Manufacturing Today - May-June 2015

mt
MAY/JUNE 2015
DIALOGUE WITH | STACI DAVIDSON
WWW.MANUFACTURING-TODAY.COM
EDITORIAL DIRECTOR
John Krukowski
john.krukowski@phoenixmediacorp.com
MANAGING EDITOR
Staci Davidson
MANAGING EDITOR, BOSTON
Eric Slack
SPECIAL PROJECTS EDITOR
Chris Petersen
SENIOR EDITORS
Alan Dorich, Russ Gager,
Celebrating Tech
Jim Harris, Janice Hoppe
ASSOCIATE EDITORS
Tim O’Connor, Robert Rakow
CONTRIBUTING WRITERS
Barbara McHatton, John Smith, Adam Stern
ART DIRECTOR
Erin Hein This issue of Manufacturing Today is jam
GRAPHIC DESIGNERS packed with coverage of major industry
Megan Green, Jonathan Lyzun, Vida Soriano
PRODUCTION COORDINATOR events happening this spring. We’re tak-
Travis Garth ing a look at EASTEC (p. 14), RAPID (p. 16)
SENIOR VICE PRESIDENT and Space Tech Expo (p.34), all of which
Jason Quan are highlighting the newest innovations in
EDITORIAL RESEARCH MANAGER
James Fuller the industry and technologies that will help
C U LT U R E C H A N G E
PROJECT COORDINATORS manufacturers work smarter, more effi-
Braxton Barber, Patrick Bell, Austin Berry,
Anthony Caruso, Ruon Cooper, David Lankin, ciently and with better quality. B UY AMERICAN
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And while it is great for these events to
C ONTENTS
Todd Lindberg, Joe Martinez,
D IALOGUE
E CONOMY
Duncan McGougan, Claudia E. Montaño,
Gino Piniero, Dan Wiggins show all of manufacturing’s expansive ca-
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pabilities, the industry still has to do a lot of
VICE PRESIDENT OF SALES
Steve Campagna work to attract the next-generation work-
force. Luckily, there are many students who
DIRECTOR OF WEB AND REPRINT SALES
Dash Blankenship are showing their interest in exciting ways.
dash.blankenship@phoenixmediacorp.com In late April, more than 18,000 students Not only did the competition highlight
from 40 countries traveled to St. Louis to engineering aptitude, but many U.S. and in-
put their engineering skills to the test at the ternational FIRST student robotics teams
annual FIRST® Championship. FIRST – also earned honors for design excellence,
For Inspiration and Recognition of Science competitive play, research, business plans,
and Technology – is dedicated to showing website design, teamwork and partner-
students that science, technology and prob- ships. All of them are tools for a successful
lem-solving are not only fun and reward- manufacturing enterprise.
ing, but also proven pathways to successful It would be great to see more major in-
careers. This year’s programs involved the dustry events involve students (check out
FIRST Robotics Competition, FIRST Tech EASTEC’s Bright Minds Program), because
Challenge, FIRST LEGO® League, and Ju- while we’re selling our new wares, why not
nior FIRST LEGO League. sell the industry to a new generation?
FOLLOW US ON TWITTER:
@MANUFACTUREMAG
MANAGING EDITOR
staci.davidson@phoenixmediacorp.com
Manufacturing Today is published bimonthly by Phoenix Media Corporation, 79 West Monroe, Suite 400, Chicago, IL, 60603. Periodical Postage Paid in Chicago,
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MAY/JUNE 2015 manufacturing-today.com 1

features >
10. 8.
14.
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Columns >
>
Technology
The cloud has been a liberating force, break-
ing IT out of the exclusive domain of the geek
intelligentsia. Page 8
Supply Chain
The use of triangulation and cloud-based
technologies will play a huge role in stream-
lining supply chains. Page 10
EASTEC
In its 34th year, EASTEC will showcase the
latest technologies transforming the manu-
facturing sector. Page 14
Last Page
On The Cover > The benefits of advanced manufacturing
Linear Mold & Engineering Linear Mold is investing in technology are being applied by Proto Labs
extensive technology and systems to address the growth it to the prototyping and production of parts.
anticipates in 3-D metal-printed components. PAGE 18
Page 184

TABLE OF CONTENTS | MAY/JUNE 2015
48. Space Vector Corp.

Space Vector Corp. space-qualifies com-
mercial components for substantial savings
and designs and manufactures new ones for
launch vehicles.
52. Space Information

Laboratories
Space Information Laboratories’ entire line
is only five products used in rockets and
small satellites, but each item has to be per-
fect for its clients.
54. LaserStar Technologies

LaserStar Technologies remains strong by
listening to its customers.
South
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39.
56. Saf-T-Cart
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Saf-T-Cart has grown to sell its products to

RAPID Space Tech Expo
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clients throughout all 50 states, Canada and

Latin America.
18. Linear Mold & Engineering 36. Alliance Spacesystems LLC
The ever-expanding market for 3-D metal Alliance has grown to serve Boeing, 62. ATC Automation
printing is spurring growth for Linear Mold Northrop Grumman, Lockheed Martin and ATC has excelled with its equipment for
& Engineering. other satellite leaders. Fortune 500 companies.
24. Proto Labs Inc. 39. Micro Craft Inc. 67. Gerdau North America
Proto Labs Inc. has the ability to manufac- Micro Craft provides test hardware for the Gerdau’s long steel business in North Amer-
ture low-volume parts in record time using aerospace industry and looks to further inte- ica sparks new innovations that will bring
machining, injection molding and additive grate itself into the production process. benefits to the company and the customer.
manufacturing.
42. Experior Laboratories 72. Atlas Machine & Supply Inc.
26. 3D Systems Ongoing service expansion is driving the Atlas Machine says it has never failed when
3D Systems fills its customers’ demanding growth of Experior Laboratories as a testing meeting its clients’ challenges.
worldwide manufacturing needs through its laboratory capable of serving multiple mar-
Quickparts service. ket sectors. 76. TSC Corp.
TSC Corp. expanded its capabilities with its
28. CyberOptics Corp. 44. Vision Engineering Solutions new 4F facility in Houston.
CyberOptics Corp. has struck a major Vision Engineering Solutions is poised to
deal to supply its new 3-D sensors to a ma- bring its advanced sensing technology to a 79. Nailor Industries Inc.
jor semiconductor inspection company. broader customer base. Manufacturing air control and distribution
products, Nailor uses clients’ needs as a
31. GPI Prototype & 46. Precision Test Solutions springboard in developing quality products.
Manufacturing Services Inc. Precision Test Solutions devises methods to
GPI is capitalizing on the growing impor- determine whether components will fit the 82. Air Relief, by Gardner Denver
tance of additive manufacturing with a laser real-world — and other world — needs of the Compressor service and repair company Air
focus on metals. aerospace industry. Relief marks three decades in operation.
4 manufacturing-today.com MAY/JUNE 2015

< profiles
84. Bullfrog Spas
Bullfrog Spas’ equal focus on customer value and finances allows it
to continue introducing new and appealing hot tub products.
88. Custom Coils Inc.

Coil manufacturer Custom Coils weathers industry shifts and
maintains a loyal client base with high-quality products and ded-
icated customer service.
91. Bonterra Builders LLC

Bonterra Builders prides itself on delivering true craftsmanship
when building its homes.
94. UEC Electronics

A recent acquisition and a push to develop its own product lines
are driving the future direction and ongoing growth of South
Carolina’s UEC Electronics.
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96. Taper Roller Bearings Inc.
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Taper Roller Bearings maintains enough inventory to meet the JIT
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needs of its customers.
98. Setpoint System

A mastery of lean management concepts and a high level of em-
ployee engagement have guided Setpoint Systems for more than
20 years.
Midwest
100. Barnes International

Barnes International continues to solidify its leadership position
as North America’s largest provider of machine tool coolant fil-
tration systems.
105. Thermwood Corp.

After more than four decades of pioneering the development of
CNC routers, Thermwood Corp. continues to look for ways to stay
out in front.
108. Poly-Wood Inc.

Poly-Wood Inc. originated the recycled plastic furniture category
and continues to lead it today by delivering quality products in a
timely fashion.
113. Control Gaging

Control Gaging highlights new automated measurement sys-
tems for improved changeover times and greater efficiency for
its customers.

TABLE OF CONTENTS | MAY/JUNE 2015
< profiles
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134. 148.
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116. Acieta LLC 130. Star International 142. GM Toledo Transmission

Acieta provides robotic systems that are Holdings Inc. GM Toledo Transmission operates a disci-
making facilities more successful. Star International designs and manufac- plined manufacturing operation with con-
tures commercial food service equipment, tinuous improvement measures taken daily
122. Dorner Mfg. Corp. and has earned a reputation as a reliable to prepare for future growth.
When a product has to be moved for manu- supplier to restaurant chains.
facturing or packaging, Dorner Mfg. Corp. 146. The Plastic Forming Co. Inc.
can provide the right conveyor to do that. 134. Vantage Plastics The Plastic Forming Co. builds its own pro-
Vantage Plastics is capable of thermoform- prietary continuous extrusion blow molders
124. Bachman Machine Co. ing a wide variety of products including auto- to manufacture the double-walled carrying
Sophisticated technology and well-trained mobile components, component packaging, cases in which it specializes.
employees are keeping Bachman Machine pallets and recreational products.
Co. a leader in stamping, machining, tool- 148. Hadco Metal Trading Co.
and-die making and molding. Northeast Hadco Metal Trading Co. says its success is
due to its capability to offer full solutions and
126. Creative Automation Inc. 136. New Era Converting responsive service.
Many of the world’s top manufacturers rely Machinery Inc.
on the automation solutions provided by New Era Converting Machinery Inc. relies 151. Nitta Corporation
Creative Automation. on its vendors to supply the quality compo- of America
nents it needs for the custom web convert- Nitta Corporation of America provides en-
128. Airmaster Fan Co., a member ing machines it provides customers. gineered belting solutions to a wide range
of the Maico group of customers with domestic manufacturing.
Airmaster Fan Co. is leading a paradigm 139. Electri-Cord Mfg. Co.
shift in which manufacturers obtain indus- Electri-Cord Mfg. has the capability to de- 154. New England Miniature Ball
trial fans from distributors and indepen- sign and produce any electrical wire harness New England Miniature Ball’s products are
dent factory representatives rather than or cable assembly product its customers can used for a range of applications, including
big-box retail stores. think up. ball bearings, valves and pens.

MAY/JUNE 2015 | TABLE OF CONTENTS
156. Masline Electronics Inc. 180. AV&R Aerospace 182. Picard Ovens/Sipromac
Masline Electronics plans to continue its AV&R Aerospace is selling custom au- Sipromac’s recent acquisition of Picard
strong legacy with e-commerce initia- tomated manufacturing systems to the Ovens will allow both operations to wid-
tives, backed by its dedication to ethics aerospace industry worldwide while re- en their market reach and attract larger,
and integrity. taining its intellectual property. high-end clients.
West
158. D&K Engineering Inc.

D&K Engineering makes it easier to
bring products to market with its
streamlined processes.
164. MTI Metal Technology

Innovation continues at Metal Technol-
ogy with new manufacturing capabilities
that enhance its customer service.
166. Core Health and Fitness
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Core Health and Fitness’ approach to
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customer service distinguishes it within
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the fitness manufacturing and market-
ing industry.
168. Gruber Industries

Gruber Industries provides products
that help to keep its customers running
at all times.
170. Spectra Logic

Colorado-based Spectra Logic helps
its customers preserve and access their
data with storage solutions made to last
for the long term.
International
172. Konnexio
Konnexio takes pride in developing au-
tomation machine technology that sep-
arates it from every other manufacturer
in the world.
175. Systemes LMP

Systemes LMP’s carbon dioxide cooling
systems offer supermarkets, warehous-
es and others a number of advantages,
including energy efficiency and limited
environmental impact.

T ECHNOLOGY
8
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S PACE TECH CONFERENCE 2015

C ANADA MANUFACTURING
B UY AMERICAN
COLUMN BY | ADAM STERN
manufacturing-today.com MAY/JUNE 2015

TRICOR SYSTEMS INC.
SILVEX INC.
ADAM STERN | COLUMN BY
Clearing the Cloud alization – bargain. It’s entirely possi-

ble for a small or midsize manufactur-
ing concern to spend $10,000 a month
how will you handle the migration? and tap enough compute power to
drive a 1,000-user company. That’s
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less than the cost of hiring a single en-
Vendors know things. They speak a special language, an informa- gineer. For those who’ve logged time
tion technology dialect that most small and midsize manufac- in large enterprises, the prospect of
turers can’t fathom, but that they respect nonetheless – perhaps living without a lifeline to the vendor
because it’s indecipherable. These manufacturers are turning to is unthinkable. That was the conven-
experts, after all, since tech is something in which they don’t spe- tional wisdom, anyway, but the mar-
cialize. They cut the vendor some slack; they reason that IT types ket has expanded “downward,” to
aren’t really proficient in their line of work, either. entrepreneurial organizations that
typically don’t include line items for

TRICOR SYSTEMS INC.
What inspired this riff is “Complicat- own security. Increasingly, they want info tech professionals, other than a
ing the Cloud,” a recent, insightful to embrace cloud-hosted comput- random consultant here and there.
article by tech industry guru Jeff Ka- ing as the preferred way to maintain
plan. Kaplan makes a number of tren- cost-effective, 24/7 support.
the cloud has actually
SILVEX INC.
B UY AMERICAN
T ECHNOLOGY
chant points, many of them coalesc- Some aspects of migration are,
been a liberating force,
E CONOMY
ing around the idea that the vendor frankly, threatening to the old guard.
breaking IT out of the
N EWS
community has a vested interest in Here and there, vendors and other
complexity. That meshes with my be- members of the IT community have exclusive domain of the
lief that it really is easy to get into the
cloud – if the decision makers don’t
fostered misconceptions about secu-
rity in the cloud – not in an effort to
geek intelligentsia.
allow the vendors to make it difficult. thwart migration, but in a bid to con-
Here’s what Kaplan has to say: “I trol it. Fear fuels both confusion and The market is now awash in Infra-
have to admit that the cloud indus- dependence. Businesses may be com- structure as a Service (IaaS) tools,
try is doing a great job of making it mitted to moving to the cloud, but not empowering organizations that may
increasingly difficult for … corporate without clutching tight to a vendor lack traditional IT resources to still
decision makers to feel confident who more than likely will overcharge benefit of remarkably robust products
about making the move,” he writes. and under-deliver. – and perhaps gain a little indepen-
“The initial success of the cloud The IT vendor’s proper role is to dence from vendors. Savvy virtual-
movement has created a series of showcase the powerful economic ra- ization providers have done the heavy
problems. First, there’s the prolifer- tionale for manufacturers to get out lifting for small and midsize manufac-
ation of players … some of whom re- of the practice of buying/maintaining turers, with solutions that companies
brand or ‘cloud-wash’ legacy systems hardware that is obsolete practically can deploy largely on their own. This
for this new market … [They want to] before the paint is dry. And then to set class of vendor knows enough to stay
join the ‘cloud rush,’ [by] adding more an example, through customer-cen- out of the way. From a data manage-
solutions to their portfolios.” And tric initiatives designed to simplify ment perspective, servers and prefab
these tendencies, as he sees them, the cloud – things like “onboarding” packages effectively take the place of
have made migration to the cloud services, aimed at eliminating the fear IT professionals and mostly keep ven-
needlessly convoluted. from the cloud migration process. dors on the sidelines – a benefit for
The cloud has actually been a lib- the manufacturing sector, a quantum
erating force, breaking IT out of the A Virtual Bargain leap toward improved ROI, and a ring-
exclusive domain of the geek intelli- The cloud may be easier than adver- ing endorsement of, yes, “easy.” mt
gentsia. Users – real people, not pro- tised but it isn’t free. Still, compute
fessional technologists – can now de- horsepower is finally a virtual – or, Adam Stern is founder and CEO of Infinitely Virtual in Los Ange-
les. Visit www.infinitelyvirtual.com for more information.
ploy their own apps and manage their perhaps more appropriately, a virtu-

COLUMN BY | JOHN SMITH

B UY AMERICAN
S U P P LY C H A I N
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D IALOGUE
EASTEC
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Connect the Dots Thanks to advanced breakthroughs in

high-tech labor management systems,
wireless devices, apps and cloud tech-
bringing connectivity into the nology, great strides have been made
in the past few years to enhance sup-
supply chain. ply chain performance. It is import-
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ant to note two essential factors that
come into play to create a smooth, ag-
In today’s fast-paced world of business, owners and managers ile and aligned supply chain.
are looking for ways to streamline the supply chain process, re-
duce costs and increase efficiency. When looking to implement Technology Boost
the most effective supply chain, many would note that technol- The first is the use of well-integrated
ogy plays a pivotal role. information systems to assist in SCM.

COLUMN BY | JOHN SMITH
The system makes the supply chain where the user updates or publishes
substantially more accurate, while information just once, and all trading
improving the efficiency and depend- partners are updated. This hub elimi-
ability of the chain as a whole. Since nates the need for the same update to
information is received in real-time, be made multiple times across multi-
the most accurate data is available the ple trading partners.
very moment it’s needed. One of the An additional key tactic that is be-
first corporations to implement the coming more readily embraced – but
RFID system into its daily operations still has yet to be widely adopted – is
is retail mega-giant Walmart. triangulation, sometimes referred to
Small businesses just starting out as match-back or street-turn optimi-
would benefit from the timely im- zation. Eliminating two of the about
plementation of RFID technology in six movements that shipping contain-
order to simplify their supply chain ers make in an average journey, this
and inventory management systems. model of transportation reduction no-
This would enable them to gain bet- ticeably increases time management,
ter control and insight into their lessens expenses and elevates produc-
With the right software and proce- business transactions and invento- tivity in the supply chain process.
B UY AMERICAN
S U P P LY C H A I N
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dures in place, movement and pro- ry needs, in addition to optimizing Triangulation allows the container,
M ARKETING
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EASTEC
ductivity in the supply chain are vastly their overall efficiency. which is typically unpacked from an
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increased, while the need for invento- importer, to be handed directly to an

ry is simultaneously decreased. The Optimizing the Chain exporter for repacking, eliminating
software employs a complex math- Technology is helping companies re- the need for the empty container to
ematical algorithm that anticipates duce costs and significantly increase be transported to and then stored at
customer demand and helps with ac- productivity at every step of the sup- an empty container park. There are
curate forecasting predictions. ply chain, but in this day and age of technological advancements and pro-
When the software is coupled with SCM 2.0, improvements can be and grams currently being implemented
an Enterprise Resource Planning always are being made. around the world to help companies
(ERP) system, everything comes to- While a new concept for some, utilize the benefits of triangulation.
gether as one unified network where many companies have already in- Some of the latest systems being ad-
everyone in the supply chain, including tegrated cloud-based management opted by many global supply chain
the consumer, is connected simultane- platforms into their SCM systems. and logistics companies promise
ously. The use of ERP is a fundamental Cloud-based technologies have al- to decrease supply chain costs be-
reason why estimated B2B sales in 2013 lowed companies to get closer to the tween 20 and 30 percent, reduce the
reached $559 billion in U.S. markets ever-important – and often elusive – need for additional drivers, increase
alone and continue to escalate. concept of supply chain visibility, en- trucker-loaded ratio, diminish emp-
The second factor adding to the abling shippers to connect with mul- ty moves and even help businesses
increased productivity of the supply tiple (even hundreds or thousands of) protect the environment by reducing
chain process is utilizing radio fre- trading partners, versus a one-to-ma- emissions by an average of 30 percent.
quency identification (RFID). The ny connectivity approach. This solu- Together, the use of triangulation
RFID system consists of three pri- tion closes communication gaps in and cloud-based technologies will
mary components: tags, readers and the supply chain, where smaller com- undoubtedly play a huge role in con-
a computer system. Used in conjunc- panies often were left out, lacking the tinuing to streamline the connectivity
tion with a warehouse management capabilities or technology to be more process throughout the supply chain
system (WMS), RFID helps ensure readily connected. of the future. mt
that the desired products are avail- The concept is akin to a common
able in the appropriate locations with social media platform, but for ship- John Smith is IntelliQuick’s senior vice president of
sales. For more information, visit www.iqcando.com.
no inconsistencies. pers, receivers and service providers,

COLUMN BY | STACI DAVIDSON
The Big East

In its 34th year, EASTEC will showcase the latest
technologies transforming manufacturing.
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There is no question that the manufacturing industry is a major economic driver, and it continues
to fuel business throughout the Northeast and nationwide. This is why more than 12,000 business
owners, engineers, designers, production managers and purchasing executives will be gather May
12 to 14 at EASTEC, the East Coast’s premier manufacturing event. Produced by SME, the biennial
event will take place at the Eastern States Exposition in West Springfield, Mass., and will features
more than 650 exhibitors and three days of complimentary educational sessions.
This will be the 34th year of EASTEC,

SILVEX INC.
which will showcase the latest tech-

EASTEC
nologies in the industry, from addi-

tive manufacturing to waterjet cut-
ting. SME organizes the show so it will
provide attendees with easy access to
industry experts, who will be sharing
insights on how to foster innovation,
increase productivity and improve
profits. This year, attendees also will
get to see more than 300 new prod-
ucts at the show.
“Since 1790 when the first cotton
mill was founded in Rhode Island,
New England has been a leader in our
country’s quest to capitalize on Amer-
ican innovation and passion for mak-
ing things,” explains Kimberly Farru-
gia, senior event manager for SME.
“EASTEC is committed to keeping
New England manufacturers compet-
itive by bringing the human ingenuity
needed and manufacturing brilliance
demanded together in a face-to-face
environment.”
According to the Manufacturers
Alliance for Productivity and Innova-
tion Foundation (MAPI) Foundation
Business Outlook, U.S. manufactur-
ing growth is holding near the stron-
gest pace in three years.
Manufacturing continues to be a
critical contributor to the Northeast-

STACI DAVIDSON | COLUMN BY
ern economy and SME has found that momentum is gath-

ering in the region. For instance, manufacturing accounts
for more than 565,200 jobs in Pennsylvania and 164,000
in Connecticut, which is just more than 10 percent of that
state’s non-farm total employment. Additionally, with more
than 7,000 manufacturers with nearly 250,000 employees,
Massachusetts is committed to advanced manufacturing
through various partnerships to create jobs, promote inno-
vation and grow throughout the state.
“At EASTEC, attendees will have the opportunity to con-
nect with resources, research and purchase the latest tech-
nologies, and discover ways to improve productivity and
increase profits,” SME explains. “Meanwhile, the compli-
mentary educational sessions will address trending topics
such as automation innovations and lean creativity, along
with other major advancements in manufacturing.”
SILVEX INC.
EASTEC’s features in 2015 will include:
> Keynote presentations from Carl Palme, applications
EASTEC
product manager at Rethink Robotics, and Jason Prat-
er, vice president of development at Plex Systems, who
will focus on problem solving complex issues that U.S.
manufacturers face;
> Products and technologies that save money, improve
quality and productivity and solve a range of challenges;
> Complimentary educational sessions in the Manufac-
turing Brilliance Theater; and
> Networking opportunities at the Celebrate New En-
gland Manufacturing Networking Reception.
EASTEC also will highlight its Bright Minds Program,

which will be a forum for students to connect and commu-
nicate with educators, industry leaders and each other to
explore career opportunities, technological innovations
and advancements, and discuss how to move the manufac-
turing industry forward and fill the employee pipeline.
“Bright Minds is a bridge for engagement, collabora-
tion, and communication between educators, industry
and students to support our future workforce,” SME says.
“The elements of this event will take the technology and
engineering portions of STEM education to the next level,
showcasing real-world outcomes and results using advanc-
es in manufacturing.
“Students and educators will see innovations first-hand
and realize the value of careers in manufacturing. The ses-
sions and demonstrations will increase the students’ aware-
ness of and preparation for opportunities in manufacturing
and will serve as a resource for educators interested in help-
ing prepare students for careers in manufacturing.” mt

RAPID
SPECIAL SECTION
18. Linear Mold & Engineering

24. 26. 31. 24. Proto Labs Inc.
26. 3D Systems
28. CyberOptics Corp.
31. GPI Prototype & Manufacturing
Services Inc.

INNOVATIVE
FOREFRONT
WITH THE RAPID 2015 CONFERENCE & EXPOSITION, SME ALLOWS MANUFACTURERS AND
INNOVATORS TO DISCOVER EVERYTHING NEW THE 3-D PRINTING INDUSTRY HAS TO OFFER.
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SPECIAL SECTION
It has been determined that there is nearly no limit to what 3-D
printing and additive manufacturing can produce, and this is great news
for the manufacturing industry, which was mainly seeing negative news
just a few years ago. To celebrate all that 3-D printing, scanning and addi-
tive manufacturing has to offer, SME is hosting the 2015 RAPID Confer-
RAPID
ence & Exposition in Long Beach, Calif., from May 19 to 21.
Expected to be the largest in the event’s 25-year history, RAP- > Innovation auditions – Qualified innovators will have five
ID will provide attendees with the opportunity to engage with minutes to capture the attention of a panel of investors and
more than 195 exhibitors and explore the future of the industry experts, and share why their idea could make a difference.
through interactive experiences and keynote addresses. The panel will provide feedback after the auditions and se-
“RAPID 2015 gives established businesses and startups alike lect one innovation that will be announced at the May 20
the opportunity to collaborate and further the growth of 3-D keynote presentation.
printing and additive manufacturing technology,” says Debbie > 3-D playground – Attendees will have an opportunity to
Holton, director of events and industry strategy at SME. “Manu- witness 3-D technologies in a hands-on lab designed by
facturers attend RAPID because they know they’ll find the latest SME and industry partners. Attendees will see state-of-
innovative solutions they need to compete successfully. Those the-art bioprinting capabilities, learn about software solu-
that don’t attend will miss out on witnessing the newest 3-D tions to simplify design challenges, engage with 3-D print-
technologies and finding their next competitive advantage.” ing-enabled STEM educational tools and more.
The RAPID show floor was designed to optimize interaction > Contemporary art gallery – Creative approaches to art
among exhibitors and attendees. This year, attendees will have creation and production will be on showcase, all made pos-
the opportunity to meet with 3-D manufacturing leaders like sible with additive manufacturing, 3-D printing, 3-D imag-
Materialise, Stratasys and 3D Systems, as well as innovative ing and digital sculpture technologies.
newcomers to the industry. RAPID 2015 will feature several in-
teractive experiences to showcase the latest advancements in “In its 25th year, RAPID has been at the forefront of the man-
the industry, such as: ufacturing industry from the start,” Holton explains. “As the
> Hovercraft races – Attendees will have a chance to race industry continues to grow and change, the RAPID conference
3-D-printed hovercrafts and win a remote-controlled hov- and exposition continues to showcase the business advantages
ercraft of their own. of additive manufacturing.” mt

LINEAR MOLD & ENGINEERING
FUTURE TRENDS
THE EXPANDING 3-D METAL PRINTING MARKET IS SPURRING
GROWTH AT LINEAR MOLD & ENGINEERING. BY JEFF BORGARDT
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SPECIAL SECTION
linear mold & engineering

specializes in additive
manufacturing, injection
molds and molding.
Linear Mold & Engineering, a 3-D printers from SLM Solutions to additional 3-D metal-printing ma-
mold-manufacturing and engineer- six machines and a grand total of all chines throughout the year. Linear
ing firm that has developed expertise SLM and EOS machines to 14 as the anticipates much growth in the design
in 3-D metal printing, recently com- company expands capacity to keep and manufacture of 3-D metal-print-
pleted its newest equipment addi- up with the demand for metal proto- ed components for the automotive,
tions. The Livonia, Mich., company types, pre-production and production aerospace and energy industries us-
has installed three selective laser end-use parts. ing both Direct Metal Laser Sintering
melting (SLM) 280 HL Twin Beam The company is evaluating machine (DMLS) and SLM technologies. “We
3-D metal-printing machines. That capacity for each upcoming quarter of are also investigating use of other sys-
brings Linear’s total number of SLM 2015, and will be acquiring multiple tems, such as E-Beam machines, to
Linear Mold & Engineering / www.linearmold.com / HQ: Livonia, Mich. / Employees: Approx. 130 / Specialty: Additive manufacturing, injection
molds and molding / John Tenbusch, president and CEO: “We can take a customer from education into production.”

