring to horticultural handiwork at the
old “new” building, which was erected in 1982.
Today Sjoberg Tool & Manufacturing Corp. oper-
ates in a 112,000-square-foot facility in Hartland,
Wis., which it has called home for over a third of its
40 years of existence. The company, founded by Sjo-
berg’s dad, a tool- and diemaker, has welcomed the
third generation of Sjobergs into the family business.
With the next generation of Sjobergs now learning
the metal fabricating ropes, they are getting a first-
hand look at what fabricating technology means for
the shop’s success.
“My family has always invested in new equip-
ment, not mansions and cars,” Sjoberg said. “I don’t
drive a jalopy, but I don’t have a $200,000 car either.
We’ve always had state-of-the-art equipment and
that is why we’ve thrived.
“I doubt other privately held companies would be
happy with our model. That’s pretty typical in the
industry. They don’t want to spend the capital. They
want to keep the profit margin huge,” he added. “A
family business is willing to do it for less [of a profit
margin] typically.”
Keeping up With Customers
Even as a youngster Sjoberg could see why technol-
ogy was so important to the business: The manufac-
turing focus could change pretty rapidly.
100 The FABRICATOR FEBRUARY 2016
Sjoberg Tool & Manufacturing began as a tool
and die shop, but in the mid-1980s it jumped into
high-volume part production. One of the company’s
sales representatives won a very substantial metal
forming contract, and Sjoberg Tool was suddenly in
the stamping business.
Some other significant contracts soon pulled the
company into the metal fabricating arena as well.
This led to the purchase of its first turret punch
press in the late 1980s and its first laser cutting ma-
chine in 1992.
The punch press and laser were kept busy, but
stamping still dominated the manufacturing mix in
the early 1990s. No one thought twice about invest-
Figure 2
Two of Sjoberg Tool’s Mazak 4-kW CO2 laser cutting machines are connected to a material storage and retrieval
system that allows for the 6-year-old machines to remain efficient part producers, particularly for 10-gauge or
thicker mild steel.
Figure 1
Sjoberg Tool’s new Mazak Optiplex 3015 4-kW fiber
laser cuts sheet metal at such a rapid pace that it is
changing the way that the shop floor approaches
certain fabrication jobs.
ing in tooling for production; it was the way it was
done in the past, and no one was questioning the
wisdom of it—yet.
That started to change by 1994, according to Sjo-
berg, when the fabricator built its current manufac-
turing facility. It was going to fill the shop floor with
laser cutting capability and fewer stamping presses.
The days of 100,000-part orders per month were
drawing to a close.
The era of low-volume, high-mix manufacturing
had yet to emerge fully. The punch presses and laser
cutting machines were still used to pump out hun-
dreds to thousands of the same part.
Sjoberg said the transition to expectations for
just-in-time delivery in the 2000s changed that.
Manufacturing customers wanted just the parts that
were needed, so they didn’t have to go to the trou-
ble of storing and tracking excess inventory.
The six- to seven-week lead time for orders has
gone the way of the duplicator punch press. Most
of the work now falls into a three- to five-day turn-
around time, if it doesn’t require paint. (Sjoberg
does not provide finishing services at its facility, but
a truck from its powder coating service supplier is
kept at the shop. The truck is filled and sent to the
custom coater as many as five times per week.)
Even long-term customers that have worked with
Sjoberg Tool long enough to accommodate a four-
week lead time typically slip in hot jobs with their
regularly occurring orders.
“Delivery is not a given,” Sjoberg said.
That’s where the fabricator can stand out. Sjo-
berg said the company maintains an on-time deliv-
ery rate of about 99 percent. (The average on-time
Figure 3
For this long part, the turret punch press can’t match
the production speed of the fiber laser cutting ma-
chine. Because the part is not hole-intensive, the fiber
laser can cut the holes quickly and then blaze through
the straight-line cuts. The turret punch would require
much more time using a shearing tool to make those
same long cuts.
Figure 4
Sjoberg Tool’s latest folding machine, a Schröder SPB
Evolution, is capable of working with material up to 11
gauge.
delivery rate for most job shops, according to the
Fabricators & Manufacturers Association’s most re-
cent “Financial Ratios & Operational Benchmarking
Survey,” is 87.12 percent. It’s been around that level
for the past four years.)
“It just keeps getting tighter and tighter every
year,” he added.
He credits his approximately 75 employees and an
experienced management team that are committed
to getting quality products out the door when they
are expected to. The can-do attitude provides the
motivation to satisfy the customer.
But having the right equipment helps the Sjoberg
Tool staff maintain that positive attitude.
Keeping up With Technology
A prime example of the investment in technology
that Sjoberg Tool makes is its new Mazak Optiplex
3015, a 4-kW fiber laser (see Figure 1). It was in-
stalled eight months ago, and the fabricator is still
getting used to its impact on the shop floor.
“We’re finding out just what we can cut,” said
Randy Manhardt, a machine programmer at Sjoberg
Tool.
For example, the fiber laser cuts 10-gauge steel at
twice the rate of a traditional 4-kW CO2 laser cutting
machine, of which Sjoberg Tool still has three (see
Figure 2). (The fabricator has six laser cutting ma-
chines altogether.) On light-gauge steel, it’s no con-
test when comparing the fiber laser’s cutting speeds
to the CO2’s. Manhardt said that they have found
that the fiber laser, in fact, is taking work away from
the turret punching equipment (see Figure 3).
Figure 5
Sjoberg Tool received a $2,500 rebate from a state energy efficiency program affiliated with Wisconsin’s utilities
for purchasing its new electric press brake. Company management said the larger size of the new generation of
electric press brakes makes it a better fit for the majority of work destined for the shop floor.
Manhardt added that the new technology re-
ally hasn’t needed full-time supervision. The auto-
mated material storage tower keeps the machine
fed, which necessary is because the cutting head
reaches speeds of up to 2,400 IPM on very thin-
gauge sheet metal. He added that the cutting head
was still using the same lens after six months of
operation.
Sjoberg Tool has a lot of bending capacity. It has
12 press brakes and four folding machines, two of
which are Schröder machines with bidirectional “My competitors are changing and
bending (see Figure 4). These machines can make adapting, and I need to as well, be-
up and down bends without the operator having to cause once you get too far behind
flip the panel. that curve, you’re never going to catch
The most recent addition to the fleet of press up. You’re going to be in trouble.”
brakes represents Sjoberg Tool’s first electric press
— Jim Sjoberg, Sjoberg Tool & Manufacturing Corp.
brake, a 100-ton SafanDarley E-Brake with a 10-ft.-
wide bending window (see Figure 5). Robert Man-
hardt, the plant superintendent, said that press
brake has the capability to get bending jobs up
and running in about 10 minutes, which includes
programming. The brake’s controller quickly de-
termines the bend sequence from CAD files and in-
structs the operator about what tooling is needed
(because the tooling library is preinstalled in the
software). The operator can install the tooling in the
Wila clamping system and go right into bending.
“Repeatability on the electric press brake is un-
believable,” Robert Manhardt said. “The hydraulics
can’t match it.”
The fabricator had a 16-ft. Accurpress press brake
installed toward the end of 2015. It almost exclu-
sively bends 24-gauge parts as wide as 13 ft.
To make space for the new equipment, Sjoberg
said the company invested in a couple of compact
racking systems with cassettes that slide in and out
of the tower structure with the assistance of a lift
Figure 6
truck (see Figure 6). He added that one of these This material racking system from Big Steel Rack has
towers replaces three racks typically found in shops. freed up space on the shop floor for new equipment.
FEBRUARY 2016 The FABRICATOR 101