SPECIAL SECTION
based in michigan, linear
mold & engineering is
dedicated to serving its
customers’ needs.
among the markets linear

complement the current laser powder mold & engineering serves
are the automotive and
bed systems,” President John Ten- aerospace industries.
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busch says.
The company also designs and
builds injection mold inserts with
conformal cooling channels through
3-D metal printing processes for the
mold manufacturing market. Con-
formal cooling offers a more uniform
way to cool the parts, thus reducing
cycle time and improving both pro-
ductivity and quality.
“The decision to expand, which was
announced last year, was based on
customer demand for 3-D printed end-
use production parts,” Tenbusch says.
“We also chose the SLM 280 HL from
SLM Solutions based on the compa-
ny’s wide range of materials and speed
to support production runs specific
to this particular phase of Linear’s
growth. However, this does not pre-
clude us from buying EOS or E-Beam
machines for specific projects.”
Linear operates six SLM machines
from SLM Solutions, as well as eight

DMLS machines from its longtime

vendor EOS GmbH. “We are advancing
our equipment plans for acquiring 3-D
metal-printing machines from the two
largest providers of this equipment in
the world,” Tenbusch comments.
Market Growth
Linear’s business includes work in var-
ious market segments such as auto-
motive, aerospace, defense, medical,
energy, oil and gas exploration, and con-
sumer products. “We are recognized as
one of the larger privately held firms in
North America using 3-D printing with
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metals,” Tenbusch explains. “We also and post-process finishing of our 3-D accommodate the 3-D printing growth
build injection molds and do injection printed production parts.” and add additional space for its mold
molding. We are pretty well rounded Linear currently occupies three shop that continues to grow, but not at
with lots of skillsets in different areas, buildings totaling 67,000 square feet. the same rate.
SPECIAL SECTION
such as design engineering, machining It is planning a facility expansion to “We started out as an auto prototype

“there are a lot of companies interested in the Tenbusch says. “There are a lot of com-
panies interested in the technology but
[additive manufacturing] technology, but they they don’t know how to use it and how to
don’t know how to use it and how to implement implement it. Over the past two years,
it.” - John Tenbusch we have been focused on educating cus-
tomers about how it can benefit them
supplier in 2003,” Tenbusch recalls. “We exploration, energy and conformal cool- for production.”
started out as 100 percent automotive ing mass manufacturing. One of the main advantages of addi-
and have since diversified.” “We can take a customer from educa- tive manufacturing is it produces less
The company is currently growing tion into production,” Tenbusch says. material waste. “Some machines are
its additive manufacturing business. “We bring them in, tell them about the
“About two years ago, additive manu- process and teach them the technology.
SLM Solutions NA, Inc. offers additive manufac-
facturing was roughly 10 to 15 percent We also offer tw0- and four-day classes turing systems for fast and cost-efficient metal part
production. To meet an increased demand for additive
of our business. It has grown substan- on the 3-D metal printing process.” manufactured parts, Linear Mold & Engineering recently
tially,” Tenbusch states. “By the end of The growth of the additive manufac- took delivery of three additional SLM®280HL systems
SPECIAL SECTION
from SLM Solutions. With options to equip a single 400W,
the second quarter 2015, it will be nearly turing sector took off after GE Aviation dual (400 +1000W), or twin (400W) lasers; the SLM
50 percent, and we anticipate it to be 75 acquired Cincinnati-based Morris Tech- 280HL’s bi-directional loader and closed-loop powder
handling achieve the increased build speed needed to sup-
percent in 2016. Additive manufacturing nology in November 2012. “This added port production runs associated to Linear’s growth. Linear
has just taken off.” Applications include legitimacy to the use of additive manu- currently runs six SLM 280HL machines, and has plans for
additional twin-laser systems to be installed in 2015.
finished parts for aviation, oil and gas facturing in production applications,”
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throwing away 75 percent of ma- “Our dedication to serving our cus-

terial volume,” Tenbusch explains. tomers’ needs has been rewarded
Additive manufacturing, on the oth- with continued opportunities from
er hand, can reduce this amount to our existing customers, as well as
about 10 percent. “There are appli- word of mouth from those customers
cations of re-design that can elimi- serving as a testimonial to potential
nate welding or brazing of parts for new customers to Linear,” the compa-
multi-part consolidation.” Additive ny says. “At Linear, we push the limits
manufacturing also offers quicker of industry practices, exploring new
lead times of 40 days or less for serial ways to ensure the highest quality in
production parts. tool design, rapid prototyping and
These obvious advantages have led additive-manufactured serial produc-
to Linear supplying a number of For- tion parts.
tune 500 customers. “We have proven “We are constantly pushing the
to them this technology is the way to industry’s boundaries to ensure the
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go,” Tenbusch states. This includes most up-to-date technology, additive

working with clients through Linear’s fabrication methods and management
Center of Excellence program, which strategies in order to keep Linear and
allows for onsite machine use and in- our customers at the forefront of our
SPECIAL SECTION
depth engineering cooperation. industry. In today’s global market,

The company is certified to AS9100, suppliers must maximize quality lev-
ISO 9001:2008 and ISO/TS16949, and els and shorten lead times while main-
is currently working on ISO 13485. taining competitive pricing.” mt
linear mold & engineering
says its services have made it
popular with many fortune
500 customers.

PROTO LABS INC.
at manufacturing over the next cou-

ple of decades, digital manufacturing
is going to be very prevalent in how
we continue to drive productivity us-
ing software.”
Digital manufacturing employs
three-dimensional software to create
parts using both traditional produc-
tion equipment, CNC machines and
injection molding, and also additive
manufacturing, often referred to as
3-D printing. “It is 3-D printing,” Holt
explains. “We call it additive manu-
facturing. We use those two words
interchangeably. At Proto Labs, we fo-
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cus on the 3-D printing technologies

that are more relevant to the indus-
trial engineer. We don’t focus on the
consumer. We offer stereolithogra-
SPECIAL SECTION
proto labs says it has reinvented

its manufacturing process to be
phy and selective laser sintering and
more cost-effective and efficient. direct metal laser sintering, which
are more complex processes that are
more relevant to the service bureau
THE NEW WAY model and the industrial engineer.”

The process starts with a 3-D com-
puter-aided design file. “We translate
that into instructions for our manu-
PROTO LABS INC. CAN MANUFACTURE LOW-VOLUME facturing process,” Holt says. “We do
PARTS IN RECORD TIME. BY RUSS GAGER injection molding, we do machining,
as well as additive manufacturing or
The time-saving benefits of ad- time and running a 96-cavity tool and 3-D printing. Additive is only about
vanced manufacturing technology getting those parts out, we’re really 7 percent of our sales today. The ma-
are being applied by Proto Labs Inc. focused on having good, consistent jority of our digital manufacturing
to the prototyping and production changeover and to efficiently move comes from injection molding and
of parts. “Our mindset around man- hundreds of custom parts through machining. That’s really where we’re
ufacturing is different from a tra- our manufacturing process.” most unique and the leaders in digital
ditional manufacturer,” President This is done by mating manufac- manufacturing in those spaces.”
and CEO Victoria Holt emphasizes. turing with advanced, proprietary
“We are focused on prototypes and software. “We’ve really taken man- Secret Sauce
low-volume production. We’ve rein- ufacturing and intersected it with Software that Holt says the company
vented the manufacturing process information technology,” Holt con- has been developing for 16 years is its
to be more cost-effective and effi- tinues. “We’re right at that forefront. secret sauce. “We continue to refine it
cient with low volumes. Instead of It’s a really exciting place to be, and by adding more complex processes,”
eking out every millisecond of cycle we’re a leader there. When you look she says. “We tear down a process and
Proto Labs Inc. / www.protolabs.com / 2014 revenue: $209.6 million / Headquarters: Maple Plain, Minn. / Employees: 1,104 / Specialty: Quick-turn
custom prototyping / Victoria Holt, president and CEO: “We’ve really taken manufacturing and intersected it with information technology.”

PROTO LABS INC.
build it back up, asking ourselves whether something is re-

ally needed in order to make a quality part for a customer.”
Another advantage of Proto Labs is its scale. “We have
hundreds of machines that are there to drop in those or-
ders when they come,” Holt maintains. “We add addition-
al machines in anticipation of our growth – which is about
25 percent per year – and we have no more than 80 percent
capacity utilization, so we always can drop in quick turns
for customers.”
Customers being able to upload 3-D CAD part designs
through the website adds to the speed with which quotes
can be received. “We have really focused our software tech-
nology on the front end of that traditional manufacturing
process and automated it,” Holt says. “We take that 3-D
CAD electronic file, upload it through our web-based ecom-
SPECIAL SECTION
merce model, and our software immediately analyzes that
part and virtually manufactures it. Then it shoots a quote
back to the customer in a matter of minutes.
“Sometimes we have to touch the model because it’s got
some design for manufacturability concerns, in which case
we turn a quote within four hours,” she continues. “The
average run is about two hours. Once you place your order,
our software immediately shoots to our manufacturing
process, and we turn around custom injection-molded or
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custom machined parts in as little as a day.”
Many Machines
The company can produce from 20 up to 100,000 parts for
its customers worldwide. “Our sweet spot is 10,000 parts
or less,” Holt says. Most of Proto Labs’ molds are manufac-
tured from aluminum, although steel molds also are used
for certain parts.
New processes Proto Labs is offering are molding opti-
cal-grade liquid silicone rubber; metal injection molding
of three new low-alloy steel materials; and turning parts on
a lathe in first-cut machining. For the future, the company
plans additional new processes and expanding its services
geographically.
“In 2014, we had a 29 percent operating margin and we
grew 28 percent,” Holt reports. “We’re in a very elite class,
and it’s enabled by technology, a unique business model and
the value we deliver to our customers.” mt
Productivity Inc. has been a partner with Proto Labs since 1999, supplying them
with Haas CNC machines for production. Since 1968, Productivity Inc has been distrib-
uting a broad range of high quality CNC machine tools, tooling and accessories, with
related equipment and services, as well as used machinery for manufacturing in the
Upper Midwest. For innovative solutions to your manufacturing challenges, please go
to productivity.com or call 1.800.328.3272.

3D SYSTEMS
which constantly demand smaller

and lighter components. “With DMP,
aerospace companies are discovering
new applications every day,” accord-
ing to Ziad Abou, vice president and
general manager of Quickparts Solu-
tions Global.
3DS’ Quickparts has ISO 9001 cer-
tification, but to meet the high-reli-
ability needs of defense contractors
and space pioneers the company has
also achieved AS9100C and is Inter-
national Traffic in Arms Regulations
(ITAR) compliant. Those qualifica-
tions have allowed Quickparts-print-
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ed components to be a part of recent

SpaceX launches, but the technologi-
cal advancements in DMP have impli-
cations for the average person as well
SPECIAL SECTION
3d systems’ quickparts
solutions service has in applications such as customized
helped its customers create
components more efficiently. titanium implants.
DMP implants are also used for
man’s best friend. It used to be that as
POWER OF PRINT dogs aged gradual ligament damage

ended their days of catching Frisbees
and chasing rabbits. But thanks to the
kinds of advancements happening in
3D SYSTEMS FILLS ITS CLIENTS’ MANUFACTURING NEEDS DMP, more than 10,000 dogs have re-
THROUGH ITS QUICKPARTS SERVICE. BY TIM O’CONNOR ceived a 3D-printed titanium implant
that heals cruciate ligament ruptures,
3D Systems’ Quickparts Solu- Direct Metal Printing (DMP) is one allowing man’s best friend to return
tions has changed the way product of those technologies that have led to to running down mailmen in only a
development and manufacturing advancement for the manufacturing few weeks’ time. Direct Metal Print-
professionals outsource custom industry as a whole. The process uses ing is enabling people to make parts
manufactured parts. Since its found- a laser to melt fine powder layer by that were previously not manufactur-
ing in 1986, the company has pushed layer, resulting in dense, chemically able in any other process.
for innovations to serve the needs of pure metal parts that can be printed
nearly every manufacturing industry, within a few days without the need for Global Footprint
from space rockets to entrepreneurs tooling. This allows the geometry of Customers may submit designs
trying to build a better mouse trap. the component to be optimized and through the 3D Systems’ Quickparts
“The culture at 3D Systems is one of the assembly to be reduced from mul- website, instantly receive quotes and
innovation across everything that we tiple parts down to a single piece. place orders 24/7. Orders typically
do,” Chief Marketing Officer Cathy DMP has had critical benefits for ship in two to four days, but can be ex-
Lewis says. the aeronautics and space industries, pedited if necessary. This has stream-
3D Systems / www.3dsystems.com/quickparts / HQ: Rock Hill, S.C. / Employees: More than 2,000 / Specialty: 3-D custom designed manufacturing /
Ziad Abou, vice president and general manager of Quickparts Solutions Global: “We have it all, produce it all and use it to serve our customers.”

3D SYSTEMS
lined the order process from design to to make the heavy capital investment Quickparts also supports its clients
delivery. necessary for in-house production. with a hybrid approach, complement-
Dedicated project managers pro- One such customer is 360Heros, ing its advanced manufacturing with
vide customers with expert advice which sells holsters for GoPro cam- traditional manufacturing services.
on which printing process and what eras that allow the user to film vid- “We’re changing the game on manu-
materials best fit their product or pro- eo with a 360-degree field of view. facturing with a hybrid approach and
totype. The company has built its own “When [360Heros] needs to produce a new design to manufacturing para-
software and scanners to test compo- hundreds and hundreds of these it digm,” Lewis said.
nents on whether they meet specifi- turns to Quickparts,” Lewis says. Although most of 3D Systems’ busi-
cations. Because 3D Systems manu- ness is centered on manufacturing,
factures its own machines, employees Making Advancements consumer interest in the applica-
have a familiarity with the equipment Those are just some examples of how tions has risen. Through Quickparts,
that ensures quality in the end-result. the company follows through on its the structure is already in place to
Quickparts counts among its cus- forward-thinking philosophy. “Every meet demand. Lewis says people can
tomers companies specializing in year we have a new technology or new make custom birthday gifts, like the
SPECIAL SECTION
medical equipment, automotive, process to offer to the customers,” “Ghostbuster” figurine with person-
shoes, aerospace, defense and even Abou says. alized faces 3D Systems debuted last
refrigerators. “You realize the world With its range of 3D printing tech- fall, or wedding cake toppers featur-
around you is made up of plastic and nologies, from ColorJet and MultiJet ing the bride and groom’s likeness.
metal parts and somebody has to de- printing, to Stereolithography, Selec- 3D Systems is also exploring edible
sign every one of those,” according tive Laser Sintering and Direct Metal 3-D printing through its “Sugar Lab”
to Brian Ford, senior director of sales Printing, 3D Systems has a solution in California. The focus is on its con-
and service. for a broad range of applications, and tinuous advancements and adoption
To serve all those markets, 3D Sys- combines that with its deep exper- of new technologies that allows it to
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tems has created a global footprint, tise in digital design and fabrication. meet a huge range of needs. mt
with dozens of Quickparts advanced
manufacturing centers across the 3d systems says its global
footprint has allowed it to
United States, Europe, Asia and Aus- serve many major customers
around the world.
tralia. “We’re responding to custom-
ers’ request for a global brand to be
what they need us to be,” Lewis says.
As 3-D printing has become more
vital to manufacturing, many of those
customers have invested in their own
in-house systems. However, they of-
ten still turn to 3D Systems Quick-
parts to supplement production
during peak manufacturing periods
and because of the company’s ability
and expertise to handle complex de-
signs. There is virtually no limit to the
size of a component Quickparts can
make, though larger designs may be
assembled in sections.
The range of scalability is suitable
for major companies, but has also at-
tracted numerous startups that need
access to parts but are not yet ready

CYBEROPTICS CORP.
THE THIRD DIMENSION

CYBEROPTICS CORP. HAS STRUCK A MAJOR DEAL TO SUPPLY ITS NEW 3-D SENSORS TO A
MAJOR SEMICONDUCTOR INSPECTION COMPANY. BY JEFF BORGARDT
cyberoptics’ sq300 aoi system CyberOptics Corp., a leading

is equipped with multi-view 3-d
sensors, enabling the fastest global developer and manufacturer of
3-d inspection in the industry.
high-precision 3-D sensing technolo-
gy solutions, has just brought to mar-
ket the new SQ3000 3-D Automated
Optical Inspection (AOI) system.
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SPECIAL SECTION
“We continue to execute on our strat-

egy of developing and manufacturing
high-precision 3D sensors for our
key vertical markets,” CEO Subodh
Kulkarni explains. “The integration
of our proprietary 3-D Multi-Reflec-
tion Suppression [MRS] sensor into
the SQ3000 AOI system enables un-
paralleled speed and accuracy.”
MRS technology inhibits reflec-
tions that could result in measure-
ment inaccuracies, which is partic-
ularly critical for inspecting shiny
objects. The MRS algorithms use a
rich data set from the multi-view 3-D
CyberOptics Corp. / www.cyberoptics.com / Annual revenue: $44 million / Headquarters: Minneapolis / Employees: 169 /
Specialty: High-precision sensors / Subodh Kulkarni, CEO: “Things are getting smaller. Our customers need detection in 3-D.”

CYBEROPTICS CORP.
sensors and suppress the reflections. This proprietary ap-

proach combined with the sophisticated algorithms that
fuse the image data, results in a precise 3-D image.
“We’ve driven this significant technology advancement
from concept to fruition into back-end semiconductor in-
spection with our recent KLA-Tencor strategic supplier
agreement, and now into SMT (surface mount technolo-
gy) inspection with our SQ3000 3-D AOI system, further
driving customer yield and productivity improvements in
both markets.”
The SQ3000 3-D AOI system maximizes return on in-
vestment and line utilization with multi-view 3-D sensors
that capture and transmit data simultaneously and in paral-
lel, enabling the fastest 3-D inspection in the industry. The
MRS technology inside combined with the highly sophisti-
SPECIAL SECTION
cated 3-D fusing algorithms offers microscopic image qual-
ity at production speeds. An easy-to-use, intuitive interface
with touch control facilitates minimal training and opera-
tor interaction.
Future Growth Potential

CyberOptics has grown significantly in the past year, in-
creasing revenue 24 percent organically in its past four
quarters. “We are a technology company focusing on devel-
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oping sensor technologies that address key market needs
for various applications in manufacturing environments,”
Kulkarni says. “We design, develop and manufacture sen-
sors for several vertical markets such as automotive, aero-
space, medical to name just a few. With the performance of
our 3-D sensor technology, our customers are able to main-
tain a competitive edge where stringent quality standards,
yields and throughput are paramount.”
There are several types of sensors and diverse applica-
tions for them. One use is to monitor manufacturing as-
sembly lines to verify product is assembled correctly. For
example, it might be placed at the end of the line in a Smart
Phone factory to verify all the proper components are locat-
ed according to specifications.
Advancing from a 2-D sensor that produces images re-
sembling photographs, the 3-D sensors can reveal things
not seen in 2-D, included the depth and breadth of the im-
age. Plus, with the incorporation of the proprietary MRS
technology, it provides a very precise 3-D representation.
“This is the new market we are playing in,” Kulkarni ex-
plains. “Things are getting smaller. Our customers need de-
tection in 3-D. For quality control, our sensors go directly
on the line where smartphones are being made to make sure
they are being assembled correctly and the dimensions

CYBEROPTICS CORP.
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SPECIAL SECTION
cyberoptics designs, develops and

manufactures sensors for several
vertical markets, such as automotive,
aerospace and medical.
are accurate, exact and precise. the industry. “We are very excited,” The company is incorporating the
With the chips, resistors and capaci- Kulkarni says. “This is a customer MRS sensor technology into a new
tors getting smaller and smaller, they with huge market share so it’s a terrif- 3-D scanning product, which is poised
need the third dimension to detect ic validation of our new technology.” to launch shortly. This technology en-
everything correctly.” It is a strategically significant rela- ables very fast and accurate 3-D scan-
The sensors play a crucial role. “If tionship, too. “We entered into a mu- ning at the touch of a button.
you look back 10, 20 or 30 years ago, tually exclusive agreement to supply CyberOptics’ sensors are being used
most of this was completed by manual 3-D sensor subsystems for KLA-Ten- in general-purpose metrology and 3-D
inspection to see if chips were glued cor BEOL (back-end of line) package scanning, surface mount technology
correctly and the right resistors were inspection systems. The agreement (SMT) and semiconductor markets
there,” Kulkarni says. “Now, there is leverages CyberOptics’ extensive to improve yields and productivity. By
automation with robots putting parts R&D efforts into 3-D sensing with leveraging its leading-edge technol-
together and sensors to make sure KLA-Tencor’s industry-leading sys- ogies, the company has strategically
parts are put together [correctly].” tems design, applications expertise established itself as a global leader in
KLA-Tencor, based in Milpitas, Ca- and customer service,” Kulkarni says. high precision 3-D sensors, allowing
lif., supplies process control and yield CyberOptics also provides 3-D CyberOptics to further increase its
management products for the semi- scanners and scanning services, penetration of its key vertical seg-
conductor, data storage, LED and na- which can be useful to inspect parts ments. Headquartered in Minneapo-
noelectronics industries. The recent printed with 3-D printers or when lis, CyberOptics conducts worldwide
announcement that it would partner plastic parts are molded by injection operations through its facilities in
with CyberOptics was big news in molding machines. North America, Asia and Europe. mt

GPI PROTOTYPE & MANUFACTURING SERVICES INC.
SPECIAL SECTION
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its dedication to customer
service has made gpi a preferred
provider of rapid prototyping.
LAYER BY LAYER in an effort to better serve its custom-

ers. “We started GPI Prototype with
plastics and quickly became a trust-
GPI CAPITALIZES ON ADDITIVE MANUFACTURING WITH A ed supplier to our clients,” Galloway
LASER FOCUS ON METALS. BY JEFF BORGARDT states. Over time, the company’s
commitment to customer service,
GPI Prototype & Manufacturing ty product with top-notch customer technical expertise, state-of-the-art
Services Inc. is a privately owned ser- service. “We deliver value through production facilities and a continued
vice provider that specializes in rapid measurable results that continuously investment in research and develop-
prototyping and additive manufac- exceed expectations. We love what we ment established GPI as a preferred
turing to serve its rapidly growing do!” says Adam Galloway, recently ap- provider of rapid prototyping and di-
customer base. Based in the Midwest, pointed president of GPI. rect digital manufacturing.
and consistent with their roots, the After three decades as a leader “As more service providers offered
company and its employees pride in product development and rapid rapid prototyping and the market
themselves on being honest, hard prototyping, the company recently began to mature, we recognized two
working and committed to providing adapted its focus to the metals side of important shifts,” Galloway says.
their clients with the highest-quali- the additive manufacturing business “One, metal was gaining traction in
GPI Prototype & Manufacturing Services Inc. / www.gpiprototype.com / HQ: Lake Bluff, Ill. / Specialty: Additive manufacturing services /
Adam Galloway, president: “We work hard to deliver the end-result the customer expects.”

As this dynamic industry develops,

constant change is the norm. “The
industry is in flux,” Galloway says. “It
has changed dramatically in the last
few years.” This change includes ma-
jor acquisitions affecting the number
and sizes of companies operating in
the sector and recent announcements
by Fortune 100 companies like HP,
who intend to enter the space in the
next eight to 12 months.
Working in a newer field like addi-
tive manufacturing, prototyping and
3-D printing requires constant educa-
tion. “We work with a lot of custom-
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ers throughout the year and help to

educate them so that they understand
with its expanding capabilities this process,” Galloway explains. “As
and skill set, gpi is seeing growth
we teach how to design and really use
SPECIAL SECTION
across all the industries it serves.

the technology, many customers ul-
terms of its applicability for addi- geometry that could not be produced timately decide to acquire machines
tive manufacturing and, second, our using traditional approaches, like themselves to bring the power of ad-
more-sophisticated client base was CNC machining.” ditive manufacturing in-house, once
increasingly challenging and pushing Industrial prototyping and additive they understand the value.” But that
the boundaries of the plastics tech- manufacturing is a fast-growing field. does not mean the customer ceases to
nologies. This is when we decided to Although it has been in existence for need the support and know-how of-
pivot our know-how to direct metal more than 25 years, in the past five to fered by GPI.
advanced manufacturing.” 10 years additive manufacturing has In contrast to standard manufac-
Over the last few years, the compa- become mainstream, moving from turing, additive manufacturing is not
ny expanded, added metals machines rapid prototyping to the production yet an exact science. “There are stan-
and the business grew rapidly. “We of actual end-use parts. The technol- dard manufacturing processes that
are experiencing growth from all sides ogy offers tremendous potential as it have been around more than a centu-
and across all industries,” Galloway essentially produces a part or product ry,” he states. “Those processes are
says. “In particular, aerospace, medi- a layer at a time, using just the materi- pretty well defined and understood.
cal and industrial are some of the ear- al required in most cases. Additive manufacturing is not there
lier adopters of precision, direct metal This gives the engineer or designer yet and with its innate ability to deliv-
services and have capitalized on our the freedom to create a part for oper even the most exquisitely complex
capacity, skills and relationships.” timal performance versus designing parts, new applications and uses are
Galloway goes on to explain, “We within the constraints of traditional emerging all the time.” This necessi-
don’t offer a product; we are much manufacturing. Although metal print- tates further work, including process
more on the service side. All of our ing is currently the domain of profes- innovation and increased under-
customers, such as NASA, GE, Black & sionals like GPI, there is discussion standing of additive manufacturing
Decker and Stryker, design their own today that additive manufacturing has capabilities and materials.
products. We offer design consulta- the potential to offer consumers per- “To better support customers, we
tion and engineering services to help sonalized machines to produce parts have recently become AS 9100C and
them create a part which will take full and toys in their homes. “3-D printing ISO 13485 certified,” Galloway notes.
advantage of direct metal advanced is now becoming mainstream,” Gallo- “Both certifications provide GPI with
manufacturing, in many cases with a way declares. standardized processes used to create

quality products and meet regulatory in 2015 than all of last year. The custom- the Mojave Desert and is scheduled to
requirements in extremely stringent ers and industry are beginning to un- launch to 10,000 feet in June. The rock-
industries like aerospace and health- derstand that additive manufacturing et was produced on GPI’s direct metal
care. The internal management system, offers true production of components, laser melting (DMLM) machine, which
created by GPI during the course of cer- not just prototypes.” is ideal for small satellites.
tification, provides assurance in all man- While GPI intends to expand into pro- The team has also explored the func-
ufacturing processes. Requirements duction, it won’t lose sight of prototyp- tionality of other printed rocket compo-
include internal audits, record keeping, ing. “Prototypes will always be at the core nents. “It is a wonderful test of the tech-
process procedures and monitoring, of our business,” Galloway says. nology and machine capabilities, which
management reviews, and corrective ac- pushes the limits of what we can build,”
tion plans.” Blast Off Galloway says. mt
GPI demonstrated its capabilities in a
New Opportunities unique way last year. The company part- 3D Systems provides the most advanced 3D digital
With its growing metals capacity and nered with the University of California design and fabrication solutions available today, including
3D printers, print materials and cloud-sourced parts.
know-how, GPI is moving beyond pro- San Diego and NASA’s Marshall Space
SPECIAL SECTION
Its powerful ecosystem empowers professionals and
consumers to bring their ideas to life using its vast material
totypes into full production. “We have Flight Center and printed the Tri-D selection, including plastics, metals, ceramics and edibles.
been actively involved in production metal rocket engine, and the second Its democratized 3D digital design products provide seam-
less interoperability and incorporate the latest immersive
quoting and orders,” Galloway says. generation earlier this year, the Vulcan-1 computing technologies. 3DS’ products and services
“We have already had more customer rocket engine. disrupt traditional methods, deliver improved results and
empower its customers to manufacture the future now.
opportunities this year for production The Vulcan-1 was recently tested in
RAPID

S PA C E T E C H
SPECIAL SECTION
36. Alliance Spacesystems

36. 44. 52. 39. Micro Craft Inc.
42. Experior Laboratories
44. Vision Engineering Solutions
46. Precision Test Solutions
48. Space Vector Corp.
52. Space Information
Laboratories
54. LaserStar Technologies

STORIES
TO TELL
ENHANCED TECHNOLOGY AND NEW INNOVATIONS HELP UNITED LAUNCH ALLIANCE FIND
RESULTS THAT ARE ‘HIGHER QUALITY, LOWER COST AND BETTER PERFORMING.’
BY STACI DAVIDSON
SPECIAL SECTION
//////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////
During the Space Tech Expo in Long Beach, Calif., from May 19 to
21, numerous exhibitors, visitors and delegates will attend the premier
event, all looking to discover the space and satellite industry’s lat-
est technologies and innovations. As COO of United Launch Alliance
(ULA), Dan Collins fully understands the need for innovation in the
S PA C E T E C H E X P O
industry because he is responsible for the Atlas and Delta expendable
launch vehicle programs. Collins will bring his expertise to the expo’s
launch services market’s keynote panel on May 19, which will focus on
competition, affordability and mission assurance.
ULA is going into Space Tech Expo having just unveiled its ponents must be kept warm and others must be kept cold. The
Next Generation Launch System in April. The new rocket, Vul- traditional system had more than 200 pieces, but with additive
can, will make launch services more affordable and accessible, manufacturing, ULA was able to reduce the system’s weight
ULA says. It brings together decades of experience on ULA’s and keep it to only 50 to 60 pieces. As a result, it had a lower cost
reliable Atlas and Delta vehicles, combining the best features to manufacture and became easier to install. “We always want a
to produce and all-new, American-made rocket that will enable result that is higher quality, lower cost and better performing,”
mission success from low-Earth orbit all the way to Pluto. Collins notes.
“We have the greatest technology in the launch industry,” It is this sort of adaptation and innovation that ULA will be
Collins says. “We use advancements in information technolo- presenting at Space Tech Expo. “We see Space Tech Expo as a
gy to ensure we are supporting our team with the data and in- place where we will be able to tell our story,” Collins says. “This
formation they need right in the work center. We take a world- is a very innovative company and we are constantly bringing
class team and make them even better with our technology.” better value to our customers. The market is starting to shrink,
One of ULA’s current innovations is the expanded use of but we won a significant role in NASA’s commercial crew pro-
additive manufacturing in its launch vehicles to help its sys- gram and we are very excited about that. We are launching
tems to their jobs more effectively and lower their weight. In missions in less than 12 months from signing the contract, and
its environmental control systems, for example, some com- with that capability we are very excited about our future.” mt

ALLIANCE SPACESYSTEMS LLC
SOARING HIGH
ALLIANCE HAS GROWN TO SERVE BOEING, NORTHROP GRUMMAN,
LOCKHEED MARTIN AND OTHER SATELLITE LEADERS. BY ALAN DORICH
bital ATK Inc. and Lockheed Martin

Corp. “These are companies that
are manufacturing satellites, among
many other things,” Byrens says.
In April, the company announced
it will become part of SolAero Tech-

nologies Corp., a provider of space
solar power solutions based in Albu-
querque, N.M. “That’s going to give us
some very good synergies,” Alliance
Director of Manufacturing Gregory
Golanoski says. “We can give our cus-
tomers more value with the combined
capabilities of both SolAero and Alli-
ance. I think we’ve got a bright future
SPECIAL SECTION
[together].”
Leading the Way

Alliance is a leader in its industry,
alliance spacesystems provides Byrens explains, because “we offer our
composite structures used
in building spacecraft and in customers a fully integrated product.”
other applications.
“So when we deliver a structure
The spacecraft market demands ance manufactures and designs com- that we manufacture for a satellite, it
an extremely high level of quality posite structures for spacecraft and is ready to go into our customers’ in-
workmanship, and Alliance Spacesys- other applications that require a high tegration facility,” he says. The com-
tems LLC has answered that call strength-to-weight ratio, superior pany also takes pride in maintaining
throughout its history, President and stiffness and dimensional stability. a tidy operation. “If our customers
General Manager Rick Byrens says. Three ex-jet propulsion lab employ- walked in our [shop], they’ll see a re-
Alliance ensures it meets its clients’ ees started the company in 1997. flection of their own clean facility that
requirements by maintaining close “The original Alliance was much they work in every day.”
relationships with them. “We very more of an engineering company,” Alliance is flexible with its clients
much rely on customer feedback and Byrens says, noting that its focus because it understands their needs,
working with our customers early in changed when it merged with Vision Golanoski adds. When dealing with
programs to make sure we’re giving Composites in 2006. “What we do factors such as costs and schedules,
them exactly what they want on deliv- now is much more rooted in compos- “You have to [find] flexible ways to
ery,” Byrens says. ites manufacturing.” work with them,” he says. “They have
Based in Los Alamitos, Calif., Alli- Alliance serves firms such as Or- their own struggles.”
Alliance Spacesystems LLC / www.alliancespacesystems.com / Headquarters: Los Alamitos, Calif. / Employees: 150 / Specialty: Composites /
Rick Byrens, president and general manager: “We rely on customer feedback and work with our customers to make certain they have what they need.”

Staying Healthy ing. It has hosted more than 20 kai- look at a very specific process, go
Alliance is enjoying healthy business zen events in the past three years, through it and make improvements.”
in its niche, Byrens says. “In the cur- Byrens says. Last month, Alliance held a three-
rent economic climate, as opposed “Some have lasted weeks and some day event where its staff mapped
to many other markets, [ours] has we do in a day,” he describes. “We out its entire supply chain and
remained healthy,” he says.
“The total market hasn’t grown,
but it has not shrunk, either,” he
says. “It’s all driven by consumer de-
mand for Internet, high-definition
television [and] all the things that
SPECIAL SECTION
satellites provide.
“That demand has been increas-
ing and continues to increase our
marketshare,” he says, noting that
Alliance has provided structures for
satellites used by DIRECTV LLC and
ViaSat Inc.
Making Snowflakes
Nearly all of Alliance’s work is cus-
tomized. “A satellite is basically a
snowflake,” Byrens says. “Every
satellite is different, as opposed to
a typical manufacturing environ-
ment where you have a production
line [that] can realize efficiencies
[through] lean concepts.”
Golanoski agrees. “It’s a little
tough to put in metrics, because we
do a lot of one-off hardware,” he says.
“Next month, I’m not sure what I’m
going to be building. It’s a lot tougher
to maintain the manufacturing floor
that way.”
This uncertainty influences the
company’s inventory. Usually, “You
try not to have inventory,” Golanos-
ki says, noting that it keeps some
common pieces of hardware in stock.
But usually, “It’s bought uniquely
per program.”
Keeping Focused
Despite the challenges, Alliance
maintains a high level of quality in
its operations thanks to continuous
improvement initiatives and train-

procurement process, from the point ners.” “They have visibility into our cus- “General Research burns the mid-
where its customer requirements ar- tomers’ forecasts and we have long-term night oil to get us something as soon
rive to the point where the products are agreements with them,” he describes. as possible,” he continues. “They’ve
delivered. “We were able to take a very Another group is Alliance’s “key sup- been one of our go-to shops to get
cumbersome process ... and reduce that pliers.” “These are typically machine last-minute stuff so we still keep a
to three days,” he recalls. shops and companies that supply us a lot normal flow. That’s been one of their
The company has set on-time delivery of hardware,” Byrens explains. niches for us.”
records and earned recognitions from cli- The third consists of “maintenance
ents. “We’re a gold supplier to Northrop suppliers,” which are often the sole Growing Content
Grumman and we’re a silver supplier to source of an item. However, “We’re con- Byrens predicts a strong future for Alli-
the Boeing Co.,” he says. “Those things stantly looking at our supplier base and ance. “I see continued growth,” he says.
don’t happen by accident. They’re a re- trying to move people into ‘preferred “We have initiatives in place to grow our
flection of the business and delivering supplier’ status if we can get the best content with the biggest satellite manu-
what we commit to with our customers.” service possible,” he says. facturers,” he says. mt
One vendor that has been very help-
Go-To Shops ful to the company is General Research General Research & Mfg. has been producing
Alliance’s suppliers have been integral & Manufacturing, which “has been a critical close tolerance components for the aerospace
industry since 1993. Our world class facility located in
to its success. Byrens notes that the great last-minute shop for us,” Golanos- the heart of Los Angeles is equipped with the latest five
axis equipment allowing us to maintain close volumetric
company classifies its suppliers in three ki says. “They have dropped everything tolerances. See what we can do for you!
categories, including “supplier part- when we’ve had last-minute changes.
SPECIAL SECTION

MICRO CRAFT INC.
READY FOR FLIGHT

MICRO CRAFT PROVIDES TEST HARDWARE FOR THE
AEROSPACE INDUSTRY. BY JANICE HOPPE
When hundreds of millions of dol- micro craft has been

building specialty hardware
lars are riding on a single test for an for aerospace testing in
tennessee since 1958.
aircraft prototype, the aerospace in-
dustry turns to Micro Craft Inc. – ex-
SPECIAL SECTION
perts in test hardware and wind tun-
nel models. “The largest wind tunnel
complex in the world is nearby,” CEO
Jim Herron says. “It is owned and op-
erated by the U.S. Air Force and it’s
extremely expensive to run. There is
a lot riding to make sure the model
hardware doesn’t fail.”
Charles Folk founded the Tullaho-
ma, Tenn.-based company in 1958 as
a provider of complex wind tunnel
models and other specialty hardware.
The company grew quickly through
the 1990s, employing as many as 1,100
people and operating 14 sites. After
a brief ownership by an investment
group, Micro Craft was acquired in
2003 by a large business.
Micro Craft was the prime contrac-
tor for design and fabrication of NA-
SA’s three X-43a scramjet-powered
airplanes, unmanned experimental
hypersonic aircraft that successfully
tested various aspects of hyperson-
ic flight up to Mach 10. “But when
the X-43 program was cancelled, our
value to our owner diminished and
we no longer fit their core product
lines,” Herron recalls. “In 2011, the
employees found a way to buy back
the company using their pensions in
the structure of an Employee Stock
Micro Craft Inc. / www.microcraft.aero / Revenue: $10 million / Headquarters: Tullahoma, Tenn. / Employees: 65 / Specialty: Test hardware /
Jim Herron, CEO: “We are building stuff people won’t see for 10 to 20 years.”

MICRO CRAFT INC.
is three months, but the F-35 model

took six months. Micro Craft’s staff of
65 includes engineers, machinists and
electrical technicians, most of whom
attend at least a two-year technolog-
ical school before coming to work at
the company. They are paired with
a mentor and trained before being
assigned to work on a model. “They
won’t be working on this stuff right off
the bat,” Herron notes. “We put them
on production work to get a feel for
the place and train them as we go.”

Senior engineers use JobBOSS, an
on-premise ERP manufacturing soft-
ware, to plan out and keep track of the
company’s workload, which can often
add up to seven or eight projects at a
time. The senior staff then assigns
teams to complete each project. New
hires are allowed to work alongside
micro craft is a key supplier their mentors on models.
SPECIAL SECTION
of complex wind tunnel

models and other specialty
testing hardware. Securing Resources
Although the models are most often
Ownership Plan. It is 100 percent to design a subscale model of the F-35 a scaled-down version of an aircraft,
employee-owned and no one owns from their full-scale aircraft. During the models can cost $200,000 after
more than 5 percent of the company.” the design phase, Micro Craft’s team parts and labor. The F-35 model was
Today, Micro Craft remains a key performed a thermal and stress anal- made from stainless steel and had a
provider of complex wind tunnel ysis, as well as determined what mate- more than $1 million price tag. “These
models and other specialty hardware. rials needed to be used. “Once we have aren’t Revell kits,” Herron says. “It’s
Its customers not only include NASA, done the design to build the model, really complicated with dozens of dif-
but also the United States Depart- we go about it like any other shop; it’s ferent flap settings that may go up and
ment of Defense (DoD) and OEMs. planned out and we start building it,” down, and tails that twist and turn.
“It’s a neat niche,” Herron notes. “We Herron says. We have to simulate all that in the
build one-of-a-kind production flight Instrumentation will be installed wind tunnel.”
hardware as well. Without ground after the model is machined. Engi- Models start from scratch every
testing, there is no plane to build 15 neers use simulators to ensure ev- time and can range in size to fit a wind
to 20 years from now. That’s the cool erything works on the model exactly tunnel about one-foot in diameter up
part: We are building stuff people as it would on the real aircraft. “For to the 80-by-120-foot wind tunnel at
won’t see for 10 to 20 years and we get example, if there is a bomb on the NASA’s Ames Research Center in Cal-
to see stuff that may never actually fly. plane, ground tests make sure it will ifornia. It makes advanced planning a
It’s a lot of fun.” release from the plane and not fly challenge for Micro Craft. “We have
back up into the plane,” Herron says. put a full-scale plane in the wind tun-
Building a Prototype “We use instrumentation to measure nel at NASA Ames in the past,” Her-
Inside its 57,000-square-foot, AS the bombs on the plane and perform ron says. “Every one is different.”
9100-certified manufacturing facili- trajectory tests.” To ensure it receives the parts it
ty, Micro Craft worked with the DoD The average manufacturing process needs on-time, Micro Craft works

MICRO CRAFT INC.
with 150 suppliers that understand the by helping its customers understand Micro Craft continues looking to
company and its work. “This whole area the pitfalls they might encounter later help its customers on the science end of
is a real unusual enclave of scientists and in production. “We can see things and development and provide more value,
technical people that know the mission; we are building the first one,” Herron according to Herron. “We can leverage
they get it and that’s kind of cool,” Her- explains. “We know when something what we do now into bigger and better
ron says. “That’s one of the reason’s we won’t work on the real plane and we are things to help them,” he adds. “I know
are here in Tullahoma, it’s easy to get hoping that’s the next big step for us.” where my bread is buttered and I don’t
people to understand what you are try- Micro Craft, for example, recently want to take their work, but we want to
ing to accomplish.” built test hardware for a new electronic complement them.” mt
Because its suppliers understand its warfare pod for Raytheon, the Waltham,
business, Herron says the company can Mass.-based defense contractor. The Cope Plastics, Inc. is a leading supplier of materials
SPECIAL SECTION
call and ask for one box of screws rather company tested a small version of its used in military planes, communications, as well as prod-
ucts and materials used by NASA. Cope is a third-gen-
than having to order hundreds of boxes pod and suggested how to improve the eration woman-owned business started in 1946 in their
grandparents’ basement. Cope’s vision is to be a leading
because “they get it.” “They are willing design of the packaging inside. “We organization by continually improving its partnerships
to do that for us and we wouldn’t be able built a smaller ground test model and with customers such as Micro Craft, who they have been
supplying for approximately 10 years; surely a result of
to do it without them,” he adds. a full-scale flight pod that flew and was Cope’s family philosophy which centers on honesty,
successful,” Herron says. “Now we have integrity, loyalty, relationships and respect. Companies like
Micro Craft are involved in Cope’s award-winning recycling
Integrated Projects seen what can and can’t be done with the program, reflecting their strong commitment to the envi-
Moving forward, Micro Craft is looking test hardware, so we want to help you in ronment. For more information, visit our website at www.
copeplastics.com.
to take its service beyond test hardware the production of this hardware.”

EXPERIOR LABORATORIES
PASSING
THE TEST
ONGOING SERVICE EXPANSION
IS DRIVING THE GROWTH OF
EXPERIOR LABORATORIES.
BY ERIC SLACK
When it was founded in 2003, Ex-

perior Laboratories began its journey
as an independent, third-party test-
ing, design verification and qualifica-
tion laboratory. Originally known as
Experior Photonics, its initial focus
was on testing fiber-optic compo-
nents. In 2010, the company rebrand-
ed as it expanded its focus to include
SPECIAL SECTION
the electrical connector and environ- experior labs has established

itself in the market with its high
mental testing markets. level of expertise in the testing
of fiber-optic components.
Today, Experior Labs provides ser-
vices to component manufacturers, to quickly grow in that arena. From base. It is the other market segments
military contractors, integrators and there, we looked for additional areas where the company has plenty of
system providers in the telecom, data- of growth.” room for growth.
com, military, aerospace and industri- “We haven’t served the other mar-
al markets. The company is headquar- Strong Presence kets for as long, and they are much
tered in Southern California where Customer service has long been a dif- larger markets,” Cartellieri says. “En-
it has 15,000 square feet of space and ferentiating factor for Experior Labs. vironmental testing will eventually
around 30 employees. Experior Labs The company assigns a program man- become our largest segment as it is
is in the midst of doubling the size of ager to each project who is responsible the largest market and we currently
its facility to handle more volume. for the entirety of each test program. serve a small percentage.”
“To get off the ground and estab- Serving as a single point of contact, Experior Labs was able to establish
lish ourselves, we built a high level of the manager can be an advocate for the itself in the electrical connector and
expertise in the testing of fiber-optic customer, which helps with customer environmental testing markets by
components,” President Lorenz Car- satisfaction and retention. leveraging the testing infrastructure
tellieri says. “We understood how In the fiber-optics testing market, it had built to support the fiber-optic
to take true ownership of test pro- Experior Labs has grasped control market while also expanding its ca-
grams and the sample, compliance of around 75 percent of the mar- pabilities. In so doing the company
and schedule requirements. Provid- ket’s share. Its goal in that arena is could increase business by serving
ing short lead times and working on to maintain the quality of its service existing customers more broadly and
projects very expediently allowed us and continue to satisfy its customer reaching new customers.
Experior Laboratories / www.experiorlabs.com / HQ: Oxnard, Calif. / Specialty: Testing, design verification and qualification / Lorenz Cartellieri,
president: “Our customers have spent a lot on development and need a reliable third-party test lab before their products to go to market.”

EXPERIOR LABORATORIES
“Within those two market seg-

ments, we do a lot of qualification
testing performed at the end of the
design cycle just before full-volume
manufacturing,” Cartellieri says.
“The goal is to have no issues during
qualification testing, which allows our
customers to ship large volumes to
their customers. We need to stick to
the schedule, as our customers have
spent a lot on development and need
a reliable third-party test lab before
SPECIAL SECTION
their products to go to market.”
Expanded Offerings
Including the expansion of its South-
ern California facility, Experior has
invested considerable resources into
enhancing its offerings to customers.
Major equipment investments have
focused on vibration and shock test-
experior labs has invested
ing, as the company has brought in considerable resources
into enhancing its offerings
state-of-the-art equipment that out- to customers.
performs its competition.
“We have leapfrogged forward and components under its ITL-FOC cer- and growth. Experior Labs will invest
expanded that service area to a large tification program. When it joined in areas that help fill out its portfolio
customer base, such as serving com- that program in 2005, there were six while also providing good profit mar-
panies producing space launch vehi- approved test labs. Now, there are gins. It must also make sure that it
cles,” Cartellieri says. “Parts of those only two. “We have been able to take maintains and builds its internal sta-
markets have been underserved by the marketshare, and the market has ble of subject matter experts so it can
limited test capabilities at the in- stagnated overall,” Cartellieri says. continue to provide a high level of ser-
cumbent labs and long lead times. In the electrical connector and en- vice even as it grows.
We are continuing on a growth path, vironmental testing markets, Expe- Overall, Experior Labs is clearly
having acquired a second Unholtz rior Labs growth strategy is focused a success story. Since its inception,
Dickie T2000 vibration system last on continued expansion of its capa- the company’s revenue has averaged
year and enhanced our shock testing bilities. The company recognizes the more than 50 percent growth year
methods. Expansion of our facility need to offer a complete portfolio as a over year. Maintaining this relatively
will help us continue to develop test test lab so it can serve its clients’ en- high growth rate as a service provid-
methods internally.” tire testing needs. “It has become es- er is only possible by continuing to
Staying on top of the evolution of sential for Experior Labs to fill gaps in make existing customers happy and
its industries will play a major part in our service portfolio to offer inclusive gaining business with existing ac-
the future direction of Experior Labs. testing programs and be able to main- counts while also finding and acquir-
In the fiber-optics space, the compa- tain total ownership of the project,” ing new customers.
ny has been able to take advantage Cartellieri says. “For our expansion to continue, we
of the erosion of competition in the As the company works to fill gaps, it must close gaps and invest in our ca-
market. For example, Experior Labs will evaluate opportunities to ensure pabilities so we have a comprehensive
is approved by Verizon to conduct it is spending on areas that will have offering in all of our markets,” Car-
qualification testing of fiber-optic the biggest impact on customer needs tellieri says. mt

VISION ENGINEERING SOLUTIONS
EXPERIENCE
MATTERS VISION ENGINEERING
SOLUTIONS REACHES OUT TO A
BROADER CUSTOMER BASE.
BY CHRIS PETERSEN
Experience means more than just

witnessing something happen – it
also involves interpreting the infor-
mation and learning how to apply
that information to the future. That’s
why Vision Engineering Solutions
owner, Ed Logue, says the company
is at the forefront of providing ad-
vanced sensing technology to the de-
SPECIAL SECTION
fense, aerospace and industrial sec-

tors. As Logue explains, the company
has put in more time actually using
the technology it provides than vir-
tually any of its competitors, giving it many of vision engineering
solutions’ staff members
a knowledge base unlike any other in have more than 20 years
of experience.
the marketplace.
“We use what we sell,” Logue says. now developing products that reflect and pointing and tracking systems.
“The software, the hardware that those lessons learned and those fea- Customers for the company’s tech-
we’ve developed are the products of tures we’ve always wanted to have,” nology and systems include the Unit-
25 years of using other people’s track- Logue says. ed States Army, Navy and Air Force,
ing systems in the field and finding Logue adds that the company has a as well as the University of Central
out where the weaknesses are.” very experienced team, with no one Florida, in applications ranging from
The professionals at Vision En- on staff who has less than five years space launch support to missile de-
gineering who develop the sensing of experience. Many of the company’s fense testing.
and tracking technology have spent staff have more than 20 years of expe- Vision Engineering Solutions is pre-
countless hours in the field perform- rience, he says. paring for the upcoming Space Tech
ing tracking in actual real-world sce- Based in Orlando, Fla., Vision En- Expo in California in the hopes that
narios including tracking projectiles gineering Solutions specializes in it can make as big a splash in the com-
from advanced weapons systems, technology including advanced sens- mercial marketplace as it has in the
drones, rockets, and satellites. “We ing and imaging, modeling and simu- public sector, and Logue says the com-
have taken that experience and are lation, data collection and analysis, pany’s technology shows a great deal
Vision Engineering Solutions / www.visionengineered.com / 2014 revenue: $2.6 million / Headquarters: Orlando, Fla. / Employees: 13 / Specialty:
Advanced sensing solutions / Ed Logue, owner: “We give you the solution, not just a system.”

VISION ENGINEERING SOLUTIONS
of promise in that regard. Capitalizing on its extensive

field experience, Logue says Vision Engineering Solu-
tions is confident it can make inroads into new revenue
streams that will strengthen its position for the future.
More Experience
Logue says one of the strongest elements of Vision Engi-
neering Solutions’ success over the years is the fact that
unlike many of its competitors, the company can deliver
a fully contained sensing solution that meets the cus- vision engineering solutions is
developing technology to op-
tomer’s every need without the need to shop around to tically track space debris and
make space operations safer.
other suppliers. “We give you the solution, not just a sys-
tem,” Logue says. “We try to give you the whole package will come out of 2015 in a much stronger position among
to solve your problem.” its competitors. Not only does the company have the ex-
For example, Logue points to the recent tracking solu- perience to remain on the cutting-edge of the technol-
SPECIAL SECTION
tion it designed, assembled, and delivered for the Uni- ogy, but Logue says it can build a better product in less
versity of Central Florida. The optical tracking system time and for less money than its competitors can.
is being used by undergraduate and graduate students “I think our tracking systems are going to become
studying physics, optics and electrical engineering. known because they have features that other do not,”
Logue says the Vision Engineering delivered much more he says. mt
than just a tracking gimbal. The company provided the
university with a complete transportable system that in-
cludes: the gimbal and gimbal-controlling software; op-
tics, sensors, and data recording software; a remote con-
trol station; a power generator; and an enclosed trailer to
carry the entire system.
Branching Out
Logue says the company believes its recent project for
the University of Central Florida will help get its foot in
the door with commercial clients. Vision Engineering
Solutions is keen on breaking into the commercial side
of the business to give it an additional customer base
alongside its existing defense and aerospace customers.
That’s also a major reason why the company is exhibiting
at Space Tech Expo.
Vision Engineering Solutions is developing technol-
ogy to optically track space debris, and augment exist-
ing space surveillance radar systems. The combination
of optical and radar data will provide space users with
increased space situational awareness and make space
operations safer. Logue says the company has a pro-
posal to install this technology on the International
Space Station.
“I think we’re going to get some traction in the area of
tracking space debris,” he says. “We have some custom-
ers that are very interested in that.”
Logue says Vision Engineering Solutions believes it

PRECISION TEST SOLUTIONS
the proximity to Cape Canaveral and

eventually the lab was able to build a
reputation as one of the premier facil-
ities in the United States for the test-
ing of high-reliability components for
military and space electronics. It be-
came part of Tektronix in 2009 before
being sold in 2013 and now operates
as a private entity known as Precision
Test Solutions.
The company conducts hundreds
of thousands of tests each year on
thousands of products, mainly com-

ponents found on circuit cards. Those
components become vital parts in
Boeing 700-series airplanes, Atlas and
Delta rockets used to deliver objects
into orbit, the International Space
Station, and GPS satellites, to name
consistency in testing helps
precision test solutions a few. Further, the company tested
ensure repeatable and reliable
results for its clients. parts for the NASA Space Shuttle pro-
gram before it was retired in 2011.
SPECIAL SECTION
“Some of these tests will simulate
FLIGHT TESTING the worst conditions that can be en-

countered terrestrially – or extra ter-
restrially,” says Carlton Chin, a senior
test applications engineer, who has
PRECISION TEST SOLUTIONS HELPS MEET THE CRITICAL been with the company for 35 years.
NEEDS OF THE AEROSPACE INDUSTRY. BY TIM O’CONNOR
The Process
When Mars rovers Spirit and Op- soil while Spirit finally lost contact Precision Test Solutions undertakes
portunity landed on the red planet with NASA in March 2010 when its so- three main types of assessments: elec-
in January 2004, their initial mission lar panels became coated in Martian trical testing, in which components
was only 90 days long. But component dust. “[Opportunity] is still working,” or products must perform at tem-
testing by companies such as Preci- says Mike McEntee, senior director of perature extremes; dynamic testing,
sion Test Solutions, which evaluated sales, marketing and quality for Preci- which McEntee describes as a “shake,
semiconductors used in optic sys- sion Test Solutions. “You know why? bake and spin” to determine durabil-
tems onboard the rovers, resulted in Because testing is knowing!” ity; and assembly verification, also
sturdy designs able to withstand the Precision Test Solutions’ test fa- known as DPA, in which the product
isolation of space, allowing the rovers cility has existed in some form since is dismantled to see if it was built cor-
to beam back dramatic images as they 1963. The lab was founded by a Massa- rectly according to MIL-STD specifi-
far surpassed their expected service chusetts company looking to become cations. “It’s like an autopsy on elec-
time. More than 12 years later, Oppor- involved in the booming space indus- tronic components,” Chin says.
tunity continues to examine Martian try. Orlando was chosen because of An area of growth Precision Test
Precision Test Solutions / www.precisiontestsolutions.com / HQ: Orlando, Fla. / Employees: 45 / Specialty: Component and Product Testing /
Mike McEntee, senior director of sales, marketing and quality: “We bridge that gap between certainty and uncertainty.”