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While its fiber laser cutting
machine may have removed
some work from the turret
punch presses, punching re-
mains a core fabricating activity
for Sjoberg Tool. The company
has six punch presses, two of
which have load/unload capa-
bility (see Figure 7).
In what was once the tool- Figure 7
room, machining is now done. This Rainer Eletek 1530 electric punching machine at-
tached to an automated material load/unload system
The company has four vertical can process more than 200 sheets unattended over a
machining centers. Sjoberg said weekend.
a majority of the machining that
takes place is for value-added
work done to sheet metal as-
semblies. The goal is to do as
much as possible of that work in-
house, eliminating the need to
send the assemblies out to a ma-
chine shop. The shop isn’t nec-
essarily seeking to take on jobs
that call solely for machining.
Figure 8
Keeping up With Trends Sjoberg Tool holds finished inventory for some large
Coinciding with the capital customers. Many of these parts are long, some reach-
ing 160 in. To maximize storage space, the fabricator
equipment investments are in- built deep racks. Unlike traditional racks, where pal-
vestments in training the work- lets eat up a lot of horizontal space, these custom
force. Supported by state grant racks ensure that a majority of the surface area can be
dedicated to part storage.
money, which covers two-thirds
of the overall training cost, the fabricator has been able to pay for 5S lean manu-
facturing and general skills training. Waukesha County Technical College has
provided the instruction for these initiatives.
Sjoberg said the company was just starting the second phase of training, in
which the remainder of the company is being exposed to basic lean manufactur-
ing terminology and practices. Training also will focus on the tutoring of “champi-
ons,” he said, who will help the company get its own program off the ground and
hopefully sustain it over the long term.
Sjoberg Tool also created a new position in 2015 to support this transforma-
tion. A new engineer, whose sole function is to identify continuous improvement
opportunities within the company, has been on the job for just over nine months.
“My competitors are changing and adapting, and I need to as well, because
once you get too far behind that curve, you’re never going to catch up,” Sjoberg
said. “You’re going to be in trouble.”
Perhaps symbolic of this need to change is the very rear of the facility. Equip-
ment doesn’t dominate the landscape back there. Shelving does.
On those shelves are long parts that came from the shop floor (see Figure
8). They are being held for a few large customers until they are needed. Those
customers are practicing their own version of lean manufacturing, and Sjoberg
Tool is responsible for supplying the parts on a JIT basis.
Managing inventory isn’t necessarily what metal fabricators want to do, but
it is what fabricators do to satisfy customers. Sjoberg Tool has adapted to hold-
ing more inventory over the years, and that probably won’t change. Company
management knows that it has to keep pace with customer demands if it wants
to remain relevant.
Editor-in-Chief Dan Davis can be reached at dand@thefabricator.com.
Sjoberg Tool & Manufacturing Corp., 535 S. Industrial Drive, Hartland, WI 53029,
262-367-4469, www.sjobergtool.com
Accurpress, www.accurpress.com
Big Steel Rack, www.bigsteelrack.com
Mazak Optonics Corp., www.mazakoptonics.com
Rainer, www.rainer.it
SafanDarley, www.safandarley.com
Wila USA, www.wilausa.com
102 The FABRICATOR FEBRUARY 2016
JUNE 12TH , 12:37 P.M .

A LUNCH
INTERRUPTED AND
A COMMITMENT KEPT
IN AN
INS TANT,
DAN PARK
RE ALIZED THE
VA LUE OF HIS
CNA INSUR ANCE
P OLIC Y

Dan picked up the phone and then dropped his

fork. The supplier he was counting on for the
materials he needed to meet a client’s deadline
was not able to deliver on time due to a fire in
his plant. That’s when Dan remembered he had
dependent property coverage as part of his policy
with CNA. After a quick review of his supply chain
plan, specially built for him with his independent
agent and CNA experts, Dan was able to call
a new source for the materials, and CNA even
picked up the cost to expedite shipment, allowing
Dan to meet his client obligations without leaving
his chair. Enjoy your lunch, Dan.

When it comes to helping FMA members

keep their supply chain flowing …
we can show you more.®

To learn more about our broad portfolio of insurance products and services
for metal manufacturers, visit www.cna.com/fma.

The examples provided in this material are for illustrative purposes

only and any similarity to actual individuals, entities or places is
coincidental. Please remember that only the relevant insurance
policy can provide the actual terms, coverages, amounts, conditions
and exclusions for an insured. All products and services may not be
available in all states and may be subject to change without notice.
CNA is a service mark registered by CNA Financial Corporation with
the United States Patent and Trademark Office. Certain CNA Financial
Corporation subsidiaries use the “CNA” service mark in connection with
insurance underwriting and claims activities.
Copyright © 2016 CNA. All rights reserved.
 Machine Spindle Tool Lubrication
Type Workpiece Torch Spindle Capabilities Punch Mark Changer System
(Clamping Feed)

Plasma Oxyfuel
Roller Feed

Countersink
X-Y Table
Gripper

Max.

Face Mill
End Mill
Max. Max. Max. Max. Amps Max. Max. Max. Max.

Deburr

Stamp
Scribe

Flood
Thickness Width Length Weight No. of per No. of No. of HP per Speed Stroke No. of Force No. of

Drill

Mist
Tap

Y/N
Model (in.) (in.) (ft.) (tons) Torches Torch Torches Spindles Spindle (RPM) (in.) Tools (tons) Stations
FICEP CORP., Forest Hill, MD Enter reader service code 886625 at www.ffid.net
Tipo C16 4 63 20 .66 1 260 1 1 14.8 4,200 4 4 4 4 4 1 12 55 4 Y 12 4
Tipo C25 4 4 100 40 2.75 1 400 1 1 15 4,200 4 4 4 4 4 1.25 14 112 4 4 Y 14 4
Tipo B 254 4 100 60 11 2 400 2 1 26 4,000 4 4 4 4 4 1.25 6 110 4 4 Y 6 4
Tipo B 164 4 63 20 5.5 2 400 2 1 26 4,000 4 4 4 4 4 1.25 4 110 4 4 N 4 4
Gemini 254 HP 4 96 80 1 400 3 1 15 7,000 4 4 4 4 4 4 4 Y 8 4
Gemini 36 HD 4 141 80 2 400 3 2 42 6,000 4 4 4 4 4 4 4 Y 16 4
Gemini 36 XD 4 4 141 100 2 400 4 2 75 6,000 4 4 4 4 4 4 4 Y 32 4
Tipo A 16 4 63 40 11 1 400 1 1 34 3,000 4 4 4 4 4 4 4 Y 6 4
Tipo 25 LG 4 98 20 5.5 2 400 2 2 34 3,000 4 4 4 4 4 4 4 Y 12 4
Tipo A 31 4 122 40 8.25 2 400 2 2 34 3,000 4 4 4 4 4 4 4 Y 12 4