PRECISION TEST SOLUTIONS
Solutions has been involved in is testing and lot qualifi- suitability continues growth avenues for Precision Test
cation of plastic encapsulated microcircuits (PEMs) for Solutions, including testing the components that con-
use in high-reliability circuits. PEMs are replacing some trol the stages on U.S. Air Force Delta rockets that deliver
ceramic-hermetic semiconductor components used objects into orbit. McEntee sees lift vehicles as a major
in older and current generation avionics, satellites and area of growth for the company, supporting programs for
military systems due to part obsolescence and cost — United Launch Alliance.
though PEMs were not designed for those applications. With the space shuttle discontinued and future access
In those situations, Precision Test Solutions can provide to Russian-supplied rockets uncertain as international
testing to determine whether the retrofitted PEM com- relations between the former U.S.S.R and Western na-
ponent will hold up to real-world use. tions have become strained, the need for American-made
Although most of the company’s competitors may fo- manned and unmanned delivery systems has increased.
cus on a subset of tests, Precision Test Solutions’ claim “That should result in some work around the area of lift
SPECIAL SECTION
to fame is its ability to handle many of those assessments vehicles,” McEntee says. There are also the technology
under one roof. When a customer’s need goes beyond the developments coinciding with NASA’s planned mission
standard tests, the company’s consultants work to devise to Mars, of which Precision Test Solutions is involved.
a unique test to fit the specifics of the product. Chin re- The company’s expertise could someday be a critical part
calls a client that had problems with chip device solder of reaching other worlds.
joints on a circuit board fracturing and opening contact McEntee says Precision Test Solution’s goals mirror
with the board. Precision Test Solutions was able to de- those of NASA and other space-oriented companies in
velop a test that flexed the boards under electrical test the Orlando area. “Their success is ours,” he declares. mt
and measured how it impacted the component’s opera-
tion, an example of the collaborative engineering Preci-
sion Test Solutions can offer customers. “We bridge that
gap between certainty and uncertainty,” McEntee says.
Consistency in testing is a key focus for Precision Test
Solutions. Conducting the same test on different parts in
the same way ensures repeatable and reliable results for
the client. “MIL-STD testing requirements prevent you
from doing an inadequate test on a poor product or an
over-test on a good product, causing them to fail,” Chin
says of the company’s methods.
An Aerospace Future
Precision Test Solutions has achieved Defense Logistics
Agency certification for MIL-STD test methods, allowing
the company to take part in several military programs,
such as missile launch systems, flight avionics and mu-
nitions delivery systems. With America’s deployment in
overseas wars winding down and a push toward extend-
ing the life of existing military platforms, there are fewer
new designs that require testing. As a result, the compa-
ny is focusing more attention on the other segments of
its business: commercial avionics, product qualification
and the space industry.
In addition to the military lab certifications, Precision
Test Solutions holds AS9100C quality system certifica-
tion, which provides confidence that the company meets
aerospace industry standards. The DLA MIL-STD lab

SPACE VECTOR CORP.
SPECIAL SECTION
space vector corp. specializes

in solutions, components and
systems for launch vehicles.
TAKING OFF a-half years or more before that plan-

etary alignment occurs again.
Unfortunately, fixing or replacing
SPACE VECTOR CORP. SPACE-QUALIFIES COMMERCIAL a box when a rocket is on the launch
pad can take several days or weeks,
COMPONENTS FOR SUBSTANTIAL SAVINGS. BY RUSS GAGER
Grabow notes. So the launch com-
ponents that Space Vector manufac-
When it’s T minus 15 minutes and emphasizes. “So we put out the extra tures are fully acceptance-tested and
counting until liftoff of a rocket from effort to make these boxes withstand space-qualified before being installed
its launch pad, it isn’t easy to get to a anything that they will encounter on a rocket.
malfunctioning piece of equipment during ground operations and flight.” Space Vector says it has launched
to fix or replace it. “Getting a rock- This includes vibration, shock, tem- 37 rockets over the past 40 years in
et ready to launch and then standing perature, humidity and even lightning support of scientific and defense-re-
down for a week while you replace strikes. Some space missions may lated projects with a success rate of
a box is unacceptable and costly for have only a very short launch window 94 percent. The company has a prime
our customers,” CEO Eric Grabow and if it is missed, it can be one-and- contract with the U.S. Air Force to
Space Vector Corp. / www.spacevector.com / Headquarters: Chatsworth, Calif. / Employees: 25 / Specialty: Components, systems and launch
vehicle solutions for the aerospace industry / Eric Grabow, CEO: ““We do our own machining as needed for more intricate assemblies.”

SPACE VECTOR CORP.
provide launch vehicles under its Sounding Rocket Pro- “We used an existing low-cost sensor and integrated it
gram (SRP-3). “Very few small companies do that type with a custom circuit board and successfully qualified
of work,” Vice President Tim Gray asserts. “We are also and delivered that for use on the Atlas 5 rocket,” Grabow
a classified facility, so we can handle classified data and says. “The launch vehicle prime contractors are getting
product development.” more flexible with this approach of taking commercial
The company provides Lockheed Martin, United hardware and adapting it for aerospace applications.”
Launch Alliance and various government agencies with Space Vector also reduces costs by designing its parts for
a variety of products and services. These include GPS manufacturing and soliciting input from its manufactur-
metric tracking units, rechargeable flight safety and ing department during the design phase.
system batteries, fuel-sensing systems and reentry ve-
hicle adapter structures and separation systems. “We’ve Manufacturing and Assembly
done almost every different type of part that goes on the Space Vector manufactures and assembles its products
SPECIAL SECTION
launch vehicle, from electronic boxes to batteries, fuel in a 22,000-square-foot plant at its Chatsworth, Calif.,
injectors and valves used on the engines themselves,” headquarters. “In addition to custom electronics, we
Grabow maintains. manufacture thruster valves and regulators used in atti-
tude control systems and build the solenoids ourselves
Reducing Costs to achieve high-response and fast-acting products,”
Many of the company’s vehicles are boosted by refur- Grabow says.
bished Minuteman motors that reduce costs substan- “We buy some sub-assemblies from manufacturers and
tially. “One of the areas that we are very good at is taking also make our own custom boards,” Gray says. “Some
things that might be space-flyable and testing and modi-
fying them,” Grabow explains. “We’ve done it for a lot of
products that were commercially viable and have taken
those into the space arena. They are very successful and
are flying on multiple launch vehicles.”
One example is a commercial survey-grade GPS sys-
tem. “It’s used by land surveyors and mappers around
the world to find accurate locations of buildings and
where they’re going to put their boundary lines,” Gray
adds. “We took one of those receivers and several other
commercial boards and developed a range safety track-
ing unit that is flying on all the Atlas and Delta rockets
every three to four weeks.”
Such upgraded systems do not necessarily use parts
from the military’s qualified lists that are prescreened
for space, so they are less expensive and often feature a
more modern design. “We take what we have and work
with a commercial manufacturer to move components
around on the board,” Grabow says. “For one board, we
might have to add extra fasteners or staking so it would
work better under a high vibration environment.”
Space Vector has located manufacturers who are will-
ing to do such work despite the low quantities required,
which might amount to only 10 or 20 annually. Neverthe-
less, such systems can be up to 10 times less expensive
than ones that use pre-qualified parts.
Another example of a commercial part used in launch
vehicles is a probe that measures the level of fuel in tanks.

SPACE VECTOR CORP.
space vector corp. says

its ability to manufacture
components for its own
products is an advantage.
things you just can’t find for a box. welding, and we weren’t getting that national Space Station. Such com-
SPECIAL SECTION
We have a custom power supply and outside, so we brought that in-house.” ponents have different designs than
filter board that are in our GPS track- The company is using 3-D printing launch components because they have
ing unit. Nobody made exactly what for rapid prototyping in plastic. “The to withstand radiation and extremes
we needed, so we designed our own more we do it, the more applications of temperature over long periods of
board. So those we build ourselves. our engineers find for it,” Grabow time. The company also is examining
Other things we buy as a completed points out. “It’s been helpful for us to possible acquisitions or partnerships
assembly and add additional staking print a product and do a fit check with with companies that specialize in
materials and conformal coatings, a plastic piece to see how well it fits in technologies that are complementary
up-screen them and do thermal and their existing system,” Gray adds. to Space Vector’s.
vibration testing.” Almost all of Space Gray attributes the company’s
Vector’s products have custom circuit Automated Testing success to its customer service and
boards in them for protection from To increase speed and accuracy in experience. “We’re really big on
electromagnetic interference and to testing, Space Vector has used new relationships with our customers
withstand three lightning strikes be- software and hardware to automate and making sure we help them get
fore launch. its testing procedures. “Before auto- their missions accomplished,” Gray
Space Vector has its own small ma- mating testing for our GPS system, stresses. “We came out of the rocket
chine shop. “We do our own machin- it took two operators 45 minutes to business. We understand what cus-
ing as needed for more intricate as- run a test,” Gray recalls. “Whereas tomers are looking for and what’s
semblies,” Grabow says. “For higher with our fully automated system, it’s important to them. We understand
production, we will outsource that to down to three to four minutes to run that schedules are king, that you
specialized machine shops. We do all the test, with a single person hitting a have to deliver and you can’t delay
our own soldering and crimping op- single keystroke.” programs. We are really good at giv-
erations, and we do spot welding for For the future, Space Vector would ing the customers what they want
battery cells that have to be connect- like to expand into the market for when they want it. We stick with
ed together. We need to have a really components that remain in space, them until the end and make sure
reliable, consistent process for this such as on spacecraft and the Inter- they have the support they need.” mt

SPACE INFORMATION LABORATORIES (SIL)
a rocket. If something happens, we’re

not liable for that if the black box
passes Department of Defense and/or
NASA-accepted Space Qualification
requirements.”
Among the many safeguards de-
signed into space-qualified products
are thicker printed circuit boards and
underfilled field programmable gate
arrays to withstand shock. “That’s
what they do in cell phones,” Burke
points out. “If you drop a cell phone

on the ground, most of the time it
keeps working. We do the same thing
for a rocket.”
The thicker circuit boards are
necessary to prevent bending. “If it
bends too much, parts start popping
off the board and fracturing,” Burke
sil only manufactures
five products, but those
products are vital to the
notes. “You have to do the finite ele-
american space program. ment stuctural and vibration analysis
at the board and box level. We have
SPECIAL SECTION
to design it to handle the shock. You
SPACE OUT don’t just throw stuff in a box and

hope it works. You have to do all the
engineering design analysis behind it.
That is very costly.”
SPACE INFORMATION LABORATORIES’ PRODUCTS ARE USED This level of design, manufactur-
IN ROCKETS AND SMALL SATELLITES. BY RUSS GAGER ing and test scrutiny are why it takes
years to design new rockets. “When
America’s space program has been vacuum, random and sine vibration, you space-qualify for rockets, it’s a
a triumph of technology for decades. shock and electromagnetic interfer- couple-year process,” Burke empha-
For every one of the thousands of ence. radiative and conductive emis- sizes. “It’s a big deal. When you show
components each rocket or space sta- sion testing,” Burke stresses. up for the final qualification testing, it
tion carries, one or more companies “You have to space-qualify four takes four to six months, and you have
are behind their design and manufac- times higher than the actual level you to pass everything. If a product fails
ture, which require 100 percent reli- are going to experience,” he adds. “It’s one test, you have to go back.
ability. This means that each system not easy to pass that. On launch, you “It takes months to redesign or
launched by a rocket – which Space In- have a stage 1 and stage 2 explosion work with the government to figure
formation Laboratories (SIL) founder that is like a bomb going off. Your out how to make the product work,”
and CEO Edmund Burke calls a “black black box may be 3 feet away, and the Burke continues. “You’ve got to pass
box” – has to be tested extensively and box has to survive that and keep work- all these tests or your black box is not
“space-qualified.” ing. Once it passes space qualifica- flown on a rocket. That’s what drives
“You have to do thermal cycle and tion, then it is allowed to be placed on the cost, because humans have to do
Space Information Laboratories (SIL) / www.spaceinformationlabs.com / Projected 2015 revenue: $3 to 5 million /

Headquarters: Santa Maria, Calif. / Employees: 15 / Specialty: Products for launch vehicles and small satellites

SPACE INFORMATION LABORATORIES (SIL)
all this testing. It’s not the parts in the black box that The company designs Class 3 printed circuit boards,
drives the cost – it’s the extensive testing.” which are the highest standard. “Class 3 PCB manufac-
turing equipment has to be calibrated regularly,” Burke
Static Electricity points out. “You do a cross-section of the board and see
When dealing with such sensitivite components, special if there are any defects. Not many outfits really focus on
manufacturing procedures must be observed. For ex- the DoD and NASA. They just want to roll off Class 1 com-
ample, electrostatic discharge (ESD) – static electricity mercial boards and make money and not worry about de-
– can damage sensitive electronic components. “When fects.” Nevertheless, Space Information Laboratories
the technicians work on circuit boards, they have a wrist has several good circuit board suppliers in California and
strap to dispel any discharge from their fingers,” Burke one in Texas.
explains. “We have an ESD area with a yellow line on the “The two emerging markets we are really focused on
floor, and when you cross it, you’re in an ESD area. Our with our technology is the small satellite market and
SPECIAL SECTION
floors are all normal industrial flooring, but there is no unmanned aerial systems or drones,” Burke says. Most
carpet and the workbenches are grounded.” of the small satellites called Cube satellites are shoe-
Space Information Laboratories tests its entire line of box-sized and can be used for earth imaging, environ-
five products, which includes the Li-Ion Polymer Intel- mental monitoring and many other applications not yet
li-Pack Battery®; the VBITS GPS Tracking and Autono- conceived. “The university students are going hog wild
mous Flight Termination System; the MIL-STD CubeSat with small satellites,” Burke reports. “The unmanned
6U/12U; the Satelllite Communication; and Intelli-Avi- aerial systems are going to revolutionize how we do busi-
onics® used on DoD, NASA and commerical programs. ness in the future.” mt
The electromagnetic interference conductive testing
is necessary because the devices onboard a rocket are
powered by batteries on the same DC electric power and
ground lines. “You have to make it so your box can handle
really bad noise on the DC lines because you’re integrat-
ing all these boxes together on the same ground line,”
Burke explains. “If one box starts conducting noise on
the ground line, all the boxes have that noise.”
The company has its own space environmental test
equipment because the closest lab with such equipment
is in Los Angeles, which is nearly three hours away. “We
have our own test equipment here for production,” Burke
says. “Every unit has to be thermal-cycled, random and
sine vibration (one minute per XYZ axis), and function-
ally tested prior to delivery of production units. So that is
all done in-house at Space Information Laboratories.”
Manual Assembly
Space Information Laboratories assembles its products
using mostly manual methods. The company’s 15 em-
ployees include two assemblers. In the aerospace indus-
try, 50 may be a large production run. “We don’t manu-
facture our own electronics,” Burke says. “Most of the
parts we use are manufactured by printed circuit board
(PCB) manufacturing companies, and SIL designs the
PCB and the layout to be manufactured. We are selecting
mainly industrial- and military-rated parts, and we’re in-
tegrating the final PCBs in a black box.”

LASERSTAR TECHNOLOGIES
as a direct sales organization,

laserstar draws on its years help ensure its customers are operat-
of expertise to help customers
solve issues. ing at their highest potential. Based
in Rhode Island, LaserStar also has
operations in Florida and California.
“We have so many different op-
tions available that we spend a lot of
time upfront to understand our cli-
ents’ needs and wants,” Gervais says.
“There are so many different vari-
ables depending on the industry that
we are always working together.
“The other value that LaserStar

brings to the market is that we are a
direct sales organization. End users
don’t have to muddle through layers
of information sharing – we draw
on years of expertise when problem
solving, which benefits them.”
Driving the Market

LaserStar’s dedication to quality and
innovation, as well as its commitment
SPECIAL SECTION
to working closely with customers, is

all part of its effort to remain compet-
NEEDS UNDERSTOOD itive. “There is a lot of competition,

so we really have to listen to clients’
needs, as well as their budget,” Ger-
vais explains. “At the same time, we
LASERSTAR TECHNOLOGIES REMAINS STRONG BY LISTENING
TO ITS CUSTOMERS. BY STACI DAVIDSON need to be aware of where the market
is taking us, in terms of the manipula-
tion of hot light.”
Maintaining a high level of cus- their real need is, what problems are The company usually takes its prod-
tomer service is not a new thing for they having and what application they ucts through a 24- to 30-month life cy-
the manufacturing industry; in fact, need help with.” cle, so it is constantly looking to can-
most manufacturers have found that A manufacturer of laser sources nibalize its own products and finding
quality service is a key way to remain and systems, LaserStar serves the ways to improve the quality while re-
competitive. LaserStar Technologies medical device, electronics, automo- ducing costs. “We strive to forecast,
takes it a step further, however, by ad- tive, aerospace, tool and die, jewelry steer or drive the laser market to en-
dressing “client pain.” and dental markets with technology sure we are first or second in our tar-
“We serve a variety of different for welding, marking, cutting, deep get marketshare and in meeting the
markets, and our first goal always is to engraving and motion systems. The needs of our clients,” Gervais says.
understand what the client’s pain is,” company continually strives to en- The company maintains this by
President and COO James Gervais ex- hance the quality, performance and heavily investing in engineering. La-
plains. “We need to understand what innovation of its laser products to serStar is able to mass-produce its
LaserStar Technologies / www.laserstar.net www.laserstar.tv / Employees: 76 /

James Gervais: “There is a lot of competition, so we really have to listen to clients’ needs, as well as their budget.”

LASERSTAR TECHNOLOGIES
standard products, but it also per-

forms more custom work. Gervais
explains customers frequently come
to LaserStar that already own one of
its machines but want the company’s
help in other areas. Therefore, the
company has its engineering team
broken into two parts: one that pro-
vides support and enhances its stan-
dard parts, and another that focuses
on complete solutions and developing
additional capabilities and new ways
to bundle its products.
In addition to its focused engineer-
ing teams, LaserStar’s operations as
SPECIAL SECTION
a whole are organized to ensure it is laserstar uses lean manufacturing
and just-in-time scheduling to ensure
working as efficiently as possible and it works as efficiently as possible.
best serving its customers. The com-
pany uses lean manufacturing tech- only company producing them 100 LaserStar also has remained a
niques, just-in-time scheduling and percent in the United States. Because major player in the market during
turns its inventory quickly. Gervais of that, customers are dealing directly rough times because of its market-
notes that it continually works to bal- with the source and benefit from our ing. Gervais notes “the Internet has
ance quality with price. application knowledge base. We also been tremendous” because potential
“That is a constant focus,” he says. have a very diversified laser marking customers can passively research its
“Not every company in this country product line allowing clients to select products’ capabilities and technical
can make every component, so we a base laser marking system or a high- features. LaserStar also produces its
are continuously looking for quality ly sophisticated multi axis program- own product and process videos to
vendors. Germany, Italy and Japan mable marking workstation.” educate its customers, as well as pro-
are our biggest competitors, so we mote its operations.
have to remain strong against them. Growing Demand “This is a business that we built
We always want to fully understand Gervais explains the past six years from scratch 25 years ago,” Gervais
our own strengths. Can we do this have been challenging as the market says. “Over the years we have engi-
ourselves? Do we have the tools in our came out of the financial crisis, but neered new products and enhanced
toolbox to do this? Can we control the LaserStar weathered the time well existing products in our portfolio. A
quality better?” because it listens to its customers large part of our new business is a re-
LaserStar ships 30 to 35 percent of and works with them. In the last 12 to sult of referrals and we are very proud
its production overseas, and takes 18 months, he notes, the market has of that statistic. Organizationally, we
pride in the amount of production been very robust, which is yielding have facilities in three states (Rhode
sold directly into the United States. greater optimism. The company also Island, Florida and California) allow-
The company boasts producing the continues to invest in new methods ing us to service our clients on a na-
highest-quality micro-welding lasers and technologies. tional level.
that are 100 percent produced in the “We’re working with new laser “Lastly, we realize that all employ-
United States. source technologies for all ranges of ment is temporary, yet we have many
“The manual welding laser systems, applications,” he says. “This will al- longstanding employees with 10+
we’ve been manufacturing them since low us to remain on the cutting edge and 20+ year tenure. We built this
the ‘90s,” Gervais says. “We produce of product development and meet the business from the ground up, and we
more than 400 of those machines each ever changing needs of our future tar- know that we are only as good as our
year. I can safely say that we are the get markets.” customers are satisfied.” mt

Saf-T-Cart
www.saftcart.com / 2014 sales: $15 million+ / Headquarters: Clarksdale, Miss. / Employees: 100 /
South
Jim Herring, controller: “When you think of a cylinder cart, you think of a Saf-T-Cart.”
saf-t-cart’s customer base

largely consists of welding
distributors and wholesalers,
such as w.w. grainger.
National Favorite not be stolen. “With this item, [users

could have] everything contained
inside the locked cabinet,” he says.
saf-t-cart has grown to sell its products in all 50 “That was the initial cart that started
states, canada and latin america. by alan dorich Saf-T-Cart.”
After nearly three decades, Saf-T- not get anyone to build it. So Walker Recipes for Success
Cart’s name has become synonymous started buying bending and forming Today, Saf-T-Cart employs a staff of
with its product. “When you think of equipment at auctions and began 100 and had sales of more than $15
a cylinder cart, you think of a Saf-T- building the carts on his own. million last year, which was “our best
Cart,” Controller Jim Herring says, Initially, Walker set up headquar- year ever,” Herring says, noting that
noting that its products are used by ters in an abandoned building that its customer base largely consists of
“most welding distributors through- once housed a school. “He bought welding distributors and wholesalers,
out the country.” it, knocked down the walls, put up a including W.W. Grainger Inc. “A lot of
Clarksdale, Miss.-based Saf-T-Cart crude conveyor system and used the our items find their way to construc-
manufactures oxy/acetylene carts, gas gym as the storage, staging and ship- tion sites due to government safety
distribution pallets and cradles, deliv- ping areas,” Herring says. standards.”
ery and medical carts, running gear, One of the company’s earliest prod- He adds that Saf-T-Cart has been
storage products, wheels, straps and ucts, he notes, was a cart that allowed successful thanks to its business
cylinder caps. Herring notes that the a cutting torch apparatus to be moved model. Walker Welders, Walker’s dis-
company is actually an outgrowth of so it could be stored in a cabinet. tribution business, had a tendency
Jimmy Walker Sr. Welding Supply Co. Without the cart, Herring says, users to ebb and flow based on the success
In 1986, CEO Jimmy Walker had the had to remove the torch’s gauges and of farming in the Mississippi Delta.
idea for a cylinder cart, but he could tips at the end of the day so they would “Conversely, Saf-T-Cart sells na-

South Saf-T-Cart
Making More Room

This year marks Saf-T-Cart’s 10th year at its current location in Clarks-
dale, which features three structures, including a building used for
laser and plasma cutting. “We also have an entire building dedicated
to manifold fabrication,” Controller Jim Herring says. “That’s all we
have certain employees do, day in and day out – build manifolds and
test them.”
A fourth, he notes, will be coming soon. “That will be an extension
of the current main building,” Herring explains. “It is for us to put more
finished product in there.”
tionwide and is not as affected by the local economy as

was the welding distribution business,” Herring says.
“The national economy is what drives our business along
with construction, OSHA and DOT,” he continues. “We
build carts to help companies stay out of trouble.”
Saf-T-Cart also has benefited from its marketing cam-
paign. “We advertise in major magazines that are specific
to our target market,” he says, naming Specialty Gas Report,
Cryogas and GAWDA magazines as examples.
The company makes sure it has a presence at regional
meetings. “We always have a nice, big booth at the American
Welding Society’s FABTECH show,” Herring says. “A lot of
end-users come by to see us.”
Diversification also has helped the company. Instead of
merely sticking to cylinder carts, “We make pallets, truck
beds, cages and cradles,” he says, noting that pallets com-
prise a large portion of its sales.
saf-t-cart’s operations are

aligned with iso 9001:2008 to
ensure manufacturing quality.

Saf-T-Cart South
“We build those by the thousands often provides training to its work- A Worthwhile Investment
and sell them by the thousands,” he ers on-site. “An instructor will come Saf-T-Cart recently helped gas sup-
says. Saf-T-Cart has sold them to all out and work with our welders to get plier Airgas Inc., which needed as-
50 states, Canada, Puerto Rico and them to certain standards, based on sistance with moving large liquid
Australia. “Our pallets have made it the needs of our customers,” he says. cylinders that weigh 800 pounds.
all around the world.”
Pure Manufacturing
Saf-T-Cart’s operations are aligned
with ISO 9001:2008, which ensures
its manufacturing quality, Herring
explains. “We are working on our 2015
standards now, which [will help] us
sell internationally,” he says.
“The main objective in ISO is to
keep your line pure,” he says, noting
that Saf-T-Cart serves many ISO cus-
tomers and regularly undergoes qual-
ity audits.
“We have them twice every year
to make sure we’re doing the things
we’re supposed to be doing,” he adds.
This reflects the company’s philos-
ophy, which focuses on standing firm
behind its products, Herring says.
“There’s quality in everything we do,
in each step of the [manufacturing]
process,” he says.
The company also backs its manu-
facturing processes with skilled em-
ployees. “The state of Mississippi has
workforce development that is better
than anywhere in the United States,”
he says.
In addition to offering classes at the
local community college, Saf-T-Cart
Not Cutting Corners

Saf-T-Cart answers the safety issue at manu-
facturing plants and construction sites with
its best-selling firewall carts, Jim Herring
says. “The carts incorporate a new lifting eye
and folded steel to meet the current OSHA
1910.253 standard concerning the separation
of oxygen from acetylene,” he says.
“Once our best-selling cart was a small
oxy/acetylene, two wheel product, now we
cannot build enough firewall carts to meet the
demands of the consumer,” he says.