MESSER CUTTING SYSTEMS INC., Menomonee Falls, WI Enter reader service code 113742 at www.ffid.net

Titan III 4 168 200 2 800 8 1 3 4 4 4 N

MetalMaster Xcel 4 4 120 50 2 800 1 1 2 5,000 4 4 4 N
EdgeMax 4 120 24 1 400 1 4 N
MetalMaster Plus 4 120 50 2 400 1 1 .5 4 4 4 N
PlateMaster 4 120 150 2 800 6 4 4 N
MPC2000 4 4 312 200 4 800 10 1 37 4 4 4 4 4 Y 12 4
TMC4500DB 4 4 600 200 4 800 12 1 65 4 4 4 4 4 Y 24 4 4

PEDDINGHAUS CORP., Bradley, IL Enter reader service code 119051 at www.ffid.net

HSFDB-3200/C 4 4 126 20 17 1 400 1 1 48 2,250 4 4 4 4 4 4 4 4 Y 12 4

HSFDB-2500/C 4 4 96 20 13 1 400 1 1 48 2,250 4 4 4 4 4 4 4 4 Y 12 4
HSFDB-1800/C 4 4 72 20 10 1 400 1 1 48 2,250 4 4 4 4 4 4 4 4 Y 12 4
HSFDB-2500/B 4 4 96 20 10 1 400 1 1 48 2,250 4 4 4 4 4 4 4 Y 8 4
HSFDB-1800/B 4 4 72 20 7 1 400 1 1 48 2,250 4 4 4 4 4 4 4 Y 8 4
FPB-1800/3C 4 4 72 40 6 1 260 2.125 3 177 4 N 4
FPB-500/3F 4 4 20 40 1.75 1 260 2.125 3 177 4 N 4
FPD-1120 4 4 30 5 .3 1 13.5 900 4 2 3 120 4 N 4

PROFILE CUTTING SYSTEMS USA, Boulder Creek, CA Enter reader service code 260773 at www.ffid.net

BHB 4 360 Any Any 4 800 20 2 60 4 4 4 4 4 4 4 Y 24 4 4

MHB 4 288 Any Any 4 800 20 2 30 6,000 4 4 4 4 4 4 4 Y 24 4 4
EHD 4 288 Any Any 4 800 20 2 14 5,000 4 4 4 4 4 Y 16 4 4
HD 4 16 Any Any 4 800 12 1 8 4,000 4 4 4 4 Y 4 4 4
FineLine 4 96 Any 8,000 2 800 1 2 8,000 4 4 N 4 4
SR 4 4 144 Any 2 800 6 1 2 8,000 4 4 4 N 4 4

VOORTMAN AUTOMATISERING B.V., Rijssen, Overijssel, Netherlands Enter reader service code 3063629 at www.ffid.net
V304 4 236 80 2 440 6 4 N
V320-2000 4 4 80 40 8.3 1 440 1 1 40 2,500 4 4 4 4 4 Y 2x5 4
V320-3000 4 4 120 40 9.9 1 440 1 1 40 2,500 4 4 4 4 4 Y 2x5 4
V330 4 120 40 1 440 4 1 40 2,500 4 4 4 4 4 Y 5x5 4
V200 4 4 40 8 .65 1 40 2,500 4 4 4 4 4 Y 1x8 4
VOORTMAN CORP., Monee, IL Enter reader service code 1003168 at www.ffid.net
V304 4 156 80 2 400 6 4 N
V320 4 4 120 39.75 9.9 1 400 1 1 40 2,500 4 4 4 4 4 Y 2x5 4
V330 4 120 39.75 1 400 4 1 40 2,500 4 4 4 4 4 4 Y 5x5 4
V200 4 4 40 4.6 .65 1 40 2,500 4 4 4 4 4 Y 1x8 4
W.A. WHITNEY CO.—A DIVISION OF MEGAFAB, Rockford, IL Enter reader service code 119298 at www.ffid.net
Plasma Machining
4 4 4 240 5.36 2 400 1 30 4,000 4 4 4 4 4 4 16 100 4 4 Y 8 4
Center

This information is provided by the manufacturers. For more information, use the corresponding advertising code at www.ffid.net or the links in the online buyers’ guide at www.thefabricator.com.
©Copyright 2016 by FMA Communications Inc. Reproduction in full or in part without written permission of the publisher is prohibited. Buyers’ guides are a part of the Forming & Fabricating Industry Directory.

104 The FABRICATOR FEBRUARY 2016

 NEXT LEVEL PLATE PROCESSING
DISCOVER THE PLATE PROCESSING SYSTEMS FROM VOORTMAN

VOORTMAN V304 VOORTMAN V320 VOORTMAN V330

CARBIDE DRILLING CARBIDE DRILLING CARBIDE DRILLING
HD PLASMA BEVEL CUTTING HD PLASMA CUTTING HD PLASMA CUTTING
OXY-FUEL CUTTING OXY-FUEL CUTTING OXY-FUEL CUTTING

PRECISION CONTOURS NO TAPER

XTENSIVE HOLE PERFORMANCE I-CUT CORRECTION

VIRTUALLY DROSS FREE

DROSS INHIBITOR

FAST POSITIONING AND BEVELING

CREATED BY A VOORTMAN V304 VOORTMAN HEIGHT CONTROL

INCREASE PRODUCTIVITY, IMPROVE QUALITY AND SAVE LABOR

PROPRIETARY SOFTWARE HIGH SPEED HIGH DEFINITION 3D PLASMA MULTI OPTION AUTOMATIC
WITH LIVE DIAGNOSTICS CARBIDE DRILLING PLASMA CUTTING BEVEL CUTTING OXY-FUEL CUTTING PART REMOVAL

WWW.VOORTMANCORP.COM
26200 S. WHITING WAY | MONEE, IL 60449, USA | SALES@VOORTMANCORP.COM | +1 708 885 4900
 Conveyor Feed Speed
Head Type
Brush/Disc (IPM)
Process
Maximum Minimum Drum/Brush/ Action
Part Width Part Length W = Wet No. of Disc R = Rotate Head Motor Dust Extraction
Model (in.) (in.) D = Dry Heads Brush Disc Drum Diameter (in.) O = Oscillate Power (HP) Min. Max. per Head (CFM)

AM MACHINERY SALES INC., Warminster, PA Enter reader service code 140085 at www.ffid.net
DiscMaster 4TD 39, 60 1 D 2 4 10 2 39.4 197 1,800
CrossMaster DD 6, 12 1 D 2 4 16 1.2 39.4 394 1,200
BeltMaster K4TD-1350 53 10 D 3 4 4 4 10 20 39.4 197 2,200
CrossMaster 2TD-500 20 1 D 2 4 4 10 2 39.5 236 1,200
DiscMaster SF 1/1 39, 60 10 D 2 4 6 5 20 157.5 1,800
DiscMaster SF 2/2 39, 60 10 D 4 4 6 5 20 157.5 2,200
AME ABRASIVE BELT MACHINERY & EQUIPMENT INC., Delta, BC, Canada Enter reader service code 1471824 at www.ffid.net
SG630-WJS+DB 24 10.5 W 3 4 4 4 Disc: 6, Brush: 8
SG-1030-WJS+2D+B 40 5 W 4 4 4 4 6.63 O 78 400
Vacuum
SG1600-2WJS+B 62 19.5 W 3 4 4
SD-H Vacuum Table 1 1 D 2 4 4 6 1
SB1000 (double side) 39.3 5.9 D 2 4

ARKU COIL SYSTEMS INC., Cincinnati, OH Enter reader service code 991833 at www.ffid.net
Edgebreaker® 4000 51 6 D 3 4 4 Drum: 17 O, R 32 20 236 8,500
Edgebreaker® 2000 51 6 D 2 4 R 19 20 236 8,500
Disc:
EdgeRacer® E (single side) 39/59/79 2 to 15 D 1 4 O 8 20 236 3,200
7 with brush
Disc: 7
EdgeRacer® D (double side) 39/59/79 2 to 15 D 2 4 O 16 20 236 4,500
with brush
APEX MACHINE GROUP, Golden Valley, MN Enter reader service code 1071517 at www.ffid.net
2 Rollers, Roller: 11.25, Disc:
Perfection BBDD 53 4 D 4 4 O 3 45
11 Discs 9.75
Perfection 2DD-1350 52 4 D 22 Discs 4 Disc: 9.75 O 3 3 45
Perfection 2DD-1850 72 4 D 30 Discs 4 Disc: 9.75 O 3 3 45
MetalPro EZ3760-M 36 6 D 1 4 6 10 3 25
Apex 5275-4TW 52 10 W 1-4 4 4 Drum: 8 O 15-40 3 25
Drum: 8, Disc: 4,
Apex 3775-4TD 36 7 D 1-4 4 4 4 O 15-30 3 25
Brush: 8
Drum: 4, Disc 4,
Apex 2575-1TD 24 5 D 1-4 4 4 4 O 10-20 3 25
Brush 6
Apex 1975-4TW 18 7 W 1-4 4 4 Drum: 6, Brush: 6 10-25 3 25
BLAST & WASH SYSTEMS., Wayland, NY Enter reader service code 1507911 at www.ffid.net
4 blast
4836 V Roller Blast 48 36 D 25 24 96 5,000
wheels
CS UNITEC INC., Norwalk, CT Enter reader service code 186451 at www.ffid.net
ROLEI PEF 500 D 1 4 .75 2,800 RPM
(Hand Tool)
ROLEI EF 165 D 1 4 .75 2,800 RPM
(Hand Tool)
ROLEI BE 5 (Hand Tool) D 2 4 6.5 .50 600 RPM 1,200 RPM
ROLEI EF 115 D 1 4 4.5 1.20 2,000 RPM 7,600 RPM
(Hand Tool)
FLADDER, Atlanta, GA Enter reader service code 841523 at www.ffid.net
AUT 39, 47 6 13.8 12 394
300 Gyro 51.5, 63 6 13.8 12 394
400 Gyro 51.5, 63 6 13.8 12 394
300 LS 5.75 2-8 5.75 20 1,950
GAUER METAL PRODUCTS INC., Kenilworth, NJ Enter reader service code 3619995 at www.ffid.net
5H-Series (Rolled Edge) .625, 52 1 D 2 12 1,200 No Dust
6H-10 (Round Edge) .625, 10 1 D 6 12 1,500 No Dust
9H-10 (Rugged Duty) .50, 10 1 D 6 12 1,500 No Dust
9H-CTL Safety Edger .50, 10 1 D 6 46 12 3,000 No Dust
8H-CTL Safety Edger .75, 10 1 D 4-6 53 12 2,400 No Dust
10H-Bar 1, 8 36 D 4 53 12 1,500 No Dust
Deburring Master
10H-CTL Safety Edger 1, 8 1 D 4 78 12 2,400 No Dust
HANS WEBER, Paola, KS Enter reader service code 455731 at www.ffid.net
NLC 60 6 W 4 4 4 4 8 30 3 30
TT1P167 60 4 D 3 4 4 4 7.25 25 3 30 1,800
TTSC 52 8 D 1-2 4 4 4 7.25 15 3 30 1,200
MK 79 4 D 1-4 4 4 4 6 30 3 30 2,200
TN 52 8 W 1-3 4 4 4 6 15 3 30

106 The FABRICATOR FEBRUARY 2016

 Conveyor Feed Speed
Head Type
Brush/Disc (IPM)
Process
Maximum Minimum Drum/Brush/ Action
Part Width Part Length W = Wet No. of Disc R = Rotate Head Motor Dust Extraction
Model (in.) (in.) D = Dry Heads Brush Disc Drum Diameter (in.) O = Oscillate Power (HP) Min. Max. per Head (CFM)

HECK INDUSTRIES INC., Hartland, MI Enter reader service code 111862 at www.ffid.net
8000 D 1 .625

12-C Bevel-Mill .625

VA-400 .50 .50 D 1

Weld Shaver .50 D 1 4 3

Turbo-Burr No max. No min. D 1 .25 6

LISSMAC CORPORATION, Waterford, NY Enter reader service code 1104633 at www.ffid.net

SBM Oxide Removal 39/59 6 D 2 4 0 157

SBM Edge Rounding 39/59 6 D 2-4 4 0 157 3,200-8,500

Steelmaster Surface 37/64 11 D 5 4 4 4 47 393 3,200-8,500
Finishing
Steelmaster Surface 37/64 11 W 4 4 4 4 47 393
Finishing

METALFINISH, Plainfield, CT Enter reader service code 434965 at www.ffid.net

Ernst Pluto/ 80 3.2 D 3 4 4 17 Up to 30 20 200 2,500-3,400
Titan HD Deslagging
Ernst Atlas Series 60 3.2 D 1-16 4 4 4 8-17 Up to 30 20 400 3,200-8,500

Ernst Neptun Wet Series 60 3.2 W 1-16 4 4 4 8-17 Up to 30 20 400

NS DM 1100/1600 64 2 D 1-3 4 4 Cross Belt Up to 40 20 320 1,800-3,200
Deburring/Edge Rounding
NS DM 660 Z-PK Extreme 26 3 D 1-3 4 4 Rotor 14 Up to 20 20 400 3,600-8,500
Edge Rounding
NS FG Series 13 4 D 1-4 4 4 6-12 Up to 15 40 800 1,200
NS TR120 Series 12 8 D 1-8 4 4 6-12 O 4.5 40 600 600
Edge Grinder
NS LR 30 AT Open 2 D 2 4 10 4 20 240 600