South Saf-T-Cart
Quick and Versatile

Saf-T-Cart improves its clients’ operational efficiency with its pallet
trailers and trucks. “A palletized operation immediately boosts effi-
ciency by moving and storing cylinders in bulk for a quick turn around,”
it says.
“A palletized truck or trailer allows you to capture that same pro-
ficiency in a variety of ways,” Saf-T-Cart continues. “Though a pallet
trailer can be docked for single cylinder delivery, its ability to load and
unload from the side [makes] it the quickest and most versatile way to
deliver your cylinders.”
Although Airgas wanted more gas at its locations,

“They had more workman’s comps claims dealing with
these cylinders,” Herring says.
“They wanted us to see if we could figure out a way of tak-
ing a cylinder cart and lifting these large, heavy cylinders,”
he continues, noting that this led to the development of a
large, motorized vehicle.
Growing Further
Herring, who is Walker’s son-in-law, joined the company
in 1998. “He offered me the job after a 16-year career with
UPS,” Herring notes, predicting that family involvement
will continue. “People have asked me, ‘Aren’t you getting
ready to sell?’ But my father-in-law has 10 grandchildren
and some of them will want to get into the business.”
Herring adds that he is proud of Saf-T-Cart’s recent
growth. Although 2008 was a slow year for the company,
“It’s steadily grown from there,” he says, noting that the
company’s services have gotten better, as well.
He expects Saf-T-Cart to expand and add more innova-
tions like the motorized cart. “I see more market penetra-
tion with things like that,” Herring concludes. mt
All Covered
Saf-T-Cart offers Saf-T-Coat, a special coating that protects its
customers’ cylinders with a plasticized layer, instead of traditional
powder coated paint. “This plastic coating eliminates the damaging
metal-to-metal contact that typically damages [the user’s] cylinders,
significantly decreasing the amount of time they spend out of circula-
tion,” the company says.
“The Saf-T-Coating process ensures that [the] cylinders retain their
professional, pharmaceutical appearance by eliminating the scratching
and chipping that would otherwise wear them out,” Saf-T-Cart says.
“Additionally, Saf-T-Coating reduces the amount of noise a loaded cart
makes, ensuring quiet transportation through hospitals and labs.”
This makes it easier for clients to move their cylinders and maintain
their professional standards, the company says. “So whether [they]
need a small, two-cylinder stand or a portable, 50-cylinder rack, we’ve
got [them] covered,” it states.

ATC Automation
www.atcautomation.com / 2014 sales: Approximately $80 million / Headquarters: Cookeville,
South
Tenn. / Employees: 225 / Tony Green: “We excel at putting things together.”
Customized Quality
atc has excelled at providing its automation equipment
to fortune 500 companies. by alan dorich
atc produces machines for

the life science, energy,
transportation and
consumer products markets.
ATC Automation is in the busi- “From humble beginnings making ru- lives of the users, from life-saving
ness of fulfilling visions, Sales and dimentary/simple assembly stations, products used in surgery to the com-
Marketing Coordinator Tony Green the company grew to meet the market puter you operate to surf the web,”
says. “We have the ability and ex- demands supplying fully integrated Green says, noting that the majority
perience to take something from a ‘Factory Management Systems’ – sys- of its work is customized. “Rarely do
concept and make it a manufacturing tems that are comprised of multiple we build two of anything the same.”
reality,” he declares. machines as well as their information ATC is a “niche” leader among its
Based in Cookeville, Tenn., ATC systems that provide 100 percent re- industry peers, occupying a compa-
manufactures assembly and test au- al-time data.” ny size that differentiates itself in
tomation equipment. The company Today, ATC employs a staff of 225 service and support but is still of an
started operations in 1977 to supply producing machines for the life sci- organizational size that can meet the
solutions to manufacturing challeng- ence, energy, transportation and con- needs of its customers, Green says.
es for the automotive industry. sumer products markets. “We excel at In the company’s market, “You have
Over time, “Our business con- putting pieces together that become several large global integrators that
tinued to grow and evolve,” he says. transformational and integral in the produce complete factories, which

South ATC Automation
ATC Advantages
ATC Automation’s range of specialties includes fuel delivery in addition
to various other products. “As a leading manufacturer of automated
assembly and test fuel supply solutions, ATC provides customers with
a wide range of innovative assembly and test equipment that meet
unique product requirements and satisfy economic assembly factors
in the competitive fuel system market,” it says.
“From lean one-piece flow systems to high-volume lines, [custom-
ers] can trust ATC to provide [them] with an effective solution,” the
company continues. “ATC has extensive knowledge with fuel rail, throt-
tle body, fuel pumps, fuel filter, manifold and many other fuel delivery
device assembly and test systems. Many Tier I and II suppliers have
deployed our manufacturing solutions, utilizing the ATC advantage.”
ATC’s capacities also include rotary dial indexers. “Dial machines are
perfect when manufacturing floor space is at a premium,” the compa-
ny says. “ATC Automation’s customized solutions offer the speed and
accuracy necessary to successfully launch [the client’s] product in the
marketplace.”
is not ATC’s market. ATC fits within a market segment

that demands strong technical talent and experience but is
devoid of larger organizational constraints in terms of cus-
tomer service.
“ATC sets itself apart with its organization ‘team struc-
ture,’” Green says. “This business model is based around
small group dynamics and teaming with an increased reli-
ance on the talent that we have in-house. Through educa-
tion, training or recruitment, we choose to ‘grow it’ and
‘build it’ rather than contract it out.
“This is a key differentiator for our customers,” he says.
“As a result, most customers continue to come back again
and again. They really find value in the process and perfor-
mance after completing a project with us.”
In fact, approximately 80 percent of its business consists
of repeat clients, “which says a lot,” Green says. “We often
do not build duplicates of the same solution; every solution
is highly customized. The fact that our customers repeated-
ly come back to us signifies to me they are very happy with
the previous project we did for them; they know what to ex-
pect with ATC.”
Keeping Secrets
ATC’s customer base largely consists of Fortune 500 com-
panies, Green says. “About 60 percent of our business is for
transportation clients,” he says, noting that another 30 per-
cent is comprised of life-science customers. “The remain-
der is split up between energy and consumer products.”
He adds that ATC has earned a strong reputation for
its discretion when working under non-disclosure agree-
ments. “We have set up a specific portion of our facility for

ATC Automation South
‘top-secret’ types of projects that suppliers right now,” he continues. Another bright spot is that tradi-
are not ready to be released unto the “Today, we are challenged to find tional manufactures who previously
public yet,” he says. good people and skilled employees. left for low labor costs are returning
This results in the company be- Simply put, it is a good time to be in to North American manufacturing,
ing involved in the development of the automation industry.” he reports. “As a result of that,
new products. “We see it before it
goes out into the market,” Green
describes. “The clients want to keep
those methods and products pro-
prietary and intellectual property
non-disclosed.”
Good Times
2015 is looking to be another good
year. It’s also a good time for ATC to
be in the manufacturing business,
Green says. Things were tough “in
‘08 and ‘09, when we were clearly in
a very deep recession. Things were
very difficult, and survival of the fit-
test meant taking a number of differ-
ent types of projects that have since
led to innovation and new business
that was not [formerly] considered
by ATC. We fortunately had a lot of
life science business at that time,” he
recalls, noting that this helped ATC
build this market segment and in
fact contributed to ATC’s surviving
the recession. “The current trend is
that manufacturing has expanded at
double-digit growth year-over-year
since 2009.
“The current climate is that in-
dustry is investing and seeing com-
petitive value for releasing a number
of new products, as well as capital
spending. There is real pressure for
capacity utilization of automation
WEISS North America is a leading supplier of

mechanical and motion control automation components
to the automation industry. Since 1946, WEISS has supplied
the world with rotary indexing tables, palletized conveyors,
linear motor-driven pick-and-place units, cam- and ser-
vo-driven assembly chassis, ring index tables, and machine
bases and tool plates. WEISS is proud to have partnered
and supplied ATC for many years with our world class
solutions. WEISS’ innovative products complement the
high quality systems and solutions that ATC provides the
custom automation marketplace.

South ATC Automation
we have targeted certain compa-

nies that are bringing manufacturing
back,” he says, noting that ATC cur-
rently has projects in the electronics
and consumer products markets that
just a few years ago left the United
States. “Apparently, they are finding
out it is not as economical as it was
10 years ago to manufacture abroad.
Throw in transportation cost and
quality concerns, and it just makes
sense to ‘come home,’” he says.
The company is also getting more
requests for modular machines, atc has a self-contained
manufacturing process and
Green says. “Modular machines allow does primarily 80 percent of
its work in-house.
users to easily make changes when
technology updates occur or when “We get a lot of attention from tle inventory and rely on our suppliers
flexibility is required. For products them,” he continues, noting that Ad- to be on time and avoid costly carry-
that often have a short lifecycle due to vanced’s location and customer service ing costs,” he says. “Once it comes
technology advancements, flexibility is advantageous. “They have a good through the doors, it goes [straight
and reusability are a key part of the resident salesperson that offers quality to] the machines.”
planning process.” technical assistance to our engineers.”
This eliminates capital projects Making Art
that would otherwise be obsolete. Quality Control A longtime veteran of manufacturing,
Modular machines help ATC’s clients ATC has a self-contained manufac- Green joined ATC in 2007. After eight
avoid such a loss, since they are easily turing process, Green says. “We do years, he is proud of the company’s
modified. “You can pull out what you primarily 80 percent of all the work team. “We have some of the best tal-
don’t need any longer and replace it in-house,” he says, noting that the ent in the industry,” he declares.
with new technology that gives you company is vertically integrated in “They are just phenomenal, all the
the needed value or quality feedback machining, manufacturing, paint and way through the manufacturing pro-
required in today’s manufacturing en- welding facilities. cess, from the concept and the appli-
vironment,” Green says. The company focuses strongly on cations team that [does] the quoting
Modular machines have proven quality and has achieved ISO 9001: to the machine builders out on the
to be an especially strong source of 2008 certification. Although ATC’s floor,” he says. “They are able to take
sales for ATC, Green adds. “Some 75 customers dictate what a project what is a concept in a customer’s
percent of our business this year will should be, “We utilize what they have mind and transform it into a function-
be modular in nature that can be up- given us [and combine that] with our ing piece of art.”
dated and redeployed as needed in the own experience that we’ve gained ATC will continue growing, he pre-
future,” he states. over the years with our ISO proce- dicts. “We’ll also continue to support
dures,” Green says. our community, as well as the indus-
Strong Supplier The ISO procedures also come into tries that we serve in the U.S. [and] our
Contributing to ATC’s success are play when it comes to product flow global customers who expect us to be
suppliers such as Advanced Control and checks, Green says. “We use proj- there shoulder-to-shoulder,” he says.
Solutions, based in Marietta, Ga. ect scheduling software to make sure ATC will help its clients by devel-
“They’re a valued supplier,” Green that we hit the target dates,” he says. oping new technologies and methods
says. “We’re one of their biggest cus- ATC also utilizes ISO procedures of manufacturing “that they will take
tomers that utilizes their advanced for inventory. Thanks to these prac- back,” he says. “We’re kind of a prov-
vision controls.” tices, “We pretty much carry very lit- ing ground for a lot of people.” mt

Gerdau North America
www.gerdau.com/longsteel / Main office: Tampa, Fla. / Gerdau headquarters: Porto Alegre, Brazil
South
/ Employees: Approximately 8,400 / Specialty: Steel production and recycling
Win-Win Solutions
gerdau’s long steel business in north america sparks new innovations that
will bring benefits to the company and the customer. by alan dorich
gerdau is a leader in mini-

mill steel production and
recycling in north america.
After more than 110 years, Gerdau ica and one of the largest recyclers in a vertically integrated network of
stands as one of the world’s leading North America. mini-mills, scrap recycling and down-
suppliers of long steel. The company Currently, fourth and fifth gener- stream operations, the company
transforms millions of metric tons of ation members of the Gerdau family serves customers throughout the
scrap into steel every year. lead the company, which has 337 in- United States and Canada, offering
Gerdau started operations as a nail dustrial and commercial units. Gerdau a diverse and balanced product mix
factory in Port Alegre, Brazil, in 1901. has more than 120,000 shareholders of merchant steel, rebar, structural
Since then, the company has evolved and is traded on the stock exchanges shapes, fabricated steel and wire rod.
and established a presence in 14 coun- of Sao Paolo, New York and Madrid. Generally, Gerdau’s North Ameri-
tries, including the United States, can products are sold to steel service
Canada, Mexico, Brazil and Argenti- Working Towards Partnership centers, steel fabricators and original
na. Gerdau employs 45,000 people With a staff of approximately 10,000 equipment manufacturers for multiple
and has an installed capacity of more in North America, Gerdau is a leader industries, including non-residential,
than 25 million metric tons of steel. It in mini-mill steel production and re- infrastructure, commercial, industrial
is the largest recycler in Latin Amer- cycling in North America. Through and residential construction.

South Gerdau North America
Gerdau operates with a business

philosophy that is based on forming
long-term relationships with custom-
ers, suppliers and others that it does
business with.
“Our objective is to create an atmo-
sphere where our employees apply
their skills and energies to achieve
partnership with our customers,
shareholders, suppliers, the public
and each other,” says Carl Czarnik,
Gerdau’s vice president of human
resources for the company’s North
American business divisions. “We be-
lieve that this protects our own future
and creates opportunities for contin-
ued growth.”
The Right Combination

Gerdau’s long steel business division
in North America, with a main office
in Tampa, Fla., has recently com-
pleted several innovative initiatives
recently. This includes the introduc-
tion of GGMULTI, a multi-grade mer-
chant bar that satisfies 10 steel grades
the company’s egerdau platform
and standards and is designed for provides customers with easy
access to information specific
high-performance applications. to their needs.
“Our customers will see a more con-
sistent product with predictability and sistent mechanical properties with ers. “With the eGerdau platform,
flexibility with GGMULTI,” says John minimum carbon content will im- customers have an abundance of cus-
Coll, vice president of sale and mar- prove fabrication processes, such as tomer-specific information at their
keting for Gerdau’s long steel business shearing, punching and bending. fingertips,” says Scott Meaney, Ger-
division. “By combining several grades GGMULTI also has improved dau’s director of marketing for its
into one, we’re able to reduce overall weldability, a result of lower car- North American long steel business.
inventory, so it’s a win-win.” bon equivalent (CE). This lower CE “They have the ability to search for
The product has restrictive alloy is value-added in situations where product availability by size, type and
ranges, which assure mechanical and steel bars are welded together such as mill location, as well as consult cur-
ductility properties will be more con- pre-engineered buildings. rent and future rolling mill schedules,
sistent. GGMULTI also has tensile GGMULTI’s tight process controls pace and review orders, check ship-
ranges of 70,000 to 80,000 pounds result in very consistent tensile and ments and consult financial state-
per square inch (PSI) for flats and yield strengths, which makes formabil- ments,” he continues.
65,000 to 80,000 PSI for shapes. ity and spring-back more predictable. In addition to bringing multiple
These ranges result in consistent benefits to the customer, eGerdau
mechanical properties compared to At Your Fingertips also benefits the company by saving
the individual specifications. The car- Gerdau also launched eGerdau, an time throughout the sales process.
bon maximum of 0.22 percent assures e-commerce platform that brings “The tool saves both parties time,
better steel ductility. Achieving con- technology enhancements to its us- increases customer engagement,

South Gerdau North America
gerdau completed a $60

million project to replace the
continuous caster at its steel
mill in st. paul, minn.
downloads and retrieves custom- Phase two of eGerdau will launch which features 100 percent sub-
er documents and facilitates an ease later this year. It will include such fea- merged nozzle casting, hydraulic
of doing business,” Meaney explains. tures as a dashboard, which is a cus- oscillators for better surface quality
“The tool is easy to navigate, and tomizable homepage with custom- and three-point unbending to pre-
customers are able to customize the er-specific information, increased vent cracking. The company also has
views and searches based on their de- functionality to search capabilities, a quality assessment in real time sys-
sired level of information.” the ability to create orders from roll- tem, which tracks every five inches of
Other eGerdau benefits include ing schedules, historical shipment the billet cast.
daily news, and updates about Ger- information, user preferences, notifi- Before the new caster was commis-
dau products and services. The goal cations, market reports and more. sioned, the mill manufactured hot
is to get the customers the informa- rolled rounds for multiple industries,
tion first. Reaching Higher Levels including construction, forging, min-
The application gives the compa- Last year, Gerdau completed a $60 ing, farm equipment and wind power.
ny’s sales team more time to manage million project to replace the contin- The new caster added aluminum grain
customer accounts because the tool uous caster at its steel mill in St. Paul, refining capabilities and allows for the
supports the operational aspects of Minn. The project was part of an ef- production of more specialty carbon,
the sales process. “The Gerdau sales fort to raise productivity and signifi- alloy and high-strength low-alloy
team is able to spend more time im- cantly increase quality levels for the steels used across many industries.
proving the process, increasing cur- engineered steels that are manufac- The project was well-received lo-
rent customer experience and en- tured in St. Paul. cally, as well. It received strong sup-
gaging new potential customers,” Gerdau implemented a four-strand port from the Minnesota Chamber of
Meaney says. Danieli billet caster at the location, Commerce and the company was of-

Gerdau North America South
fered state and local incentives from

the state of Minnesota, the city of St.
Paul and the St. Paul Port Authority.
Gerdau also formed an agreement
with Xcel Energy that will help the lo-
cation stay competitive.
The caster represents the mill’s first
step in manufacturing higher-end
products. “As the caster reaches full
production, we will see increased
quality of products,” says Rogerio
Turatti, Gerdau’s vice president and
general manager of the St. Paul mill.
“As we expand and develop the oper-
ation, we will see our product offering
increase, and the mill’s focus turning
more to specialty carbon steel.”
gerdau’s north american
capabilities include rebar
fabrication for clients’
Rebar Excellence demanding projects.
Gerdau’s capabilities in North Ameri-
ca include rebar fabrication, for which “Epoxy-coated reinforcing steel sion-bonded epoxy coating plants.
it pools together its physical and peo- typically protects structures subject The CRSI Epoxy Coated Plant Certi-
ple assets; including sales, estimat- to deterioration from salt-induced fication Program sets high standards
ing, and CAD detailing capabilities corrosion,” Diggs says. “The bars are for quality and consistency in the ep-
as well as its fabrication and delivery coated and fabricated in compliance oxy coating and handling of reinforc-
resources for completing demanding with exacting specifications of all fed- ing steel.
projects while also keeping its cover- eral and state highway agencies and all These high standards assure that
age personalized in local markets. other regulatory bodies.” the epoxy-coating reinforcing steel
“This flexibility enhances our abil- Gerdau participates in the volun- bought from Gerdau meets the most
ity to adapt to fast-paced changes in tary certification program for fu- demanding specifications. mt
our industry and on the client’s job
site,” says Pete Diggs, vice president
of reinforcing steel for Gerdau’s long A Green Opportunity
Gerdau takes part in environmental initiatives, such as partnering with Summerhill Impact and other organi-
steel business division. zations to transport end-of-life vehicles from Northern Canada. Gerdau delivered the vehicles to its recycling
Gerdau’s vertically integrated mod- operations in Whitby, Ontario, in October 2014 and the materials were subsequently shredded and melted at
el includes steel manufactured at its its steel mill.
own mini-mills. “Manufacturing the The project, known as Tundra Take-Back, encouraged environmentally sustainable recycling practices in
Canada’s northern region. “A total of 80 vehicles were depolluted and prepared for shipment south to the
steel we fabricate enables us to main-
Gerdau Whitby facility,” explains Bob Downie, regional environmental manager at Gerdau. “Due to a shortage
tain extremely high levels of quality of sea containers, only 10 end-of-life vehicles were shipped to the mill in 2014, and the rest will follow when
control, from the plant furnace, to containers become available.
the fabricating plant, to the jobsite,” “To prepare for the recycling process, they were decommissioned of large amounts [of] fuel, mercury,
batteries, windshield washer fluid, antifreeze, tires and other ozone-depleting refrigerants were removed,
Diggs continues. “This start-to-finish
packaged and safely shipped to recyclers in the Montreal area,” he adds.
accent on quality is the customer’s “Though Gerdau usually sources recycled scrap metal within a 200-mile radius of its steel mills, this project
assurance of the best fabricated steel was a great opportunity to contribute to clean up in the North.” Downie says. “We are pleased to be able to
products available.” contribute to this important initiative, and demonstrate our commitment to sustainability.”
The Tundra Take-Back project resulted in the development of a community-led model for ongoing waste
The company can deliver fu-
management in Canada’s North. This environmental initiative not only helps to protect the area’s water quali-
sion-bonded epoxy coating as a pro- ty, but improves local capacity for ongoing pollution prevention.
tective coating for reinforcing steel.

Atlas Machine & Supply Inc.
www.atlasmachine.com / HQ: Louisville, Ky. / Employees: Approximately 210 / Dennis Hanna,
South
VP and GM: “We can supply a repair part faster in most cases than an OEM can get it for you.”
Up to
the Test
atlas machine says it has
never failed when meeting
its clients’ challenges.
by alan dorich
Some companies achieve growth
through acquisitions, but Atlas Ma-
chine & Supply Inc. does it by “listen-
ing to our customers and developing
solutions to meet their needs,” Presi-
dent Richie Gimmel says. “As long as
they keep having new problems, we’ll
have new ways to grow.”
Based in Louisville, Ky., the firm de-
signs, repairs and remanufactures a atlas’ customer base
includes steel mills, power
wide variety of industrial equipment plants and heavy equipment
manufacturers.
including air compressors, gearbox-
es, punch presses, steel mill rolls, shops and service centers in Louis- 1958. “Dick probably had as much to
rock crushers, construction vehicles, ville; Cincinnati and Columbus, Ohio; do with building what we are now
fluid-cooling systems and vacuum and Indianapolis and Evansville, Ind. as much as one person could,” the
pumps. A group of machinists started In addition to its machining business, younger Gimmel says.
Atlas in 1907 as a manufacturer of cus- Atlas is an authorized distributor and “He’s the real icon of this place,” he
tom freight elevators. service provider of Gardner Denver continues. “A lot of the people that
In 1925, ownership passed to the air compressors. are running the business today were
family of its superintendent, Rob- Atlas’ customers include steel brought up by him. He led the compa-
ert N. Gimmel. Under his leader- mills, power plants and heavy equip- ny into what we are today, which is an
ship, “We started working on Model ment manufacturers. “We touch the industrial service firm.”
T and Model A engines for Ford,” power generation, oil and gas, heavy Hanna also credits its staff and its
Vice President and General Manag- equipment, rock crushing, steel and ability to adapt to the ever-changing
er Dennis Hanna explains. “At the aluminum [markets],” Richie Gim- needs of customers who ask it to keep
time, spare parts and service weren’t mel says. them running. “We’re constantly try-
much of a focus for the automotive The company also serves the auto- ing to be what we call ‘the industrial
manufacturers.” motive industry, working for many of fire department,’” he says.
Atlas repaired the engines and the top brands. “We also do work for “Most of the calls we get are when
manufactured the components. a lot of their suppliers,” he continues. they’re in a hurry,” Hanna continues.
“That lasted into the ‘50s, until when “Those are often where the products “We pride ourselves on our ability to
we started working on construction are actually manufactured.” change and adapt.”
equipment and getting into heavy in- Gimmel agrees, adding that its
dustry, which is what we’re in now,” Company Icons employees have the ability to think
he says. Gimmel credits Atlas’ success to the on their feet. “We’ve got really good
Today, Atlas employs a staff of work of his grandfather, Dick Gim- machinists, grinders and welders,”
approximately 210. It has machine mel, who took leadership of Atlas in he states.

Atlas Machine & Supply Inc. South
On the Upper End at your compressed air system and ways tomers better than a standard quality
Atlas strives to be on the upper end of it may be operating inefficiently.” system,” Hanna says.
quality and service, Gimmel says. “Giv- Compressed air is considered a utility This includes checks and double
en our capabilities and our ability to turn for its customers. “So much of the equip- checks of every item on a repair report.
jobs around quickly, we feel like we are ment in a manufacturing plant runs off “We certify the inspection and the quali-
the best value for a plant that needs to compressed air, customers are unable to ty of the part we repair,” he says.
keep its operations functional.” run their plants if there is a problem with Additionally, “We do have some
Hanna agrees. “We can supply a repair their system,” Gimmel states. customer-driven quality programs,”
part in most cases faster than a customer Gimmel adds. “Our system is flexible
can source a spare part,” he says. “That’s Keeping Industries Running enough to allow work for a company’s
actually key to why people come to us. Atlas has implemented its own quality specific needs.”
They know we can get them out of a jam assurance program, which it designed The company also sharpens its em-
in a hurry and get them up and running.” around ISO principles. “It fits our cus- ployees’ skills. “We do constant train-
This is especially true of the compa-
ny’s compressed air division, Gimmel Midwest Metals Corp. views every relationship as a long lasting partnership; with the sharing of knowledge and experi-
ence each partner becomes successful. Midwest Metals takes pride in our relationships with companies like Atlas Machine.
says. Not only does Atlas sell and service Midwest Metals brings an accumulation of 70 years of involvement with Scrap Mills, Scrap Yards and Manufacturing
compressors, “We also do design and Companies.
Our customers, like Atlas Machine, benefit from our experience, providing them with market analysis to help minimize their
optimization,” he says. risk and maximize their rewards on the recycled scrap generated.
“We’ll go out and do air audits in Referrals are the greatest compliment you can give in a service industry. Thank you, Atlas Machine, for recognizing the
importance of our partnership in business. We owe it to our customers to be the best when it comes to service!
plants,” Gimmel continues. “We’ll look

South Atlas Machine & Supply Inc.
ing across the board, from the people in the office to the
management people on our floor,” he says, noting that it
provides safety and management training.
The hard work has paid off. “There’s never been anything
brought to Atlas that we couldn’t provide a solution for,”
Hanna says, noting that he is proud of the company.
“We see those daily accomplishments,” he states. “We can
be proud of the fact that there’s a lot of industries running
today because of the efforts of Atlas Machine & Supply.”
Gimmel agrees. “I feel a sense of pride working with the
people we have here,” he says. “It’s an honor to represent all
of the wonderful people on our team.”
Growing its Own

Atlas is coping with the challenge of recruiting skilled work-
ers. “We’ll watch the news and see that there’s a shortage of
jobs in the country, but meanwhile, we can’t find the people
we need to find,” Gimmel says.
“There’s a misalignment of the jobs that are available and
the skills of the unemployed workforce,” he continues. “We
can’t find people with machining experience. The wages we
have to pay these folks also are growing exponentially.”
Atlas has proactively reacted to the problem with an ac-
credited apprenticeship program for skilled machinists and
compressor technicians, Hanna says. “We grow our own be-
cause in the past, the only way to get skilled people was by
training them,” he says.
“We’re also heavily rooted in the vocational schools and
colleges around the area,” he continues. “We try to get the
best talent from those schools. When they’re done [with the
apprenticeship], they’re making [up to] $70,000 a year.”
However, this can only take the company so far, since the
training process can be time consuming, Gimmel admits. “I
think that this problem is going to be a bottleneck for us,”
he says.
“If you look at the way it’s trending, we’re going to hit
a wall if we’re not already there,” he says. “So we’ve got
to find some [more] ways to deal with that. We’ll have to
look at things like a way to increase the output of the peo-
ple we support via technology. We are doing this currently
through investing in more efficient equipment, adopting
lean manufacturing principles and automating our pro-
cesses where possible.”
Family Benefits
Atlas is a family-owned and operated business, which al-
lows it to work “with the long-term in mind,” Richie Gim-
mel says. “We don’t have pressure on us to post impres-

Atlas Machine & Supply Inc. South
sive numbers to shareholders each quarter. We are driven

by a sense of stewardship to our employees and custom-
ers and we can focus on doing our best to do right by them
each day.”
With that approach, Atlas has made sure to prepare for
the future. “One hundred percent of our profits are rein-
vested back into it,” he says. “Either we buy equipment or
do research and development with it.
“The goal of the business isn’t to make as many dollars as
we can today,” Gimmel says. “It is to be a healthy business
over the long term.”
The family ownership has nurtured loyalty from employ-
ees, including Hanna, who has been with Atlas for 35 years.
“It’s more of a family than a business,” he says.
“The owners actually care about the people that work
for them,” Hanna states. “They cultivate careers and lives.
They’re interested in people.”
Evaluating Opportunities
Atlas will continue providing new innovations to its cus-
tomers, Gimmel says. “Our growth is going to come from
staying tuned into our customers’ challenges and working
with them as a partner.
“We also have to take a look at expanding the products
we distribute and expanding the geographical footprints we
have,” he says. “I could see some potential acquisitions for
us if the right opportunity came along.”
The company also might add space to its main headquar-
ters in Louisville, Gimmel adds. “We’re getting to a point
we’re about up against the wall, so we need to be thinking
about some expansion of this facility,” he says. mt
atlas machine takes pride in
the numerous solutions it
has provided for its clients
as a result of its hard work.