NS - Oxide Removal 44 7 D 2 4 Cross Belt 7.5 20 200 2,500

Gecam G3 Series TT 12 6 D 1-3 4 4 4 6-10 Up to 5.5 40 400 600

Gecam G6 Series 26 6 D 1-4 4 4 4 6-10 7.5 40 400 Up to 1,800

Gecam G11 Series 44 6 D 1-4 4 4 4 6-10 15 40 400 Up to 3,300

Gecam G13 Series 51 8 D 1-4 4 4 4 8-12 20 40 400 Up to 4,600

Gecam G16 Series 64 8 D 1-4 4 4 4 8-12 Up to 25 40 400 Up to 6,800

Gecam Wet G6/G13 26 / 51 8 W 1-4 4 4 4 6-12 7.5-20 40 400

Gecam GT13-S 2-3 Top and
51 6 D 4 4 Drum 8 - Cross Belt Up to 25 20 320 Up to 3,300
Edge Rounding Bottom
Gecam GT1-B 2 Top and
51 6 D 4 Cross Belt 7.5 20 320 2,500
Oxide Removal Bottom

SUPERMAX TOOLS, St. Paul, MN Enter reader service code 1118616 at www.ffid.net
SuperBrush 24 with 24 3 D 1 4 Var. 5 30 600
Vacuum Hold-down
SuperBrush 24 24 10 D 1 4 Var. 5 15 600

SuperBrush 36 36 10 D 1 4 Var 5 15 600

SuperBrush 36 36 10 D 2 4 Var. 5 30 800
Double Head
SuperBrush 49 48 10 D 1 4 Var. 5 15 800

WideBelt 25 24 10 D 1 4 60 10 or 20 15 60 800

WideBelt 37 36 10 D 1 4 60 15 or 20 15 60 800

TIMESAVERS INC., Maple Grove, MN Enter reader service code 115951 at www.ffid.net

Mini-Belt 8 5.5 D 1 4 3.25 5 15 15 500

1100 Series 8 5 W 1-2 4 3.25 5 10 30

1200 Series 8, 24, 36 5 - 8.5 D 1-2 4 3.25 - 6 5 - 15 10 45 Var.

1221-11-05 8 1 Sq. D 2 4 4 3.25, 14 5 10 30 500

1200 Slag Grinder 36 8 D 2 4 6 15 - 10 10 25 1,000

2100 Series 36 8 W 1 4 6 10 - 15 15 45

2200 Series 36, 51 9, 10 D 1-3 4 4 6-8 O 15 - 30 15 45 Var.

2200 Slag Grinder 36 10.75 D 3 4 4 6, 8 O 25, 20 10 30 4,500 (Total)

2200 Rotary Brush 51 4 Sq. D 1 4 12 10 5 30 5,250

Lynx (19MWT) 18 8 W 1-4 4 4 6 O 20 10 30
Lynx (37MWT) 36 8 W 1-4 4 4 6 O 15 -20 15 45
PUMA (52MWT) 51 10 W 1-4 4 4 8 O 15 - 30 5 25
Drum: 7 Disc:
4100 Series Disc 24, 36, 51 3 Sq. W 1-3 4 4 4 O 5 - 30 3 30
36/48/60
4200 Series 36, 51 11 - 13.5 D 1-4 4 4 7, 11 O 15 - 40 15 65 Var.
4200 Slag Grinder 36, 51 13.5 D 3 4 4 7, 11 O 30, 30, 25 10 30 3,000 or 4,400 (Total)
4200 Rotary Brush 51 4 Sq. D 1-3 4 4 12 12 5 30 Var.

This information is provided by the manufacturers. For more information, use the corresponding advertising code at www.ffid.net or the links in the online buyers’ guide at www.thefabricator.com.
©Copyright 2016 by FMA Communications Inc. Reproduction in full or in part without written permission of the publisher is prohibited. Buyers’ guides are a part of the Forming & Fabricating Industry Directory.
FEBRUARY 2016 The FABRICATOR 107

News and information from the Fabricators
& Manufacturers Association, International ®
May 4-6, 2016
Centro Banamex, Mexico City, Mexico
FABTECH® Mexico, co-sponsored by the Fabricators &
Manufacturers Association Intl. (FMA) and SME, co-locates
with AWS Weldmex, METALFORM and Machining Mexico,
and COATech again in 2016. The largest metal forming,
fabricating, welding, and finishing exposition in Mexico
anticipates 575 exhibiting companies and 140,000 net
square feet of floor space. Over 13,000 attendees from
Mexico and South America will converge on the Centro
Banamex to network, learn, and experience the latest
innovations in the metal forming, fabricating, welding, and
finishing industries.
FABTECH Mexico features bending and fabrication products,
including laser and plasma cutting, coil processing, roll
forming, plate and structural fabricating, saws and cutoff
machines, tooling, press brakes, shears, punching, and tube
and pipe equipment. AWS Weldmex showcases welding and
cutting products, including thermal spray, metal finishing,
and safety equipment. METALFORM and Machining Mexico
offers metal forming products, including tool and die, metal
stamping, forming, and assembly. COATech will highlight
finishing technologies including paint and powder, coatings,
and corrosion control.
For more information or to find out how your company
can be part of this exciting industry event, log on to
fabtechmexico.com or call 800-432-2832.
108 The FABRICATOR FEBRUARY 2016
Follow the conversations at any
of our social sites, or join our
online member community.
TOUR, LEARN, AND NETWORK AT THESE
APRIL FMA WORKSHOPS!
Developed by volunteer councils, the following conferences and workshops connect attendees
with the industry knowledge and insight they need.
Share Best Practices at the 8th Annual Safety Conference
The Safety Conference will be held in Dayton, Ohio, April 13-14, 2016. An excellent forum for sharing the
successes and challenges of your company’s safety program with industry peers is provided through interactive
presentations and a reception and dinner honoring FMA/CNA Annual Safety Awards winners.
An additional highlight will be a plant tour of The Dupps Co., the 2015 recipient of FMA’s highest safety honor,
the Rusty Demeules Award for Safety Excellence. Learn how you can improve the safety record at your
company from those who share the same challenges.
Registration is $395 for FMA/TPA members and $595 general.
Roll With the Experts at World-class Roll Forming Workshop
Strengthen your skills and know-how with a comprehensive industry update at FMA’s World-class Roll Forming
Workshop April 26-27, 2016, in Charlotte, N.C.
Designed with smaller workshop sessions for more interaction, this workshop features roll forming experts
who are committed to answering your questions, providing solutions to your problems, and giving insights
that will help you improve your operation.
You can take full advantage of the presenters’ experience while spending an evening with them at a Networking
With the Experts Reception. Bring your parts, drawings, and challenges to get the solutions you need.
Registration is $695 for FMA/TPA members and $895 general.
See Advanced Technology in Action at the 2016
Coil Processing Workshop & Tours
Gain a fresh perspective on today’s competitive market by attending FMA’s Coil Processing Workshop &
Tours April 25-27, 2016, in Charlotte, N.C. Three full days are packed with plant tours and multiple technical
presentations from industry leaders.
Whether your expertise is in slitting, blanking, or leveling, you’ll acquire technical know-how and discover
practical solutions to your toughest processing challenges. Industry experts will share the newest innovative
techniques.
Tours of the Charlotte Motor Speedway Track, Freightliner, and others will give you an exciting, behind-the-
scenes look at equipment advancements in action.
Registration is $595 for FMA/TPA members and $795 general.
For more information or sponsorship opportunities on these upcoming
events, visit fmanet.org/calendar or call 888-394-4362.
 Your leading educational resource

WELCOME, SUSTAINABLE
MANUFACTURER NETWORK
FMA is pleased to announce the integration of the Sustainable Manufacturer Network (SMN) within its
existing membership structure effective Jan. 1, 2016. The important area of environmentally sustainable
manufacturing continues to be a high priority for FMA. Ongoing services for FMA/SMN members include
the following:
• Eligibility to participate on the SMN Advisory Board
• Discounts on SMN educational events and conferences
(Sustainable Manufacturing 101 and Energy Efficiency courses coming up this summer)
• Access to sustainablemfr.com, your source for the latest industry articles, news, and
product information
• Subscription to the SMN e-zine published monthly
If you’d like to add the SMN designation to your membership, contact customer service
at 888-394-4362.

Become an FMA member

and save on your 1st event!

FMA PRESENTS MEMBER COMPANY

UPCOMING
WITH 2016 INDUSTRY AWARD
Congratulations to FMA member MEC, Mayville, Wis., on
EVENTS
becoming The FABRICATOR® 2016 Industry Award honoree.
This award is bestowed upon an individual or company that Coming Soon….
has successfully improved operations, attained business
success, and contributed to both their local and business The FABRICATOR ®’s Leadership Summit & Toll Processing
Conference at FMA Annual Meeting
communities.
Feb. 24-26, 2016, Paradise Point Resort & Spa, San Diego, Calif.
“Manufacturing has been the backbone of America, and we FabCast: Ask the Software Experts - Supply Chain, Lean &
feel it’s appropriate to honor the heroes of the industry by Inventory Management
paying tribute to those companies that exemplify success,” March 3, 2016, 10-11 a.m. CT
said James Warren, senior director of Member Services, BMO Harris Bank Plant Tour Series
Education & Foundation for FMA. “Congratulations to the March 17, 2016, Milwaukee, Wis.
management and staff.”
Educational Sessions at FABTECH Canada
March 22-24, 2016, Toronto, Canada

Looking Ahead….
11th
Coil Processing Certificate Course
ANNUAL

April 4-5, 2016

Press Brake Safeguarding Certificate Course
April 12, 2016
Safety Conference
April 13-14, 2016
BMO Harris Bank Plant Tour Series
April 19, 2016
Coil Processing Workshop & Tours
April 25-27, 2016
World-Class Roll Forming Workshop
April 26-27, 2016
Educational Sessions at FABTECH Mexico
May 4-6, 2016
Celebrate with the award recipient in a ceremony during The FABRICATOR ’s 11th Annual
®
ALAW® - Advanced Laser Applications Workshop
Leadership Summit, which begins Feb. 24 at Paradise Point Resort in San Diego. MEC President June 6-8, 2016
and CEO Robert Kamphuis will make brief remarks about the company’s accomplishments BendFab & PlateFab Workshop & Tours
qualifying them for this prestigious recognition. June 8-9, 2016
More information is available at fmanet.org/annualmeeting or by calling 888-394-4362.
Details at fmanet.org/calendar or call 888-394-4362.

FEBRUARY 2016 The FABRICATOR 109

 Time for the Silent Auction —
It’s a Win-Win Situation
NBT brings the silent auction to San Diego! The annual silent auction not only
grows the camp and scholarship programs, it also gives the auction donors
a way to get their company brand in front of industry colleagues, coupled
with a nice tax deduction.
Trends to Watch in 2016
By Dr. Chris Kuehl, FMA Economic Analyst
Well, this is a nice way to start a new year. It seems that it doesn’t require
massive snowstorms to make the first quarter miserable; this time it is enough
to get worried about China and to watch the price of a barrel of oil plummet.
The No. 1 question now is whether this is just a phase or a signal of what is to
come in 2016. If last year is any indication, it is probably going to be hard to
pin down just what growth will look like in 2016.

U.S.’s
If you remember that roller coaster of a year
signed
signedsports
sportsmemorabilia
memorabilia processing
processingservices
services table
tablefabricated
fabricatedbybystudents
students custom
in 2015, wecustom fire
firepit
pit Q1 followed by a clay
had a miserable claytar
ta
trading Q2 that was almost at 4 percent growth. The
third quarter was anemic but not awful (2.0),
partners are and the estimate of Q4 is something under
struggling. 1 percent. Should we look forward to another
year of these ups and downs? Probably.
At the end of the day we are likely to see that 2015 finished with annual growth
pretty near the norm of the last few decades — somewhere between 2.0 percent
ces
ces table
tablefabricated
fabricatedby
bystudents
students custom
customfire
firepit
pit clay
clay
andtarget
target
2.5 thrower
thrower
percent. Phantom
Phantom
This is not enough to cause either33panic
drone
drone
or dancing in the
streets — it is just the kind of steady and somewhat disappointing activity we
have come to expect of late.
For those who want to play economist at home, keep an eye on three trends —
two that would make things worse and one that would herald an improvement.
The first bad thing is a continued slide in global economies. The U.S.’s export
levels have fallen, and that has been attributed to the strength of the dollar.
This is a factor, but the real problem is that most of the U.S.’s trading partners
t clay
claytarget
targetthrower
thrower Phantom
Phantom33drone
drone are struggling. The second negative trend is the continuation of higher interest
rates as set by Fed policy. If rates get high enough, they will cause the economy
The silent auction will take place on Wednesday, Feb. 24, during the welcome to stall.
reception at the FMA Annual Meeting in San Diego. Here, over 300 conference
attendees will get the opportunity to haggle over the most coveted items The positive trend to watch is the consumer. They have the money to spend
or services offered — everything from home items to sports memorabilia, if they desire to do so. They have been willing to buy cars, but not much else.
conference passes to jewelry, artistic creations to techie electronics. Past When they elect to open their wallets, the economy will start to hum.
contributions even included a time-share stay in Mexico!

NEW in 2016!
This year NBT is accepting donations of processing or fabricating services your
company offers. Examples of manufacturing services that can be donated to
this auction are pickling, slitting, transportation, and ad space.
You are invited to consider donating an item or company service to the
auction. Feel free to be creative and use your imagination. If you would like
to participate, contact Diane Engel at 815-381-1338 or dianee@fmanet.org.
Find out more about this event at nutsandboltsfoundation.org/2016-silent-
auction.
Would you like more economic insights twice a month, delivered
straight to your e-mail? FMA members get Dr. Kuehl’s Fabrinomics®
e-news as one of their benefits. Join as an individual or a company
member at fmanet.org/join or call 888-394-4362. To ask a question
of Dr. Kuehl, send it to Fabrinomics@fmanet.org.
Dr. Chris Kuehl
Author of Fabrinomics

LOOKING FOR A WAY TO HONOR EMPLOYEES’

SAFE WORK HABITS?
Turn in your application for the FMA/CNA Safety Award program by Feb. 29!
Learn more at fmanet.org/safetyawards.