TSC Corp.
www.t-s-c.com / Headquarters: Houston / Employees: 50 / Specialties: Offshore and onshore
South
drilling equipment and services
Here to Stay
tsc corp. expanded its capabilities with its new
4f facility in Houston. by alan dorich
tsc corp. provides equipment for

offshore and onshore drilling.
Flexibility has been key for TSC Over time, “We started to slowly as Transocean, Ensco and others,
Corp. as it serves its clients, Vice Pres- expand and grow our product offer- Smith says. Its customers frequently
ident Charles Smith says. “We are tru- ing,” Smith says, noting that TSC require financing assistance, which
ly a solutions-driven company,” he Group moved into drilling rig com- TSC Corp. is happy to provide or in-
says, noting that it specializes in of- ponents. “We also added engineering troduce the parties.
fering custom products and services and manufacturing out of the Unit- “[We’ll] say, ‘We know you want a
to the drilling sector. “We don’t nec- ed Kingdom and the United States rig, but you don’t quite have the mon-
essarily have a fixed basket of goods.” through some acquisitions.” ey,’” Smith describes. “‘We can sell
Based in Houston, TSC Corp. pro- The company formed TSC Corp. you the rigs or you can do an off-bal-
vides equipment and services for in 2008. Today, it serves an onshore ance sheet transaction to lease these
offshore and onshore drilling. Its client base of small- to middle-ti- rigs for a couple years.’”
parent company, TSC Group Hold- er operations that typically have TSC Corp.’s onshore clients, he
ings Ltd., started operations in 2001 fleets of two to 10 rigs as well as notes, typically do not have the large
as an electrical components compa- offshore clients ranging from small cash reserves of many majors, such
ny in Xi’an, China. to the largest in the industry, such as Nabors or Trinidad Drilling. How-

TSC Corp. South
ever, “We try to give them a rig and a financing solution former that allows us to do a lot of the testing right here
that can help them compete and grow their company,” in our facility, if the client requires.
Smith states. “It provides a more comprehensive and flexible solu-
TSC Corp. also makes sure to put itself in its clients’ tion to our clients,” Smith continues. “We can handle
shoes with each of its services, he adds. “That creates a more of the work in-house, allowing us to manage proj-
customer for life,” Smith says. “Those are the rewards for ects more effectively, while saving our clients money.”
the company.”
Built Around Quality
Going On-Land TSC Corp.’s focus on manufacturing quality recently
Smith joined TSC Corp. in 2011 after working on the off- earned its 4F and 7K monogram certification from the
shore contracting side of the business with Noble Corp. American Petroleum Institute, while maintaining its
and Hercules Offshore Inc. On-land equipment and ser- Q1 and 2C monogram. “The way we maintain quality is
vices are new for both Smith and the company, which is at by having well-trained people that not only care about
work growing its land rig business. the job, but the success of the company,” Smith says. “It
“We have some designs of fast-moving rigs, both for makes them focused and want to do their job.”
conventional drilling and unconventional drilling,” he The company also employs an experienced staff, includ-
describes, noting that TSC Corp. is working to have one ing a QHSE manager who carries nearly 20 years’ experience
finished sometime by the end of this year. in manufacturing. “When you build your system around
Although the offshore side of the business tends to be seasoned, quality people and you treat those people right
more sophisticated, “We tried to take that [same] focus then that system has a very hard time failing,” he says.
and mentality and use it to enhance the land rig design,”
Smith describes. “We wanted to make it more lean, effi-
cient and technologically savvy.”
This will help TSC Corp. compete against the products
offered by competitors such as Drillmec International
Ltd. and NOV. “We think our rig is better and more effi-
cient, and we can meet the price points that our clients
are looking for,” he says.
However, “The unfortunate ups and downs of the in-
dustry have slowed down what would have been a banner
year in our progress,” he admits. “But we are still pushing
very hard to grow this year and be profitable.”
“We think it’s very possible and achievable to begin
work on multiple land rigs this year,” he says.
An Enhanced Presence
TSC Corp. recently acquired a new 53,000-square-foot
facility in Houston. With the location, “We are establish-
ing a much more robust service presence,” Smith says.
“We are here to stay.
“We can offer a lot of value to our clients by giving them
a flexible option to fabrication, whether it’s onshore or
offshore products and services,” Smith says, noting that
the facility features 80 tons of overhead crane capacity
and five acres of stabilized backyard.
“This manufacturing facility gives us a lot of space to
handle a variety of manufacturing and service-related
projects,” he says. “We also installed a very large trans-

South TSC Corp.
the company says it is

concentrating on lean
manufacturing as a way to
improve efficiency.
TSC Corp. also focuses on con- to day-to-day dealings with their em- conservation of cash and reduction of
tinuous improvement. “We monitor ployees, but we take a much more per- capital projects,” he says.
our productive and non-productive sonal and family oriented approach. “It’s forced us to be flexible, which
time,” Smith says. “We also do les- “I try to get to know the people is what we’re good at, and look at oth-
son-learned meetings to understand around me,” Smith says, noting that er parts of the industry to do work,”
where we have failed to improve, as he often takes employees and their Smith continues. “It’s also opened
well as where our successes are and families out to dinner. “We get to more doors for us to get in and take
how we can repeat those. know each other so we can know our some of the marketshare from some
“Lean manufacturing is certainly own strengths and weaknesses. of the bigger boys that don’t want to
what we’re striving towards,” he says. “Once [a job] becomes more than reduce their rates.”
“Certainly, when we get our ERP sys- just a paycheck, you begin to care TSC Corp. will continue growing
tem in place in the coming months, more about the organization and its in these lean times, Smith predicts.
that is going to be the basis of what success,” he says. “You’re willing to “I truly feel we are going to have our
we’re going to use for our manufac- work hard to ensure that success. best year ever this year in an other-
turing process.” That’s what I’m most proud of: the wise extremely disappointing and
people at this organization and how disastrous year for some of our com-
Getting Closer hard they work.” petition,” he says.
Smith takes pride in TSC Corp. and its “We’re going to grow marketshare
staff. “There’s a lot of investment and Best Year Ever this year,” he says, noting that if oil
time spent in growing and developing Current oil prices have impacted TSC prices rise, TSC Corp. will grow.
our people,” he says. “Some organi- Corp.’s client base, Smith says. “They “We’re hoping TSC Group Holdings
zations are very rigid when it comes have caused an amazing amount of will see $1 billion by 2017.” mt

Nailor Industries Inc.
www.nailor.com / Headquarters: Houston / Annual revenues: $100+ million /
South
Specialty: Commercial HVAC air control and distribution products / Employees: 1,200
In Control
nailor industries uses its clients’ hvac system
needs as a springboard. by barbara mchatton
When the company was estab-
lished in 1971, Nailor Industries
manufactured one air control device.
Today, the company’s considerable
growth has positioned it as a major
manufacturer of air control and dis-
tribution systems that are sold all
over the world.
“Our product line currently con-
sists of more than 1,200 products,”
asserts Julian Rochester, Nailor’s vice
president of marketing. “We are a
market leader in the HVAC industry.”
The company has 10 plants total-
ing more than 800,000 square feet of
manufacturing space. Distributing its
products worldwide, Houston-based
Nailor also has facilities in Las Vegas,
and Toronto and Calgary, Canada.
The company operates in the Unit-
ed Kingdom as Advanced Air (UK)
Ltd. Nailor boasts an international
distribution network, “[that works]
together to not only meet but exceed nailor industries says it has
been recognized as the leader
the expectations of clients, engineers in developing innovative new
technologies.
and customers around the world,” the
company says. However, what sets this company products’ energy performance, low-
Nailor offers a wide variety of apart is its technology advancements. flow and dynamic wind tunnels, and
air-handling units, fan coil units, According to COO Steve Nailor, his a mockup facility. “We’re a very mar-
variable air volume (VAV) terminal company is considered the industry’s ket-driven company,” Nailor asserts.
units (commonly referred to as VAV technology leader. “At our Houston “We listen to what our clients need
boxes), grilles, diffusers, life safety facility, about 40,000 square feet of both from a performance perspective
dampers and louvers, as well as elec- our manufacturing space is set aside as well as aesthetically.”
tric duct heaters, under-floor air dis- for research and testing laboratories,”
tribution (UFAD) and displacement he says. “We have the ability to fully Product Innovation
ventilation systems for the com- test our products under actual oper- Nailor pioneered the use of electron-
mercial HVAC market. Operating ating conditions.” ically commutated motors (ECMs)
with state-of-the-art manufacturing Nailor’s research, development for the commercial HVAC market.
equipment, including laser machines and testing laboratory includes a re- The ECM is an ultra-high-efficiency,
and robotic brakes and welders, en- verberant sound room to test prod- programmable, brushless DC motor
sures high quality in the company’s uct noise levels, an environmental that is used in air terminal units. Pre-
finished manufactured products. room and a curtainwall facility to test vious to this innovation, the single

South Nailor Industries Inc.
air-moving systems that mitigate

germs and minimize the risk of surgi-
cal site infections (SSIs) due to bacte-
ria in the operating rooms. The com-
pany created an advanced air-moving
system called the Steri-System Hos-
pital Operating Room Air System,
which is comprised of two major
components: linear slot diffusers and
laminar flow diffusers.
Linear slot diffusers, which are lo-
cated around the perimeter of the op-
erating room, are used to create a con-
tinuous curtain of air that is angled 5
to 15 degrees outward. This airflow
creates a curtain that encloses the op-
erating area, thus minimizing the risk
of contaminated air entering the sur-
gical area. “The laminar flow diffusers
are installed above the operating ta-
ble,” the company describes. “These
produce a low-velocity, non-aspirat-
ing vertical air pattern that allows
nailor industries developed clean, conditioned air to flow over the
a custom system for the new
exxon mobil campus being operating table and greatly increase
built in houston.
the ventilation rate within the surgi-
speed permanent split capacitor preventing smoke from permeating cal area.”
(PSC) induction motor, combined into other areas of a building in the “The air enters the room clean,”
with an electronic silicon controlled event of a fire.” Nailor asserts. “As low-velocity air
rectifier (SCR) speed controller, was Hospital projects re- flows over the patient, it’s drawn
used, which proved to be very ineffi- quire the use of away, keeping the patient as
cient. Whereas the PSC motor effi- germ-free as possible.”
ciency ranged from 12 to 45 percent, The company was
ECMs maintain a 65 to 72 percent
efficiency at all speeds. Nailor also
maintains that the ECM uses one-
third of the energy needed to power
the PSC systems.
Another product born of Nailor’s
expertise was a UL classified combi-
nation fire/smoke damper that could
also meet stringent European build-
ing codes. “Most damper blades, par-
ticularly at elevated temperatures
under fire conditions, can separate
leaving up to a 3/4-inch gap,” Nailor nailor industries pioneered
the use of electronically
commutated motors in its
says. “We created a damper in which hvac units.
the blades could interlock, thereby

Nailor Industries Inc. South
also instrumental in developing a VAV system for the Exxon

Mobil Campus, which is currently under construction on a
385-acre parcel in north Houston. The 20-building campus,
which will achieve LEED gold certification for sustainable
energy efficiency, is one of the largest commercial construc-
tion projects underway in North America. It will consist of
“multiple low-rise office buildings, a laboratory, conference
and training centers, and facilities such as child care, a well-
ness center and other employee amenities,” the client says.
Nailor was assigned the task of developing a custom
UFAD system. This air handler configuration consists of
custom-designed vertical air column units and VAV ECM
fan booster boxes feeding perimeter linear convection
heaters and high induction floor swirl diffusers in the interi-
or that will be installed under the floors. The floor diffusers
allow personal control at each workstation. Designed as a
partially stratified one-pass system, the air enters the room
at floor level, mixes rapidly and rises slowly upward, exiting
at ceiling level. Occupied comfort in the space is high with
low average room air velocities of 20 to 30 feet per minute.
This high-performance system is designed to significantly
reduce the central air-handling energy required to deliv-
er cooling to the occupied space. In addition, the one-pass
system will improve indoor air quality (when compared to
traditional overhead full mixing air distribution systems)
by helping to carry illness-causing germs upward instead of
across the room This, in turn, will reduce the spread of in-
fection among building occupants, thereby improving both
employee health and productivity.
Nailor states that the company’s biggest asset is its em-
ployees. “I’m proud of all of the people here,” he says. “We
have many long-term employees who have helped the com-
pany grow.” mt
the company says its diffusers

are often utilized in health-
care settings where air needs
to be kept clean.

Air Relief By Gardner Denver
www.airrelief.com / HQ: Mayfield, Ky. / Employees: 40 / Specialty: Service of air compressors /
South
Murray Raetz, general manager: “We’re committed to providing our customers air for life.”
ry focuses since joining the company

a year-and-a-half ago. In January 2014,
Air Relief launched a new website,
inbound marketing and use of social
media blogging on its Facebook and
LinkedIn pages. The inbound market-
ing effort has seen enough of a spike in
business to offset its cost.
The company’s twice-annual train-
ing seminars, held at the Mayfield
facility, have also been reformatted
into “customer appreciation days,”
as Raetz calls them. At events taking
place over three days, clients receive
extensive training on air compressors,
such as techniques to prevent un-
scheduled shutdowns and mechanical
assembly and disassembly. “We’ve es-
tablished ourselves in the compressed
air community as an expert compres-
air relief is known as the
no. 1 service and repair
sor service and repair organization,”
supplier in the air compressor
market, the company says.
Raetz says.
Air Powered High-End Capabilities

Most of the centrifugal compressors
Air Relief’s technicians work on are
compressor service company air relief marks between 500 and 5,000 horsepow-
er, according to Raetz – equipment
three decades in operation. by tim o’connor large enough provide air to large
manufacturing and aerospace testing
Mayfield, Ky., has long been home ed by servicing Ingersoll Rand Cen- facilities. To keep pace with the tech-
to a number of air compressor manu- tac centrifugal compressors but has nological demands of customers, Air
facturers and servicers, but within the since branched out to repair multiple Relief recently invested $300,000 to
so-called “Mayfield Mile” few compa- brands, including Cameron, Cooper, purchase a coordinate-measuring
nies have as much to offer as Air Relief Joy, Atlas Copco, FS-Elliott, Clark Iso- machine from German manufacturer
Inc. “We’re known as the No. 1 service pac and Worthington. Zeiss used to better inspect machined
and repair supplier in our industry,” Air Relief’s operations have grown components for centrifugal compres-
says Murray Raetz, general manager alongside its service business. The sors. Gardner Denver also supplied
of sales and operations. company designs and manufactures a 30-ton-capable hoist that allows
Now celebrating 30 years in busi- its own control systems (TurboLogix. workers to easily lift heavy equipment
ness, Air Relief’s equipment invest- com), intercoolers and provides its and repair it at the Air Relief facility.
ment and expertise enable the compa- own compressor lubricant CenLube This equipment has opened up new
ny to test and service air compressors 32. Air Relief’s customer base spans opportunities for the company, such
capable of 5,000 horsepower, enough much of the globe. as the recent performance test it ran
to power a community of 5,000 people. on a 2,500-horsepower compressor
Air Relief was founded in Mayfield Reaching Customers for a major American manufacturer.
in 1985 and was purchased by Gardner Enhancing Air Relief’s reach in the in- Air Relief provides service to approx-
Denver in 1999. The company start- dustry has been one of Raetz’s prima- imately 2,500 companies. Raetz de-

Air Relief By Gardner Denver South
scribes it as a low-volume, high-mix ser- available when the customer’s need aris- compressor and make adjustments to
vice and repair industry because many es, with technicians flying or driving to its operation if necessary. ”Utilizing our
clients may go years before needing an client’s sites even on short notice. The in-house expertise remotely provides
air compressor repaired. quick turnaround can ensure equipment our customers with a maintenance ad-
is running again within 24 to 48 hours. vantage unmatched in the industry. We
Maintaining Quality Remote monitoring technologies are like to call our remote access capability
But that low volume speaks well of Air allowing Air Relief to take that speedy ‘boots in the air,’” Fisher says.
Relief’s work in keeping centrifugal response time to another level. “The In- Those in the manufacturing indus-
compressors maintained properly. Ev- ternet provides our engineers the abili- try know that dependable air is vital to
erything the company ships carries an ty to monitor, diagnose issues and tune their operation. To ensure that need is
18-month warranty, though some equip- TurboLogix systems from anywhere in met, Air Relief goes beyond the typical
ment can last as long as 12 years, accord- the world,” says Joel Fisher, manager of extended warranty through the com-
ing to Raetz. Most technicians hired engineering and quality. pany’s “Air For Life” service. The pro-
are certified by the original equipment If one of those monitored levels is gram is akin to an insurance policy for
manufacturer and all technicians are trending in the wrong direction, an an air compressor. If the machine breaks
OSHA certified, ensuring quality service email can be automatically be sent to the down, Air Relief will service and repair
& repair of every item, to every custom- client warning them of the possible mal- the equipment, or possibly even replace
er, every time. This attentiveness is fur- function, even in the middle of the night. it. “We’re going to commit to providing
ther reflected in Air Relief’s response Back at Air Relief, employees reviewing you air for the life of your compressed
time. The company prides itself on being the data can communicate with the air needs,” Raetz says. mt

Bullfrog Spas
www.bullfrogspas.com /Headquarters: Bluffdale, Utah / Employees: 150 / Specialty: Spas /
South
Jerry Pasley, president and CEO: “We strive to achieve best-in-class in customer experience.”
Innovators of Luxury
bullfrog spas’ focus on customer value and finances allows it
to continue introducing appealing products. by jim harris
bullfrog spas’ patented jetpak For Bullfrog Spas, ensuring that its
technology allows its hot tubs
to be customized to meet the products meet the needs of its cus-
needs of individual customers.
tomers is of equal importance to its
bottom line. “The way we approach
business is somewhat unique in our
industry, in that we place weight on
the financial perspective as well as
making sure we hit the customer val-
ue proposition,” says Jerry Pasley,
president and CEO of the Bluffdale,
Utah-based company. “Most compa-
nies maybe focus just on profitability,
but we believe in framing that equal-
ly with customer value and building
plans accordingly.”
The company’s strategic approach
to the luxury hot tub products it man-
ufactures and markets keeps both
Bullfrog’s dealer base and end-user in
mind. “We strive for a customer expe-
rience that is best-in-class,” he adds.
“We look at our dealers and end-users
as business partners and not just as
customers.”
Products are designed with cus-
tomers and manufacturability in
mind. “We do our best to identify
what our consumers’ needs are and
design for eye appeal as well as func-
tionality, so the consumer experience
is paramount,” Pasley says. “We’re
constantly coming to market with
innovative new products in terms of
design and technology.”
This approach to business has al-
lowed the company to continue to
grow in a luxury market dependent
on discretionary spending. “For most
consumers, a spa is on the top-10 list
of items they’d love to have but won’t
necessary run out and spend money

South Bullfrog Spas
in plumbing decreases water friction

in the plumbing system, enabling a
more powerful spa. This reduction
in plumbing and the location of the
H2Air manifold in the spa’s water also
make Bullfrog Spas the most ener-
gy-efficient in the spa industry. Fur-
thermore, because there are few, if
any, holes drilled into the seatbacks,
Bullfrog Spas are virtually leak-proof.
Users can choose from 16 different
JetPak configurations allowing them
to completely personalize their mas-
sage experience. “The patented Jet-
Pak system really differentiates us in
the market,” Pasley says, “This tech-
nology allows the consumer to cus-
tomize the product, yet still allows us
to operate our plant in an efficient and
effective manner.”
All Bullfrog spas are supported by a
molded ABS plastic structure, dubbed
the EnduraFrame, which is made
without wood or metal, so it will not
rot or corrode. A molded base has
bullfrog spas ceo and president three convenient electrical chase-
jerry pasley says the company is
committed to manufacturing its ways, a retractable exterior drain for
products in the united states.
easy access, and a rodent screen to
on,” he adds. “It’s our job to move the then-existing hot tub technology, keep out unwanted visitors.
that up the list.” Ludlow rethought the entire hot tub The base supports a series of in-
system itself. If leaks occur in pipes jection-molded Z-beams that create
Unique Technology and because of perforations in the an exact connection between the
The company’s focus on design and in- hot tub, the elimination of that infra- base, shell and cabinet. These injec-
novation extends back to 1989, when structure would help to eliminate the tion-molded components are stron-
founder and inventor David Ludlow leaks themselves. Ludlow created an ger than a traditional wood struc-
set out to create the world’s first leak- entirely new technology that reduces ture and will last much longer than a
proof hot tub. Instead of working with pipe and pipe fittings by up to 90 per- metal frame that can rust. The laser
cent, which today is called the JetPak precision process used to create each
Diversified Machine Systems (DMS) designs and Therapy System. Bullfrog Spas was component means the structural
manufactures 3 Axis CNC & 5 Axis CNC Routers, and Large Format founded as a company in 1996. columns and spa base are molded
CNC Machining Centers. With over 30 years of innovation,
custom engineering and industry experience as an Original The highly-engineered JetPaks are the exact same way every time with
Equipment Manufacturer (OEM), DMS serves almost every removable spa seats, each equipped no human error, resulting in a well-
industry, especially aerospace, automotive and consumer
goods. DMS started their business relationship with premier spa with an individual array of jets. The built, durable and worry-free prod-
manufacturer, Bullfrog Spas, when they bought their first DMS
machine back in 2005. Bullfrog Spas purchased their second DMS
jets in each JetPak are supplied with uct. Portions of this precise and du-
machine, a 5 Axis Twin Moving Tables CNC Router last year in 2014. water and air by an advanced manifold rable frame and base system are also
While Bullfrog Spas is known for their advanced Jetpak Therapy
Systems, the company uses their DMS CNC Routers to machine
system that eliminates the need for protected by U.S. and international
detailed fiberglass molds of their spas and to accurately trim key individual pipes. This H2Air JetPak patents, adding to Bullfrog Spas’ dif-
component panels.
Manifold and the resulting reduction ferentiation advantage.

Bullfrog Spas South
“the people here have a strong pas- “We’ve designed a true cubistic product that stands
out from what you’d call a hot tub today, which typically
sion to learn and grow in our skill- feature soft corners and distinct contours,” Pasley adds.
sets and in the way we develop and “The clean aesthetics of STIL will appeal more to mod-
manufacture products.” - Jerry Pasley ern buyers, but it will also fit in nicely in a traditional
backyard.”
Custom Yet Efficient The STIL spa’s design has won a number of awards in-
Bullfrog Spas’ manufacturing floor utilizes CNC router cluding the 2015 International Forum iF Design Award
equipment provided by Diversified Machine Systems for excellence in product design.
(DMS) to mold, cut and trim JetPaks and spa bases. “We Pasley credits the company’s success in design, manu-
value our consumers and dealers as partners, but equally facturing and marketing to its internal focus on contin-
value our suppliers and also treat them that way,” Pasley uous development as well as the work of its staff. “Our
says. “Our relationship with our suppliers is paramount team works very effectively in a non-hierarchal, horizon-
to our success.” tal structure,” he says. “The people here have a strong
Suppliers also play a critical role in Bullfrog Spa’s passion to learn and grow in our skillsets and in the ways
lean manufacturing efforts. The company practices we develop and manufacture products.
lean, Six Sigma, 5S and just-in-time methodologies. “Ultimately, we’re a group of people building products
“Suppliers help us maintain low inventory levels and that consumers want, and we take that really seriously,
ensure components meet our specification and arrive and have built a process and system that allows that to
on time,” he adds. happen,” he adds. mt
Each spa on the company’s manufacturing line is built
to order based on JetPak configurations, designs and col-
ors. “Our business is custom by nature, but still very lean
and efficient,” Pasley says. “We’ve designed our products
in such a way that they can be customized without slow-
ing down manufacturing.”
Bullfrog Spas recently added tooling and product
distribution capabilities to its 100,000-square-foot
manufacturing facility in Salt Lake City. “We’re very
committed to keeping this product in the United
States,” he adds. “We have the size and capacity at
our current facility to handle the next three years of
growth and demand.”
Appealing Designs
The company regularly refreshes its existing products
and introduces new product lines. “We have a three-year
plan for products we’re going to introduce, and employ
a very structured and focused design and development
team that ensures regular and exciting product launches
that meet consumer needs,” Pasley notes.
Bullfrog Spas in November 2014 launched its newest
spa, STIL. The highly designed, square-shaped hot tub
features two lounge seats and an open seating concept
that give users freedom to sit either upright or at a re-
cline. The spa features an elegant modern contemporary
design that immediately distinguishes it from competing
products, the company says.

Custom Coils Inc.
www.customcoilsinc.com / Headquarters: Jacksonville, Texas / Employees: 65 / Specialty:
South
Heat exchangers / Clay Wilson: “We’re small enough to be nimble, but big enough to get it done.”
Custom Service
coil manufacturer custom coils weathers industry shifts with
high-quality products. by tim o’connor
custom coils is maintaining a

loyal customer base because
copper bests aluminum in
efficiency and durability.
Even as many companies mull as vital pieces in equipment used for of the company. Some of those parts
switching to cheaper aluminum parts, medical imaging machines, geother- have been in production for 20 years
Custom Coils Inc. continues to sat- mal heat pumps prepackaged ice vend- with few revisions, proving them-
isfy customers with its high-quality ing machines, X-ray machines and selves a stable component of Custom
copper coils and dedicated custom- electronics cooling in cell phone tow- Coils’ business.
er service. “We consider customer ers. The company’s 45,000-square-
service of paramount importance in foot manufacturing facility employs Watching The Industry
our business,” President Clay Wilson about 65 people who produce coils for But although there is stability in Cus-
says. “That’s really what we sell.” the entire United States, most of Can- tom Coils’ longtime clients, high cop-
Custom Coils, based in Jackson- ada and parts of Mexico. per prices have fueled a trend among
ville, Texas, has been supplying pre- “In a good year, we’re probably some customers to use less-expen-
mium-quality copper tube aluminum working with 1,200 different part sive, fully aluminum heat exchangers.
fin heat exchangers since 1971. It was numbers that will repeat production However, this isn’t the first time Cus-
acquired by US Holdings in 1986. Cus- several different times during the tom Coils has faced a major market
tom Coils’ customers use its products year,” says Wilson, a 13-year veteran shift – and come out on top.

Custom Coils Inc. South
The company got its start in the “we don’t have a product of our own. one
1970s supplying parts for aftermarket
air conditioning systems for cars at a
hundred percent of what we make is for our
time before most drivers and passen- customers’ specifications.” - Clay Wilson
gers expected to stay cool in sweltering
heat. It was a seasonal business because Custom Coils employs. The company is Custom Coil’s partners are unlikely to
few drivers sought out cooling systems not ready to move into aluminum, but it replace a known, proven part for a po-
during the chilly winter months. Then, is exploring what such a change would tentially inferior product. “[It’s] that
when auto manufacturers began build- entail. “We’re certainly keeping an eye old adage, ‘if it’s not broken, don’t fix
ing in air conditioning units, Custom on it and investigating the cost to get it,’” Wilson says.
Coils responded by expanding into more into those processes,” Wilson says. The same can be said of the service
stable year-round markets such as resi- Custom Coils provides. The company
dential and light commercial heating, Focusing On The Customers strives to meet the needs of custom-
ventilation, air conditioning and refrig- Because copper bests aluminum in effi- ers, no matter what the size of the part.
eration components for original equip- ciency and durability, Wilson says Cop- Custom Coil’s machinery, which in-
ment manufacturers. per Coil’s existing customers remain cludes Burr Oak and Amada equipment,
Today, making the switch to all-alu- comfortable working with the metal is adaptable to a wide range of projects:
minum heat exchangers would require and having Custom Coils made com- from items that can be held in a hand, to
a different manufacturing process from ponents in their final products. There’s massive pieces that take two people to
the stamping and fabrication methods the reliability factor, as well. Many of lift. At any given time, Custom Coils

South Custom Coils Inc.
by using a batch manufacturing

process, custom coils can meet
customers’ unexpected needs.
is filling orders for about 80 other A programmable CNC turret press, the production lines and had the parts
companies, each of which may have as which makes the sheet metal brackets shipped out of Dallas/Fort Worth In-
many as 80 different parts designed. supporting the coil, has also sped up ternational Airport by that same af-
“We don’t have a product of our the process. ternoon. “We’re small enough to be
own,” Wilson says. “One hundred Because Custom Coils must deliver nimble, but big enough to get it done,”
percent of what we make is for our on those specifications, the company Wilson says.
customers’ specifications.” maintains a strong focus on customer The adoption of new technologies
The company is UL recognized and service. Like any other parts maker, it over the years has aided those ef-
has a framework for ISO 9000 stan- has a production schedule it strives forts. Email in particular has allowed
dards in place, though it is still work- to meet. But its modest size can be an Custom Coils to better arrange pro-
ing toward certification by this com- advantage over competitors. duction schedules by speeding up
ing fall. Manufacturing is done through communication between manufac-
From initial design to delivery of a a batch process, allowing frequent turing and the customer. Wilson says
product, the entire process averages shifting of production. Each day can it keeps partners updated on a weekly
four weeks, though that can be expe- see a new item fabricated. It also al- basis at minimum.
dited, according to Wilson. However, lows Custom Coils to meet unex- This focus on maintaining commu-
previously designed parts that are pected needs, such as when one of its nications with customers and dedicat-
reordered can be more quickly fab- largest customers ran out of a paring itself to meeting their needs has
ricated as specifications and design ticular component and requested an burnished Custom Coils’ reputation
drawings are kept on Custom Coils’ emergency order. Despite the short in the industry. “I think our greatest
computers and can be easily recalled. notice, Custom Coils quickly changed offering is quality,” Wilson says. mt

Bonterra Builders LLC
www.bonterrabuilders.com / Headquarters: Matthews, N.C / Employees: 70 / Mark Panzik,
South
vice president of construction operations: “You can see the difference in what we build.”
see the difference

bonterra builders delivers true craftsmanship
when building its homes. by janice hoppe
Bonterra Builders has been build-

ing its reputation as an exceptional
homebuilder over the past 14 years
by delivering high-quality products
that are recognized throughout the
industry. The company was awarded
the Quality Builders Warranty Corp.’s
“2013 Builder of Integrity” award for
its demonstrated commitment to ex-
cellence in customer service and qual-
ity construction.
“We offer features that are con-
sidered a better end-product by the
consumer,” Vice President of Con-
struction Operations Mark Panzik
says. “Darren Sutton – the president
of Bonterra Builders – is a person who
bonterra builders is dedicated to providing homes that involve careful planning, innovation, award-winning
has a relentless passion for home- floor plans and exceptional materials and finishes.
building and customer satisfaction.
He has a feel for architecture like I
have never seen before. You can see
the difference in what we build in the
way out homes present themselves
from the exterior. Once inside, our
floor plans do not disappoint.”
The Matthews, N.C.-based com-
pany was founded in 2001 and closed
its first home one-year later. Bon-
terra Builders offers five floor plans
with options for homebuyers to cus-
tomize things like finishes, cabinetry
and flooring, for example. Structural
changes can be a limited option de-
pending on the stage of construction.
“Buyers are looking for certain things,
want what they want and are ready to
buy it,” Panzik adds. “We offer a wide novation and award-winning floor fort, value and energy efficiency. Its
range of selections and options with plans with emerging trends and homes are built in conveniently lo-
the ability to offer a personal touch.” exceptional materials. During the cated communities with a variety of
The designs of Bonterra Builders’ homebuilding process, the compa- amenities, and range in price from
homes involve careful planning, in- ny keeps its eye on delivering com- $250,000 for a townhome to $1.2

South Bonterra Builders LLC
million for a single-family home. The company also

dabbles in multi-family and commercial developments, as
well as land development.
Professional Builder Magazine named Bonterra Build-
ers one of the 50 “Big Gain Builders” in 2013 for its revenue
growth in 2012 and before the recession in 2007 the mag-
azine also named it the “Fastest Growing Builder in the
Country.” Bonterra Builders’ goal is to reach $500 million
in sales next year. “I have been here for two years and the
company has grown at a pace I couldn’t have imagined,”
Panzik notes. “In this time, all of the employees have em-
braced the changes needed to grow our business.”
Enticing Features
Homeowners today are doing away with formal dining
rooms because it is now considered underutilized space.
People are looking for more functionality and usefulness
out of their homes, Panzik explains. “They don’t want five
bathrooms anymore, for example, because they realize they
have to clean them all,” he says. “That’s something I would
always mention to homebuyers.”
Today, Bonterra Builders is seeing more requests for
lifestyle-type amenities. For example, home automation is
an emerging trend that Panzik says is becoming a popular
request among homeowners. Buyers are also still interest-
ed in open floor plans, indoor/outdoor living spaces and
hardwood floors. “We put site finished hardwood in several
of our neighborhoods to differentiate ourselves in the mar-
ket,” Panzik says. “We are one of only a couple builders that
can offer a job site finished product versus a factory site fin-
ished product.”
One trend that has yet to pick up in momentum in the
North Carolina market is green building, but every Bonterra
Builders home is Energy Star-certified. “I’m personally ex-
cited about it because I love to see the new products emerge
as we trend towards more energy-efficient products,” Pan-
zik notes. “We include Energy Star certification across the
board and we are probably about 10 years from going to net
zero energy homes like California is doing now.”
An inspection is performed on the home by a third-party
inspector three times – first in the framing stage and again
in the final stages – to certify the home. Energy Star-certi-
fied homes are designed and built to standards well above
most other homes and deliver energy efficiency savings of
up to 30 percent.
“There isn’t enough demand as of today for green homes,”
Panzik says. “Customers are not yet prepared to pay for the
cost increase needed upfront. We make little tweaks inside

Bonterra Builders LLC South
“we are one of only a brands, ranging from innovative en- contractor it has worked with for a long
try-level to inspired design premium time is not able to keep up with demand,
couple of builders that suites. The variety of appliances is de- Bonterra Builders will bring in a new
can offer a job site fin- signed to meet the needs of each home- company and is careful to always com-
ished product versus owner, Electrolux says. Most of the municate that with its current trades-
a factory site finished products offered are Energy Star certi- men. This is key to maintaining relation-
product.” - Mark Panzik fied, which meet the demands of Bon- ships within the market.
terra constructing eco-friendly homes. Moving forward, Bonterra Builders
Headquartered in Charlotte, N.C., will continue to offer a diverse array of
Electrolux Major Appliances says it is floor plans to meet its customers’ needs
the home that make a big difference, proud to be part of the success of one while focusing on continuing to be one
such as sealing the drywall and caulking of the most respected new homebuild- of the nation’s top-growing firms. “We
to hold in heat. Energy Star-certified is ers that has been building the future for offer a higher-end product and have
assumed with us because we are com- people in North and South Carolina for a reputation that supersedes that of
mitted to it as a company.” more than a decade. others,” Panzik says. “Our customers
The company believes that its open expect more and we are able to deliver
Trusted Partners communication and prompt payments more than any of the other competitors
Bonterra homebuyers choose from a with trade companies has helped it because of a team of employees who are
variety of kitchen and laundry appli- maintain positive relationships and committed to one of the nation’s fast-
ances from the Electrolux family of keep a core team together. If however, a est-growing homebuilders.” mt

UEC Electronics
www.uec-electronics.com / Headquarters: Charleston, S.C. / Employees: 200 /
South
Specialty: Electronic components and subsystems
uec electronics has developed a large

customer base for its components
over the last 20 years.
Full Power cle, or sometimes only the production

piece, for specific systems and subsys-
tems, ranging from small electronic
a recent acquisition is driving the future direction modules up through complex inte-
of south carolina’s uec electronics. by eric slack grated assemblies and test systems.
Program managers and customer
representatives maintain dynamic re-
When it was founded in 1995 as an for missiles, torpedoes, munitions, lationships with each customer to en-
entrepreneurial start-up, UEC Elec- airplanes, communication systems, sure UEC is meeting or exceeding ex-
tronics focused on providing engi- ground vehicles, test systems and var- pectations while proactively helping
neering and electronic manufacturing ious industrial and medical applica- to develop solutions for customers.
solutions for a diverse set of custom- tions,” CEO Mark Matthews says. UEC’s abilities to develop or enhance
ers and industries. Today, UEC has customer products, provide rapid
approximately 200 employees with Serving the Market prototypes and quickly transition to
four facilities located in Charleston, UEC has developed a large customer production have been its strengths as
S.C. It is a Tier 1 and Tier 2 supplier base over the past 20 years, and more a contract manufacturer.
of mission-critical electronic compo- than 90 percent of growth last year “Our manufacturing and design
nents and subsystems to major OEMs was with existing customers. Howev- capabilities along with lean process-
and government agencies, primarily er, UEC always looks to add additional es allow us to deliver sophisticated,
in the aerospace and defense markets. customers each year. cost-effective solutions and prod-
“We design and manufacture sub- Projects range from engineering ac- ucts,” Matthews says. “These core
systems and complex components tivities through the production lifecy- manufacturing and design principles,

UEC Electronics South
when applied to new product design and development, and strategies consistently help meet these challenges.
result in not only a product that hits the mark in terms of “We continuously strive to take costs out of our prod-
performance but a product that is designed for manufac- ucts and services while investing in new capabilities to
turability from the conceptual phase forward.” meet our customers’ evolving needs,” Matthews says.
A number of investments and initiatives have impact- UEC believes a large percentage of growth will result
ed UEC’s approach to growth over the last few years. from managing and storing power in a variety of applica-
UEC has focused on developing its own intellectual tions ranging from a few hundred watts to 50kW. UEC’s
property and product lines, diversifying into more of a renewable and hybrid power collection, storage and
product-based company. A solution provider of energy power management products have defense, industrial
collection, energy storage and power management sys- and commercial applications both domestically as well
tems for off-grid power and mobile applications, UEC is as in the international market. In addition to providing
delivering its hybrid power and vehicle power manage- clean and continuous power to off-grid applications,
ment solutions through products that include primary these products reduce fuel costs with respect to both fuel
and secondary battery packs, renewable and hybrid ener- consumption as well as the cost of transporting the fuel.
gy systems, and combat vehicle electrical systems. To reach these new markets, UEC must develop global
The company has invested in environmental testing sales channels to ensure it is effectively reaching the cus-
capabilities and is developing a sales team with defined tomers that need reliable, inexpensive remote power.
channels into target markets including the Department “Our challenge will be to maintain a culture that is
of Defense, disaster relief and emergency responders, flexible and focused on continuous improvement in all
remote industrial applications and international users aspects of our organization,” Matthews says. mt
seeking off-grid, clean and continuous power.
New Direction
Another major change for UEC was its acquisition by
Arotech Corp. in 2014. By partnering with a parent com-
pany like Arotech, UEC has been able to invest needed
capital into both product development activities and
business development resources.
“Our plan is to grow organically through our new prod-
ucts as well as through key strategic acquisitions that are
complementary to our core strengths,” Matthews says.
In the years ahead, UEC will continue working to build
strong ties with suppliers and vendors such as PEI Gen-
esis. External suppliers provide critical resources, allow-
ing UEC to achieve results for customers.
“UEC builds trust by fostering lasting relationships
based on mutual respect,” Matthews says. “We hold our-
selves and our suppliers to high standards of fairness,
honesty and professionalism. We focus on understand-
ing our supplier’s technical capabilities and capacity to
accurately match them to our requirements. Our rela-
tionship with PEI Genesis demonstrates each of these
elements, as we have built a trusting relationship over
more than a decade of teaming.”
In what is a very competitive and fiscally constrained
environment, UEC’s customers are looking for high-end
solutions and aggressive delivery schedules, all at the
lowest cost. UEC’s current capabilities, infrastructure

Taper Roller Bearings Inc.
www.taper.com / Headquarters: Lexington, Ky. / Employees: 27 / Specialty: Tapered roller bear-
South
ings and spacer assemblies / Tom Jones: “We can produce extremely high quantities in a short time.”
taper roller bearings

builds assemblies for four
of the world’s largest
bearing manufacturers.
Same Day Service sures a constant flow of product with

just-in-time or same-day delivery.”
taper roller bearings maintains enough inventory Bearing Manufacture

to meet the jit needs of its customers. by russ gager Many components used in advanced
weapons systems and transport ve-
hicles by the U.S. Department of
Tapered roller bearings are used “It’s about innovation,” President Defense (DOD) and the Defense
in a wide variety of equipment, in- and CEO Tom Jones proclaims. “We Logistics Agency (DLA), have their
cluding automobiles, printing press- build assemblies for four of the five bearings manufactured in a dedicated
es, military vehicles, food pumps, and largest bearing manufacturers on the manufacturing facility. “We purchase
even in equipment to hydraulically planet. We strive to exceed our cus- U.S.-made steel and machine, grind
fracture oil and natural gas wells. tomers’ inventory requirements by and process that raw material into
The ability to ship bearings same- being prepared for their maximum us- component parts,” Jones explains.
day, at least 80 percent of the time, is age at any given time of the year. That “The steel goes to a heat-treating fa-
the specialty of Taper Roller Bearings enables our customers to rest assured cility and then it is returned for con-
(TRB) Inc., Lexington, Ky. The com- they are insulated against any poten- tinued, finished processing. Our asso-
pany remains dedicated to providing tial slowdown in the external inven- ciates are proud to serve all members
same-day response to distribution re- tory system, such as a dock strike that of the U.S. Army, Marine Corps, Navy,
quirements by maintaining superior can wreak havoc with delivery times. Air Force, Coast Guard and the De-
inventory levels for assemblies as well This eliminates any potential nega- partment of Homeland Security.”
as exemplary associate teamwork. tive impacts to our customers and en- TRB also manufactures spacer as-

Taper Roller Bearings Inc. South
semblies. It offers made-to-order

Class 3 precision bearings and has the
experience and capacity to manufac-
ture and assemble 30434 code-bear-
ing assemblies. Additionally, the
company finds, assembles and deliv-
ers bearings for gear boxes, printing
presses, motion control devices, steel
manufacturers, fracking and many
other industries.
TRB uses proprietary manufactur-
ing equipment it produces in-house.
“We continuously upgrade our mea-
surement and process equipment,”
Jones stresses. “It’s proprietary be-
cause we’re under non-disclosure
agreements with all our suppliers
and with the individuals that service
our equipment. Ultimately, by striv- trb credits its workforce
for helping to contribute
ing to always improve our produc- to more than four decades
of success.
tion equipment and processes, we
are able to provide superior products
to our customers.”
Shipping Prowess
Jones attributes much of the compa-
ny’s success to its associates, who try
to surpass customer requests. “We
strive to never say ‘no,’” Jones says.
“It’s our corporate mindset, our cul-
ture, to always find ways to solve the
problem for a customer. We source
worldwide. All members of our sales
team are logistics experts.
“Ultimately, it’s about reducing
downtime for our customer. That
means our associates have to be well-
versed in how you ship 15 pounds of
product from Shanghai to Chicago in 18
hours, or a package from Germany that semblies per day, this type of perfor- processed, turned into assemblies,
weighs 1,000 pounds to England in the mance requires a team effort from all 100 percent inspected for 100 percent
most economical and efficient method, departments. Each associate swings quality, and then shipped back to the
or assist an individual in Indiana have into action and reallocates their pro- customer in literally a matter of days.
their plant back online within three duction schedule. No job is too small We attribute our more than four de-
hours by efficiently and effectively pro- or large. We can produce extremely cades of success to our founder’s vi-
ducing the required assembly.” high quantities in a short time period. sion, our entire team and their ability
Jones notes that “whether we are When we say just-in-time, the mate- to exceed the demands and require-
producing 800, 900, 1,000 or more as- rial has barely hit the dock when it is ments of our customers.” mt

Setpoint Systems
www.setpointusa.com / Headquarters: Ogden, Utah / Employees: 45 /
South
Specialty: Lean automation systems / Mark Coy, CEO: “We’re truly a project management specialist.”
Automatic Quality
a mastery of lean and a high level of employee
engagement guide setpoint systems. by jim harris
When they founded Setpoint Sys-
tems in 1992, engineers Joe Cornwell
and Joe VanDenBerghe were deter-
mined to do things differently from
their previous employer. The pair –
known affectionately as “the Joes” by
the company’s employees – wanted to
ensure their employees knew where
they stood with regard to their proj-
ects as well as the company’s health.
Cornwell and VanDenBerghe es-
tablished an open-book employee
engagement program that not only
made engineers accountable for the
progress of their projects, but made
the company accountable to em-
ployees with regard to finances.
Every Monday, the company’s
staff receives a briefing on prof-
its and losses incurred during the
previous week. Project managers
each report their project status to
Setpoint’s accounting team before
setpoint systems designs
9 a.m., and the accounting depart- and builds lean-based
automation systems for
ment then prepares a fully detailed a variety of industries.
report broken down by project.
“I’m proud of our ability to keep Concepts Realized ny, but we’re truly a project man-
employees involved in our business Setpoint’s staff applies its engineer- agement specialist,” Coy says. “For
systems,” says Mark Coy, CEO of ing expertise to two main types of both of the things we do, we start
the Ogden, Utah-based company. projects. The company designs and with customer concepts and end
“Many companies struggle to get builds automation systems for the with a finished system that is qual-
profit/loss statements weeks after ammunition, automotive and oth- ified by the customer.”
the financial period closes; we are er industries including aerospace The company’s design, prototyp-
able to put those together during and medical devices. In addition, ing and testing activities are heavily
the first four hours of each week.” the company engineers and builds influenced by lean manufacturing
Employees are kept informed of amusement park rides including roll- philosophies. All of the automation
successes or challenges related to fi- er coasters. Products are produced in systems it provides to customers
nances. “It’s critical in business, es- three facilities in Ogden all located in are also designed with lean in mind.
pecially one like ours that requires proximity to each other. “Even if our customer isn’t famil-
highly qualified people, to have “If you were to tour our facility iar with lean, we will explain how it
them be engaged in the company,” and see what we do, you would think works and work an understanding
he adds. that we’re an engineering compa- of lean into the design of our equip-

Setpoint Systems South
ment, and our clients appreciate that,”

he adds.
Excellence Recognized
Setpoint Systems’ dedication to employee engagement and lean manufacturing principles has earned it
Setpoint offers a line of standard au- a number of recognitions in recent years, including:
tomation systems used in the ammu- > Inc. magazine’s Inc. 500 list of the fastest-growing companies in the United States;
nition manufacturing industry includ- > Utah’s manufacturer of the year for 2014; and
ing machines that prime bullet casings > Recognition as one of Utah’s fastest-growing companies.
and load them with gunpowder. The
company’s efforts to make ammuni-
tion manufacturer ATK lean helped signing how the machine will function tracking,” Coy says. “We monitor the
Setpoint thrive during the Great Re- and look, Marketing Manager Nick information that goes into each part
cession, Coy notes. Banz notes. made on one of our machines better
Systems used in other industries Once designs are approved by the than any of our competitors.”
including controls, robotic arms and client, Setpoint fabricates, machines
pick-and-place systems that are de- and de-bugs machines before meeting Delivering Speed
signed and produced to order. All with customers for a buy-off process One of Setpoint’s main goals is to “be
products begin with a scope-of-work that includes reviews and tests of all the fastest in the industry,” Coy says.
document describing what the cli- machine parts. “We want any company looking for
ent wants the automation system or One thing that sets Setpoint apart a lean automation system or amuse-
theme park ride to do, followed by an from other automation companies ment park ride and needs it turned
engineering process that includes de- is “we’re uniquely skilled at quality around quickly to come to us.” mt
MAY/JUNE2015 manufacturing-today.com 99
Barnes International
www.barnesintl.com / Headquarters: Rockford, Ill. / Specialty: Coolant filtration / William
Midwest
Kirchner, president: “Our systems are the heart of the whole machining and grinding bays.”
barnes international excels

at building both large
and small machine tool
filtration systems.
Cleanliness Counts ters, vacuum media filters, pressure

filters, rotary drum filter conveyors,
bag filters, high-pressure skids and
barnes international leads the way in machine tool magnetic coolant separators used
coolant filtration systems. by jim harris in conjunction with grinding, hon-
ing, machining, turning and other
The importance of clean coolant product quality, as well as substan- operations in a variety of industries
within machine tooling operations tially reduce coolant life. For the past including automotive and aerospace
cannot be overstated. Tens of thou- several decades, Barnes International manufacturing. “These companies
sands of gallons of coolant are typical- has helped companies ensure that the produce machined parts such as en-
ly used during manufacturing opera- coolant they consume remains prop- gine blocks and often run around the
tions daily, making it one of the most erly filtered while allowing recycling clock, so they’re constantly pushing
common and vital parts of the produc- of metal waste. their equipment to the maximum,”
tion process in multiple industries. The Rockford, Ill.-headquartered CEO President William Kirchner
Keeping coolant clean is a high company is the largest manufac- says. “Our systems are the heart of the
priority for manufacturers because turer of machine tool filter systems whole machine bay; without proper
unfiltered coolant can build up bac- in North America. The company’s filtering and cooling, you can lose the
teria and otherwise negatively affect products include deep bed gravity fil- whole bay.”

Barnes International Midwest
Experience Counts
Many of Barnes International’s systems filter the coolant
used in multiple tooling machine bays. The company is an
expert at building systems that can filter coolant for up to
100 machines on a single system. These machines can range
between 10 gallons to more than 10,000 gallons of coolant
required per minute.
“our organization is focused on

quality and building the best pos-
sible product, right down to the
individual level.” - William Kirchner
“We’re one of only a few companies that’s equally good

at building large systems used on multiple tools as we are
making smaller systems for one machine tool,” Kirchner
adds. “We’ve learned over the years that the way you be-
come No. 1 in the industry is through valuing the customer
and providing the best product and support in the industry,
and we believe that is our strong suit.”
The company’s team of technicians possesses more than
1,000 years of filtration experience combined. “Our people
are the heart of our business and the key to our success,”
Kirchner says.
The staff’s experience is often called upon by large man-
ufacturers including General Motors, for whom Barnes
International helped develop large, regional above-ground
filtration systems. These systems, which can be moved
around facilities if needed, replaced large centralized sys-
tems that included troughs in the ground to carry coolant to
and from machines.
“We worked closely with GM to develop the technical
specifications for these systems, which have reinvented the
way the automotive industry approached coolant systems,”
he adds. The movable systems also give GM greater flexibil-
ity in its operations, and have reduced the company’s cool-
ant consumption and scrap while also reducing installation
and start-up time.
Great Lakes Pump and Supply, the trusted name in fl¬uid handling equipment
is proud to offer the time tested quality engineered products from the Ruthman Family
of Manufacturers. These top name companies include Gusher Pumps, the innovators
in horizontal and vertical centrifugal pumps since 1926, Process Systems, Inc., manu-
facturers of “Thrust Head” grease lubricated Vertical Turbine Pumps and Nagle Pumps,
producers of heavy duty slurry and sludge pumps. A prime example of a successful
working relationship is Great Lakes Pump and Barnes International, with the integra-
tion of each of these combined Ruthman Company products strategically to enhance
and increase efficiency in the Barnes Filtration product manufacturing process.

Midwest Barnes International
barnes international ceo

william kirchner credits his
staff with the company’s
ongoing success.
Manufacturing Capabilities
Barnes International operates manufacturing plants in
Rockford and Bowling Green, Ohio; and maintains service
and engineering centers serving the North American mar-
ket in New Albany, Ind.; and Brighton, Mich. The company’s
manufacturing capabilities include fabrication and assem-
bly of full systems as well as assembly of the plumbing and
electrical components used in those systems.
The Rockford facility includes 140,000 square feet of
fabrication and assembly space, and includes 12 high-bay
assembly bays. The 80,000-square-foot Bowling Green site
includes 36 high-bay cranes. Both facilities feature 2-D and
3-D workstations.
“One of the keys to our success is our ability to rapidly
customize filtration designs to fit any machine tool pro-
duced worldwide and deliver in a little as 4 to 6 weeks in
small or large quantities at a competitive price,” Kirchner
Boll Filter Corporation is the U.S. subsidiary of the world renowned German
manufacturer, BOLL & KIRCH Filterbau GmbH. Serving as a proud supplier to Barnes
International, Boll provides automatic back-flushing filters as a complimentary, polishing
level of particulate separation.

Barnes International Midwest
improve their output quality, and pre-shipping reviews and testing

all products undergo various levels during installation.
of testing. This includes pressure
testing for leaks, running conveyors Decades of Growth
multiple times, component testing, In addition to its North American
explains. “We manufacture all crit-

ical components, and work with a
strong vendor base that understands
our needs and turns around parts for
us rapidly.”
Barnes International closely mea-
sures the number of rejected parts as
well as scrap and other quality met-
rics. “Our quality system is based on
individual teams and processes,” he
adds. “We have our whole organiza-
tion focused on quality and build-
ing the best possible product, right
down to the individual level.”
Manufacturing employees are
regularly trained and coached to
SlipNOT® Metal Safety Flooring supplies slip resis-

tant plates and grating to Barnes International, Inc., which
provides a high traction surface for Barnes’ manufacturing
and automotive clients. Barnes’ innovative approach to
improve supply chain management has lowered costs for
customers while improving production times.