110 The FABRICATOR FEBRUARY 2016

NORTH AMERICA’S LARGEST METAL FORMING, FABRICATING, WELDING AND FINISHING EVENTS

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112 The FABRICATOR FEBRUARY 2016

 ADVERTISERS’ INDEX

Please visit our advertisers’ showrooms by entering their reader service codes at www.ffid.net
RS RS RS
Code Page Code Page Code Page
4M Partners, LLC . . . . . . . . . . . . . . . . . . . . . . 44 179241 Diamond Ground Products . . . . . . . . . . . 45,47 795213 Midwest Automation . . . . . . . . . . . . . . . . . . 44
www.learning4M.com www.diamondground.com www.midwestgroupone.com

3013934 AAF International . . . . . . . . . . . . . . . . . . . . . 26 122865 Durma USA . . . . . . . . . . . . . . . . . . . . . . . . . 22,23 115254 Miller Electric . . . . . . . . . . . . . . . . . . . . . . . . . 32
www.aafintl.com www.durmausa.com www.millerwelds.com

140085 A M Machinery Sales . . . . . . . . . . . . . . . . . . . 20 465486 Eriez Magnetics . . . . . . . . . . . . . . . . . . . . . . . 40 199945 Mitsubishi Laser . . . . . . . . . . . . . . . . . . . . . . . . . 5

www.ammachinerysales.com www.eriez.com www.mitsubishi-world.com

256955 ATI Industrial Automation . . . . . . . . . . . . . . 28 548629 Ermak USA Inc. . . . . . . . . . . . . . . . . . . . . . . . . 11 100154 Multicyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
www.ati-ia.com www.ermakusa.com www.multicyl.com

135296 Addition Manufacturing Fabricators & Manufacturers 104109 Murata Machinery USA . . . . . . . . . . . . . . . . . 35
Technologies . . . . . . . . . . . . . . . . . . . . . . . . . 77 Association, Intl. . . . . . . 39,49,52,76,78,102 1-800-428-8469
www.additionmt.com www.fmanet.org
259602 OTC Daihen . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
130391 Admiral Steel . . . . . . . . . . . . . . . . . . . . . . . . . 46 FABTECH® . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 www.daihen-usa.com
sales@admiralsteel.com www.fabtechexpo.com
880614 Ohio Laser . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
1137920 Ajan Elektronik Servis San Ve Tic . . . . . . . 59 898815 Faccin USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 www.ohiolaser.com
www.ajancnc.com www.faccin.com
119051 Peddinghaus Corporation . . . . . . . . . . . . . . 41
233945 Alternative Parts . . . . . . . . . . . . . . . . . . . . . . 16 559230 Fastenal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 www.peddinghaus.com
www.altparts.com www.fastenal.com
750734 Pinnacle Systems . . . . . . . . . . . . . . . . . . . . . 44
122726 Amada America . . . . . . . . . . . . . . . . . . . . . . . 7,9 841523 Fladder - Hansen & Hundebol . . . . . . . . . . 24 www.pinnaclesystems.com
www.amada.com 770-452-1271
546337 Prab Conveyors . . . . . . . . . . . . . . . . . . . . . . . 36
172057 Andersen Industries . . . . . . . . . . . . . . . . . . . 58 Foster Printing Services . . . . . . . . . . . . . . . . 54 www.prab.com
www.andersenmp.com fosterprinting.com
459013 Practical Machinist . . . . . . . . . . . . . . . . . . . . 38
1071517 Apex Machine Group . . . . . . . . . . . . . . . . . . . 47 869258 Fronius USA . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 www.practicalmachinist.com
www.appexmachinegroup.com www.fronius-usa.com
125962 Prima Power . . . . . . . . . . . . . . . . . . . . . . . . . . 15
316550 Arbor Image . . . . . . . . . . . . . . . . . . . . . . . . . . 45 558379 Greiner Industries . . . . . . . . . . . . . . . . . . . . . 21 www.primapower.com
734-741-8700 www.greinerindustries.com
1123930 Radan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
991833 ARKU Coil Systems . . . . . . . . . . . . . . . . . . . . 71 455731 Hans Weber . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 radansales@radan.com
www.us.arku.com jerry@weberamerica.com
487288 Rex-Cut Abrasives . . . . . . . . . . . . . . . . . . . . . 47
841889 BLM Group USA . . . . . . . . . . . . . . . . . . . . . . . 30 111862 Heck Industries . . . . . . . . . . . . . . . . . . . . . . . 45 www.rexcut.com
www.blmgroup.com www.heckind.net
101042 Salvagnini America . . . . . . . . . . . . . . . . . . . . 57
152919 Behringer Saws . . . . . . . . . . . . . . . . . . . . . . . 72 461901 Hougen Mfg. . . . . . . . . . . . . . . . . . . . . . . . . . . 68 www.salvagnini.com
www.behringersaws.com www.hougen.com
547350 Sharpe Products . . . . . . . . . . . . . . . . . . . . . . 44
200844 Bluco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 112061 Kalamazoo Industries . . . . . . . . . . . . . . . . . 54 www.sharpeproducts.com
www.bluco.com www.kalamazooind.com/fab/
271000 SigmaTEK Systems . . . . . . . . . . . . . . . . . . . . 63
101902 Bystronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 827184 Keller USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 www.sigmanest.com
800-247-3332 / 847-214-0300 www.kellerusa.com
3296387 Soitaab USA . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1008586 C Marshall Fabrication Machinery . . . . . . 92 550998 Kloeckner Metals . . . . . . . . . . . . . . . . . . . . . . 53 www.soitaabusa.com
www.cmarshallfab.com www.kloecknermetals.com
111610 Steelcraft Tool . . . . . . . . . . . . . . . . . . . . . . . . 42
192234 CML USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 137224 Koike Aronson . . . . . . . . . . . . . . . . . . . . . . . . 37 734-522-7130
www.ercolina-usa.com 585-492-2400
842265 Tigerstop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
132848 CNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 102149 LVD Strippit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 www.tigerstop.com
www.cna.com 716-542-4511 / 1-800-828-1527
1144983 Trilogy Machinery . . . . . . . . . . . . . . . . . . . . . 79
186451 CS Unitec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 285520 LA - CO Industries . . . . . . . . . . . . . . . . . . . . . 89 www.trilogymachinery.com
www.csunitec.com www.laco.com
100798 TRUMPF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
855986 Camfil Air Pollution Control . . . . . . . . . . . . . . 4 279971 Laser Mechanisms . . . . . . . . . . . . . . . . . . . . . 46 info@us.trumpf.com
www.camfilapc.com www.lasermech.com

1104633 LISSMAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 2092741 Turkish Machinery . . . . . . . . . . . . . . . . . . . . . 61

578883 Carell Corporation . . . . . . . . . . . . . . . . . . . . . 83 www.turkishmachinery.org
www.lissmac-usa.com; 518-326-9094
www.carellcorp.com
434869 Mac-Tech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1662037 United Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1069543 Cidan Machinery . . . . . . . . . . . . . . . . . . . . . . 55 www.unitedlens.com
770-692-7230 www.mac-tech.com

115588 Mate Precision Tooling . . . . . . . . . . . . . . . . . . . 3 1003168 Voortman . . . . . . . . . . . . . . . . . . . . . . . . . . 73,105

132540 Clemco Ind / Zero Pdts Div . . . . . . . . . . . . . 16 www.voortman.net
www.clemcoindustries.com www.mate.com

200835 COLE-TUVE / CT Machinery . . . . . . . . . . . . 67 136506 Mazak Optonics Corporation . . . . . . . . . . 115 475428 Vytek Laser Systems . . . . . . . . . . . . . . . . . . . 48
877-989-0700 Toll Free www.mazakoptonics.com www.vy-tek.com

104523 COMEQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 138243 Messe Dusseldorf North America . . . . . . . 65 1175345 Walter Surface Technologies . . . . . . . . . . . 93
www.comeq.com www.tube-southeastasia.com www.walter.com

435282 DAVI . . . . . . . . . . . . . . . . . . . . . . . . . . 12,13,18,19 841725 Metamation . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 103673 Weiler Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . 69

www.davi.com/us www.metamation.com www.weilercorp.com

FEBRUARY 2016 The FABRICATOR 113

 BACK PAGE
Read more from Sue Roberts at www.thefabricator.com/author/sue-roberts
How to build a
whale of a sculpture
Reggin Industries reinvents procedures
to create public art
The beauty and grace of a baleen whale were the inspir-
ation of the “Sei” sculpture designed by Michael Yahgu-
lanaas and fabricated by Reggin Industries for the McAr-
thurGlen Designer Outlet Mall at the Vancouver Airport.
By Sue Roberts, Contributing Editor
“S
ei,” a 7,902-lb. sculpture, dominates the
center square at the McArthurGlen De-
signer Outlet Mall at the Vancouver Air-
port. Steel and copper brought to life artist Michael
Yahgulanaas’ design that emulates the graceful,
curved lines of a baleen whale as it breaks the wa-
ter’s surface. Sei is the Norwegian name for the spe-
cies that grows to 64 ft. long and can weigh 28 tons.
Bringing Yahgulanaas’ vision to reality required
graceful coordination among the artist; the metal
cutting facility; and Reggin Industries, a fabricating
shop that specializes in stainless steel architectural
features and located in Calgary, Alberta.
Yahgulanaas provided the conceptual details.
Reggin created virtual 3-D models in SolidWorks® to
explore what could be done with sheet metal while
considering manufacturability, budget, and a tight
production time frame.
“We started discussions with the artist in early
February of 2012 and delivered the project the first
week in June the same year. We had to be very dis-
ciplined in our design and manufacturing approach
to avoid changes and keep moving forward. The
trick was to innovate the fabrication process,” said
Brett Kostka, senior designer at Reggin.
In most Reggin projects, the artist or designer
develops high-level drawings and sends them out
to tender. When the job is awarded, the fabricator
typically develops shop drawings, moves into fab-
rication, and then installs in a very linear process.
For “Sei” the design, drawings, and build happened
concurrently.
“By applying lean manufacturing, we built what
we needed as we progressed, working with the art-
ist and structural engineers and including manufac-
turing in internal reviews to make sure the project
would be buildable.
“We finished the structural design and ordered
the parts at the same time we started designing the
internal rib structure. We designed and built one
114 The FABRICATOR FEBRUARY 2016
step ahead of the other—sometimes within one day.
This allowed us to get feedback instantly on what
was being designed and make changes on-the-fly.”
The Issue of Size
The sculpture, without its base, is 158 in. high and
123 3⁄8 in. wide. It had to be built in one piece, fit
through the shop door, and meet shipping regula-
tions. The build plan required innovation. “Sei” was
built on an angle within its shipping frame.
Kostka explained, “since it was so tall, we had to
build it at an angle—about 10 degrees off its true
standing height. It started out upright in the 3-D
model and I virtually changed its world by putting
the floor at an angle.
“We used the shipping frame to create datum
planes. We used the floor and the side walls of the
frame to measure dimensions and find X, Y, or Z co-
ordinates that related to the 3-D model.”
“Sei”’s interior, fitting for its location, resembles
the support structure of an aircraft wing to combine
strength with light weight. Construction started
with 12-in. Schedule 40 304 SS structural pipes
welded to the base plate.
“The curvature was derived from spline shapes
that required close attention,” said Kostka. “They
were constantly changing in radius, so we used a
CNC bending process for the structural pipes. In CAD
we developed CNC cutting specifications for the 304
SS structural ribs that attached perpendicularly to
the pipes. Perpendicular to these ¼-in. plates were
12-ga. 304 SS ribs that created the curvature for the
12-ga. 316 SS external skins to fit to.”
Templates ensured that the curvature of each skin
component was perfect. Tolerances were constantly
checked to be sure they were within ±0.010 in.
The “Sei” sculpture was built within its shipping frame
at a 10-degree angle from its upright position.
More than 1,500 sheets of copper leaf were applied to
the whale’s underbelly by gilding artists Holly Graff
and David Graff.
Clean and Precise Cuts
Reggin relied on Empire Cutting Corp. for the pre-
cise laser cutting of the majority of components.
“My part of the project was ensuring that we
cut the right lines from the 5-ft. by 10-ft. brushed
and mirror-finish stainless sheets,” said Vincent
Larsen, Empire’s president. “Clean cuts were criti-
cal because just about every piece was exposed,
and some sheets were butted together rather than
welded, which requires precision.”
Larsen received drawings as they became avail-
able and, at times, had Reggin trucks waiting as
parts were completed on the Kern 400-W laser sys-
tem. A preburn removed the protective vinyl from
the mirrored sheets before cutting to eliminate in-
terference with the automatic material and cutting
head gap adjustment. Larsen said that they pushed
the system to its upper speed limits, and accuracy
was “dead on.”
Smooth Lines, Shiny Surface
The budget precluded welding and polishing the en-
tire surface to eliminate seams, so some reveal lines
were introduced. Alignment pins, tabs, offset clips,
and even glue helped secure the skins to minimize
welding.
“We used prefinished mirrored sheets and pol-
ished the weld lines” said Kostka.
“Some of our fabricators said “Sei” was the ‘cool-
est’ project they had worked on.”
Photos courtesy of Reggin Industries Inc., 10605 42nd St.
SE, Calgary, AB T2C 5B9, Canada, 403-255-8141, www.
regginindustries.com.
Empire Cutting Corp., 4207A Ogden Road SE, Calgary, AB
T2G 4R2, Canada, 403-264-2611, www.empirecutting.com
Kern Laser Systems, 1501 Industrial Drive, Wadena, MN
56482, 218-631-2755, www.kernlasers.com
The FABRICATOR®(ISSN 0888-0301) is published 12 times yearly by FMA Communications
Inc., 833 Feather­stone Rd., Rockford, Illinois 61107-6302. is circulated free upon request
to those who qualify and who are involved in metal fabricating; sub­scription to all others
is $75.00 per year. Inter­national subscription is $140.00 per year. Periodical postage paid
at Rockford, Illinois, and additional mailing offices. POSTMASTER: Send address change
to 833 Featherstone Road, Rock­ford, Illinois 61107-6302. Printed in the U.S.A. ©Copy­right
2016 by FMA Communications Inc. Repro­duction in whole or in part without written per-
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