Midwest Barnes International
operations, Barnes International lives up to its name by

maintaining support and service centers in Spain, Mexico,
China, India and Brazil. The organization in Italy, Barnes
Europe, opened in late 2014. Barnes Europe is a full filtra-
tion equipment builder with engineering, manufacturing
and full service capabilities.
The opening of Barnes Europe closely followed the 2014
acquisition of the Henry filtration product line from a Ger-
man company. The expansions are the latest major changes
in the company’s long history, which extends back to 1907,
when it was founded as Barnes Drill Company, a drill and
tapping company serving the automotive industry.
In the late 1950s, Barnes became the first machine tool
builder to apply numerical controls to metalworking drills
and boring machines.
The company eventually abandoned the drills, and in the
1980s became involved in a super-abrasive honing process
in which bores could be machined to a very precise toler-
ance and surface finish requiring even tighter filtration re-
quirements. This process created finite metal particles that
ended up in the coolant, necessitating the need for cleaner
coolant during the machining process. The company intro-
duced magnetic separators to remove this metallic sludge,
which brought it into the filtration world. Later Barnes add-
ed gravity, pressure and vacuum filters to meet all honing
and grinding requirements. In 1990, Barnes entered into an
agreement with Japanese manufacturer Mosnic to license a
filtration technology. This agreement made the company a
worldwide entity, leading to the change to its current name.
Barnes made the decision to focus entirely on filtration
eight years ago, when it sold its honing division. “Honing
was becoming a smaller market, but on the machine tool fil-
tration side there is a very large market for growth,” Kirch-
ner adds.
The company continues to seek opportunities to grow.
“Our long-term strategy is to continue to build our sales
base within the industry while looking for additional com-
panies that would add technology or products to our base,”
Kirchner says. “We’re looking for other companies to pur-
chase and continue to develop the best filtration for the vast
majority of application in the industry.” mt
Brinkmann Pumps, Inc. has been a leading supplier of coolant pumps in the ma-
chine tool market for over 60 years. The company is headquartered in Germany and has
global presence. The 25,000 sq ft. facility in Michigan offers sales, service, assembly and
repair capabilities. Its complete range of pumps teamed with its modular design system
allows Brinkmann to customize pumps very efficiently and economically. Brinkmann
Pumps has proudly been supplying coolant pumps to Barnes International for many
years for various applications, ranging from low pressure, chip handling dirt side applica-
tions all the way to high pressure, clean side applications.

Thermwood Corp.
www.thermwood.com/ Headquarters: Dale, Ind. / Employees: 100 / Specialty: CNC routers /
Midwest
Jason Susnjara, vice president of marketing: “For us, every day is exciting.”
Leading
by
Example
thermwood corp.
continues to look
for ways to stay out
in front of its
market. by eric slack
From its beginnings, Thermwood

Corp. has incorporated a high level of
technology in its business. The com-
pany was established in 1969 as a plas-
tic molder of wood-grained parts.
During the last 40-plus years, Ther-
mwood has developed a number of
innovations. These include a unique
molding process and the first com-
mercial CNC machine tool control.
Much of the plastic molding and trim-
ming machinery Thermwood used
was designed and built in-house.
“Thermwood began selling this
trim equipment for plastics, compos-
ites and woodworking applications
and the CNC router was born,” Vice
thermwood’s machines are
President of Marketing Jason Susnja- used to make everything
from bicycle helmets to
ra says. truck bodies.
Diverse Applications to some very large and widely known sets for many movies. Our machines
Located in southern Indiana, Ther- companies. The interiors of most helped rebuild Windsor Castle and
mwood operates in a facility that is commercial jet airliners are pro- the Opera House in London. Even
about 175,000 square feet and em- cessed on Thermwood machines, as NASA has used Thermwood machines
ployees about 100 people. Besides are many helicopter blades, structural to build the Mars Flyer and Mars
producing the first CNC router, parts for military aircraft and tile un- Lander. For us, every day is exciting
Thermwood is known for producing derlayment for the space shuttle. due to the sheer differences of the in-
high-quality machines and controls, “Thermwood machines produce dustries we serve.”
as well as for the capabilities of its ser- parts from bowling alleys and bicycle Numerous methods are employed
vice department. helmets to spas, motorcycle parts and to help Thermwood reach its target
The company’s customers cover truck bodies,” Susnjara says. “Many markets. At one time, print advertis-
a wide range of industries ranging of the sets on Broadway were built ing was the only way. Now, the Inter-
from single-employee cabinet shops on Thermwood machines, as were net is key.

Midwest Thermwood Corp.
fectively is a main goal of Thermwood

as it grows through 2015.
In addition, 3-D printers are a big
item right now. Thermwood was in-
volved with the first 3-D printed car
for the subtractive portion, and it has
decided to follow that up with the de-
velopment of a six-axis 3-D printer.
There are a few challenges for the
company to face. For example, in the
wood industry – specifically cabinet
and closet making – the Chinese are
importing cheap CNC machining
centers, making it difficult to compete
on price alone. For a technical compa-
ny such as Thermwood, it is import-
ant that it works on finding ways to
come up with better solutions and
outstanding customer service.
the company’s facility in The currency exchange is some-
indiana fearures more than
175,000 square feet of times damaging as well. Thermwood
manufacturing space.
exports products all over the world.
“We sell our equipment to various “Their knowledgeable engineering When the U.S. dollar strengthens, it
industries, and it’s easier to do via the staff is very courteous and quick to makes exporting much more difficult
Internet because you can target a larg- respond to sizing and maintenance and gives importers a price advantage.
er amount of people, with more infor- questions,” Susnjara says. Fortunately for Thermwood, it has
mation,” Susnjara says. a long history of demonstrating excel-
Supporting Thermwood’s legacy of Continued Development lence and leadership in the develop-
innovation is a team of creative think- Thermwood is refining on a new ma- ment of high-performance, affordable
ers with extensive engineering back- chine for the wood industry. The com- CNC routers. There is every reason
grounds. The company continuously pany came out with this new machine to believe that Thermwood will be
tries out new and different ways to last year but it is continuously work- able to confront and move past its
make its equipment more successful ing to perfect it. challenges as it strives to build a com-
for the customer and easier to use. “We call this new machine the Cut pany that can compete for another
“We are the only CNC manufactur- Ready, Cut Center,” Susnjara says. half-century and beyond. mt
er that not only builds our own ma- “All CNC machines need to be pro-
chine but also builds our own control- grammed either with entering lines of Andantex USA, Inc.is proud to be the rack and
ler,” Susnjara says. code or using some sort of design soft- pinion axis drive suppler for Thermwood Corpo-
ration. The relationship started over 10 years ago
Strong relationships with vendors ware. The Cut Center requires zero and continues to evolve with the quality and speed
requirements of Thermwood Routers. Andantex offers
are also extremely important. Ther- programming and software using an a complete library of precision reducers (Servo-worm
mwood has developed solid ties with intuitive control interface that runs and planetary) combined with a standard range of racks
and pinions. This library of products allows Thermwood
vendors big and small, which has a lot through a series of questions that the to select standard components that meet the torque,
to do with the quality of the product user answers.” precision, and price requirements of each application.
The precision Andantex components combined with
and service the company can provide. As the company looks ahead, it re- Thermwood’s unique volumetric compensation system
For example, Andantex USA, a pro- alizes that the collection of dust par- insure accurate positioning of each axis as well as high
speed and repeatability. Furthermore, Andantex sup-
vider of high-precision motion con- ticles is a big issue, whether in wood, plies components for automatic lubrication of the racks
and pinions to insure long life. For more information
trol components and systems, offers plastics or composites. The ability to call 800-713-6170 or visit www.andantex.com.
good service and on-time deliveries. remove those airborne particles ef-

Poly-Wood Inc.
www.polywoodinc.com / HQ: Syracuse, Ind. / Specialty: Recycled plastic furniture / Megan Midwest
Pierson, director of sales and marketing: “The way we’re set up, we have a really smooth system.”
Category Leader
poly-wood inc. originated the recycled plastic furniture category
and continues to lead it today. by chris petersen
ross munn (from left), brady

maller, megan pierson, doug
rassi and sean rassi comprise
poly-wood’s management team.
It is said that gold is where you the attention of a company called The bility and unique appeal. Pierson says
find it. For Poly-Wood, Inc. it was Sharper Image, which first purchased the company adds to the appeal of the
found in the mountains of recycled Poly-Wood recycled plastic furniture products themselves with a robust
plastic created by government recy- and featured it in its catalog and retail infrastructure that can turn around
cling programs. Director of Sales and locations. From there, the rest is his- orders in a relatively short timeframe.
Marketing, Megan Pierson, says the tory. Today Poly-Wood remains the With the “outdoor living room” con-
company’s founders saw a great op- leader in the recycled plastic outdoor cept becoming more and more pop-
portunity in that overabundance of furniture category. ular with homeowners, Pierson says
recycled materials and started using “We’re doing really well,” Pierson Poly-Wood is excited about the future
it to create extruded plastic lumber in says. “We’re the originators of the of the category and the company.
their garage that became the founda- category, and have spent 25 years pio-
tion for the company’s first samples neering.” Material Strength
of outdoor furniture. After exhibiting Poly-Wood’s furniture has found a The lumber used to create Po-
these initial products at a furniture successful niche in the outdoor sector ly-Wood’s outdoor furniture is
show in Chicago, Poly-Wood Inc. drew thanks to its low maintenance, dura- formed from a proprietary blend of

Midwest Poly-Wood Inc.
“our furniture really has a unique

style. it’s sleek, sophisticated and
we have a variety of color options.”
- Megan Pierson
thermoformed plastics and additives mainly derived

from post-consumer bottle waste such as plastic milk
jugs and detergent bottles. Pierson says the company
extrudes all of its own plastic lumber at their location in
Syracuse, Ind., giving it strict control over the quality of
the materials that go into its furniture.
The high quality of the materials that go into Po-
in addition to its popular
ly-Wood furniture makes them ideally suited for outdoor adirondack chairs, poly-wood
offers many other options in a
use, and the company says customers appreciate how lit- variety of colors and styles.
tle maintenance they require. The company’s furniture
requires no waterproofing, painting or staining, and is furniture fading, cracking or rotting like they would with
exceptionally resistant to environmental stresses. Pier- traditional wooden furniture, or rusting like metal prod-
son says customers don’t have to worry about Poly-Wood ucts. On top of that, Poly-Wood offers customers peace
of mind through its 20-year warranty, which guarantees
residential users will get 20 years of worry-free use out of
their Poly-Wood furniture.
There’s more to the appeal of Poly-Wood furniture
than its technical specifications, however. The compa-
ny’s most popular products are its Adirondack chairs,
but Poly-Wood offers a wide variety of options rang-
ing from bar chairs to dining chairs to chaise lounges.
Additionally, the company offers these options in an
extensive array of color and style choices. Pierson says
Poly-Wood challenges the common perceptions of plas-
tic outdoor furniture. “Our furniture really has a unique
style,” she says. “It’s sleek, sophisticated and we have a
variety of color options.”
Behind the Scenes

Beyond the inherent advantages of the products them-
selves, Poly-Wood has earned its leadership position
in the marketplace through its state-of-the-art manu-
facturing processes and highly responsive supply chain
operations. Pierson says the company’s infrastructure
is capable of turning an order around in one day, making
it a highly valued partner for many big-name retailers in-
cluding Home Depot and Target. “The way our system is
set up allows for a fairly seamless fulfillment process,”
she says.
Poly-Wood’s manufacturing facilities feature CNC
and robotic welders, ensuring the most efficient manu-

Poly-Wood Inc. Midwest
facturing and the most consistent quality across all product

lines. The company also stamps each and every piece of fur-
niture it produces with a serial number as well as the date
and time of manufacture. This allows the company to pin-
point down to the specific workstation where any defects or
issues with any piece of furniture originated.
Pierson says the company has a robust IT infrastructure
that controls every point along the manufacturing process
and supply chain, which creates precision control and al-
leviates one of the major headaches most manufacturers
encounter in terms of efficiency and consistency. “I think
that’s probably the biggest challenge for anyone in this cat-
egory, and it’s not a challenge for us,” Pierson says.
New Directions
Pierson says the company is excited about the current trend
toward the concept of outdoor living rooms, where home-
owners value furniture that is comfortable as well as capa-
ble of withstanding the elements. She says Poly-Wood is
hard at work on developing several new products that can
fit this concept and help customers create the type of out-
door seating and entertainment area they desire.
Poly-Wood also is developing an innovative new product
in the deep seating category. Pierson says this new type of
seating can be shipped fully assembled and folds flat for eas-
ier shipping. She says the company expects to save a lot of
money on freight costs with this new product. Beyond that,
Pierson says Poly-Wood continues to look for new oppor-
tunities in international markets. With the addition of new
types of materials to its product lines, Poly-Wood expects
to continue to hold onto its position as an innovator and
market leader. mt
poly-wood is embracing the
concept of outdoor dining
and living rooms with a
range of new products.

Control Gaging
www.controlgaging.com / Headquarters: Ann Arbor, Mich. / Employees: 34 / Specialty: Gage
Midwest
solutions / Dave Hayes, president: “We excel on projects where changeover time is critical.”
A Step Above
control gaging’s automated measurement systems
improve changeover times. by janice hoppe
control gaging founder jack

Control Gaging first made a name brown patented the world’s
first quick-step gage head.
for itself more than 40 years ago when
founder Jack Brown patented the
world’s first quick-step gage head that
reduced changeover time from 20
minutes to 30 seconds.
That innovative spirit continues
within the company today as it con-
tinues to develop automated gage
systems while maintaining its reputa-
tion for superior-quality products and
dedicated customer service.
“We excel on projects where
changeover time is critical,” Presi-
dent Dave Hayes says. “Typically, our
products offer faster setup time than
the competition and those are the
products we have an advantage on.”
The company was founded 43 years
ago in Saline, Mich., to address a need
in the manufacturing industry for
more sophisticated instruments to
control automatic machinery and
produce higher-quality products.
“We know from experience that auto-
matic control of machining processes
through real-time measurement can
cut production costs through im-
proved productivity and quality,” the
company says.
Today, Control Gaging is a leader
in measurement systems and process
controls for the machining industry.
It designs and manufactures in-pro-
cess gages that provide closed-loop
feedback to machine controls based
on real-time part measurement.
The company also produces gage
systems that can be integrated into
material-handling systems so parts
can be measured while transported.

Midwest Control Gaging
Petra Electronic Manufacturing,

based in Moline, Mich., supplies cir-
cuit boards for Control Gaging’s
products. The companies work close-
ly together when developing a new
solution for customers, Hayes says.
“We involve them in the manufactur-
ability of our products and they offer
us ideas on how to improve our circuit
board designs,” he adds.
The company says its extensive
technical knowledge, innovative gage
products, and dedicated field service
and support earn customers’ loyalty.
Control Gaging supplies its products
to customers in the automotive, heavy
truck, construction vehicle, bearing,
medical and aerospace industries.
control gaging has been
a place for innovation “Our customers can expect products
since day one.
from us that work, are durable and
easy to use,” Hayes notes.
Innovative Culture and the World Gage product line of Over the past couple of years, Con-
Control Gaging has been a place for enhanced products with greater du- trol Gaging has developed new post
innovation since day one, and over the rability and accuracy was rolled out by process and inner diameter grinder
years it has not only introduced the Control Gaging in 2006. gages. The automated post-process
first electronic quick setup gaging sys- “Today’s highly competitive mar- gage systems require fast retooling
tem, but also the first quick-setup ID ketplace requires reliable gaging sys- for multiple part configurations.
gage for through-spindle applications. tems,” the company says. “Control Once machining is completed, the
In 1985, the company moved to its Gaging responds to [our customers] automated systems provide accurate
current location in Ann Arbor, Mich., needs with gages that are easy to set- measurements of the finished part
which offered more space for growth. up, produce precise measurements to compensate the machine tool and
Throughout the 1990s, Control and are extremely reliable.” prevent bad parts from entering the
Gaging patented its first crank pin product stream.
gage and center-less shaft gage, as well Reliable Products The center-less grinder TFX In-
as introduced the fourth-generation Control Gaging manufactures cus- line Diameter Gage offers precise size
of micro-based monitors. In 2000, tom-engineered solutions for a vari- control of small parts and spools at
the company became a registered ety of industries. “Typically we run a production rates. “The TFX provides
TE9000, tool and equipment quality design/build model,” Hayes says. “We the accuracy and throughput, as well
standard company, and earned ISO will quote a system for a given part as the flexibility for changeover, that
9001 and QS 9000 certifications. and our customer’s manufacturing manufacturers of these parts have
Control Gaging introduced its first process, then we build a custom de- been looking for,” the company says.
electronic monitor with digital signal sign for them. Everything is designed Control Gaging’s Post Process Shaft
processing to produce greater accu- and machined in-house.” Gage offers a flexible fixture design
racy and speed for premier products.
The introduction of the Grip-Gage-
Go solution that integrates measure-
“typically, our products offer faster setup
ment devices directly into materi- time than the competition and those are the
al-handling systems followed in 2004 products we have an advantage on.” - Dave Hayes
Control Gaging Midwest
that makes purchasing a post-gage ufacturing space by 5,000 square Hayes says. Control Gaging also
for in-feed center-less shaft grinding feet. The company expects further plans to stay true to its roots by con-
simple and affordable. When mount- growth because of the mass reloca- tinuing to develop innovative auto-
ed adjacent to the grinding machine, tion and re-shoring of manufactur- mated gage systems and remain an
the fixture receives work pieces from ing companies to the United States, industry leader. mt
a gantry or robot loader.
The gage sends size readings to a
D500 controller that monitors size
trends and feeds appropriate com-
pensation signals to the machine to
maintain tight tolerances.
The fifth-generation WG2 Dual
Finger Gage was developed by Con-
trol Gaging with design advance-
ments, including the bearing struc-
ture, corrosion resistance, coolant
seals, setup and retract mechanism
reliability, crash-resistance, easily
accessible adjustable features and is
easier to repair. WG2 offers repeat-
ability of less than .0005mm, sets up
in less than 30 seconds and comes
with a two-year warranty.
Control Gaging will be featuring
its new systems in May at EASTEC,
2015. “The most important benefit
with trade shows is to stay in touch
with the current trends and tech-
nology, and find new customers,”
Hayes says. “For us it’s also a way to
keep existing relationships estab-
lished and communications going by
spending more time talking to our
customers about existing equipment
and new opportunities.”
Moving forward, Control Gag-
ing has prepared for further growth
by relocating to a new building in
Ann Arbor that increased its man-
Petra Electronic Manufacturing has been

partnering with Control Gaging for over 10 years now.
We have had the good fortune of manufacturing the PCB
assemblies that are the backbone of their product line. Our
capabilities include the SMT placement of BGA and other
fine pitch state of the art IC packages, as well as through
hole and mixed technology production. Two complete SMT
lines, automated optical inspection and BGA reworking ca-
pability make us a good fit for a company concerned about
a quality product at a competitive price like Control Gaging.
Contact us today to find out what we can do for you!

Acieta LLC
www.acieta.com / Locations: Pewaukee, Wis., and Council Bluffs, Iowa / Specialty: Industrial auto-
Midwest
mation and robotics / Blake Consdorf, VP of sales: “We’re really helping our customers be competitive.”
acieta has been recognized as

one of the world’s leaders
in providing industrial
automation.
Future Tense turers to introduce automation into

their own operations no matter how
big or small. Vice President of Sales
acieta provides robotic systems that are making Blake Consdorf says Acieta has more
than 30 years of experience in the ro-
facilities more successful. by chris petersen botics industry, and that has been a
major component of its success.
The future is now for the indus- relegated to the world of science fic- Recognized as one of the world’s
trial automation industry because the tion, a factory where humans and ro- leaders in industrial automation, Aci-
use of robotic automation in plants bots work side-by-side has never been eta works with a broad base of cus-
and factories around the world is ex- more common, and industrial auto- tomers throughout North America.
pected to grow by as much as 500 per- mation providers such as Acieta LLC Consdorf says its customers range
cent over the next decade. No longer continue to make it easy for manufac- from small job shops with two or

Acieta LLC Midwest
three employees to major manufac-

turers such as John Deere and Bob-
cat. The company opened its doors as
Automated Concepts Incorporated
in 1983, providing robots used for ma-
chining, welding and palletizing. The
company changed its name in 2005 to
Ellison Technologies Automation to
reflect its relationship with distrib-
utor Ellison Technologies. In 2014,
however, the company became free to
work with any machine tool company
in the marketplace once again and re-
branded itself as Acieta. Today, Acieta
operates out of two locations; one be-
ing in Pewaukee, Wis., and the other
in Council Bluffs, Iowa, and employs
more than 140 employees.
Even though the expansion of in-
dustrial automation continues at a
breakneck pace, Consdorf says Acieta
understands that a major part of its
role as an industry leader is to educate
potential customers about the ben-
efits of introducing robotic systems
into their facilities and dispel myths
about the effect they have on the acieta hasfacilities
their found that its biggest competition
because they fear comes
hav-from manufacturers thatlarge
do notportions
automate their
of operations, so
it focuses on helping potential customers understand anding tothe
justify layinvestment
off their
in robotics and automation.
workforce. By introducing potential
customers to the company’s long leg-
acy of innovation and success in the
industry, Consdorf adds, Acieta con-
tinues to win over customers and help
keep North American manufacturers
operating at peak efficiency.
Winning Them Over

The biggest competition Acieta faces
doesn’t come from another manu-
facturer or distributor of robotic sys-
tems, Consdorf says. Rather, it comes
from manufacturers who choose not
to automate their operations at all.
“Typically, the biggest selling we have
to do is to help the end-customer un-
derstand and justify the investment,”
he says.
Many potential customers are wary
of introducing more automation into

Midwest Acieta LLC
workforce. Consdorf explains the idea that robots sim-

ply replace human workers is simply not true, adding that
the tasks robots normally perform on a production floor
are mundane, repetitive tasks ill-suited for humans. By
giving these tasks to robots, manufacturers can move their
employees around the floor to handle more complex tasks,
increasing employee engagement and satisfaction.
By helping manufacturers increase the volume of produc-
tion, Consdorf says, robots such as the ones manufactured
and installed by Acieta create a ripple effect that results in
growth and ultimately more positions created for people.
“Robotics and automation create jobs, they don’t necessar-
ily replace them,” he says.
Fully Experienced
Once customers make the decision to take the plunge into
automation, Acieta makes a strong case to be their provid-
er of the robotic systems they will need. Consdorf says the
company’s experience and dedication to solving problems
for its customers make it the clear choice when compared
to the rest of the industry. “The first thing we have is just
the sheer number of years of experience,” he says. “We
robots like these built by

acieta help clients increase
productivity, which results in
growth and job creation.

Midwest Acieta LLC
acieta is strict about testing

and proving all of its new
technologies before integrat-
ing them into clients’ facilities.
have installed more than 4,500 also indicates its quality management nology before you put it into a cus-
systems in the United States.” ensures the highest quality. tomer’s facility,” he says.
Whether the customer needs one One of the latest and most promis-
system or multiples, Acieta has the Cutting-Edge Technology ing advancements Acieta has integrat-
capability and experience to build Acieta continues to live on the cut- ed into its product line is 3-D vision for
robotic systems that are scalable for ting-edge of technology, as evidenced bin-picking robots. This allows robots
growth and specific to the customer’s by some of the company’s most recent to select components and parts from
unique requirements. The company’s additions to its technological capabil- a random assortment much easier and
dedicated project management group ities. Consdorf explains that staying more effectively than in the past.
gives customers the peace of mind on top of the latest advancements in Another area of excitement for
that their project will be overseen robotics is one of the company’s pri- Acieta is the advancements in col-
from start to finish by an Acieta proj- mary goals. “When you’re an integra- laborative robotics, which is when
ect manager, rather than an engineer tor like we are, it’s very important to humans and robots work in the same
who may be juggling multiple projects test out and prove out that new tech- space. Unlike traditional robotic sys-
at the same time. This contributes to
Acieta’s 95 percent on-time delivery ‘the first thing we have is just the sheer num-
rate. “The end-product’s always dif-
ferent, but the process by which they
ber of years of experience. we have installed
are executed is the same,” Consdorf more than 4,500 systems in the united states.’
says, adding that the ISO certification - Blake Consdorf

Acieta LLC Midwest
No matter what the future holds

for the industrial automation sector,
Consdorf says Acieta will survive and
thrive thanks to the high quality of its
systems and the benefit those systems
bring to customers.
“We’re really helping our custom-
ers be competitive on a global level by
helping them do more and lowering
their costs,” he says. mt
acieta says its high-quality Lincoln Electric is the world leader in the design,
systems help its customers development and manufacture of arc welding products,
be more competitive on a
global level. robotic arc welding systems, plasma and oxy-fuel cutting
equipment and has a leading global position in the brazing
and soldering alloys market. Headquartered in Cleveland,
Ohio, Lincoln has 48 manufacturing locations, including
tems that needed to be heavily guarded a human is nearby and adjust its work to operations and joint ventures in 19 countries and a world-
to protect human workers from them, create a safer environment. These more wide network of distributors and sales offices covering
more than 160 countries. Lincoln Electric has proudly
the new breed of collaborative robots sophisticated robots also have the abil- worked with Acieta since 1995 and today is working to
are equipped with sophisticated sen- ity to prepare and hand components to provide new, innovative products that will keep Acieta at
the forefront of the industry.
sors that allow the robot to sense when human workers.

Dorner Mfg. Corp.
www.dornerconveyors.com / Headquarters: Hartland, Wis. / Employees: 195 / Matt Jones, Midwest
director of sales: “We’ve been growing nicely. We’re constantly adding new equipment.”
curves, accessories and more. If cus-

tomers need help choosing the right
solution, the product selector feature
will ask a series of application-relat-
ed questions intended to guide them
to the right conveyor. They can then
enter the appropriate specifications.
In both cases, the tool will deliver
a complete bill of materials and the
ability to download a variety of draw-
ing types, all available within minutes.
Customers then can request a quote
for the product.
“In relatively short order, we send
that off to our sales channel and
have that quoted,” Jones says. “The
customer can oftentimes receive a
preengineered conveying solution in
as short as three to 15 days from re-
ceipt of order, depending on the com-
dorner mfg.’s solutions
group enabled the company
plexity of their conveying request.”
to develop complex conveying
solutions for clients.
For more complicated systems,
Dorner Mfg. Corp. established a
Unique Position solutions group two years ago. “We’ll

take on complex conveying solutions
with requirements that are really tai-
dorner mfg. provides the right conveyors for lor-made to the customer’s applica-
tions,” Jones says. These can include a
a diverse range of client needs. by russ gager vacuum conveyor, one with a lift gate
or retracting tail and many more op-
Whether being used for industrial washing,” he continues. On the other tions, thereby allowing customers to
or sanitary purposes, conveyors from side of the wall in primary or second- achieve their product-handling goals.
Dorner Mfg. Corp. really keep things ary packaging, daily washdowns of All of the company’s conveyors are
moving. Director of Sales Matt Jones the conveyors may not be necessary, built-to-order.
says the company’s products touch so they can be made from stainless
on over 1,200 standard industrial steel or even aluminum. Manufacturing Efficiency
classifications. “We have a very wide “We’ve got a pretty unique position The company’s conveyors are sold
product line,” Jones asserts. “We rein the marketplace,” Jones maintains. mainly in the United States, Canada
ally have two paths to the customer. “Why we’re successful is we make a and Mexico, but they also are distrib-
We make products that are geared preengineered conveying solution uted in Europe, South America, Aus-
toward applications as different as that is really geared toward speed.” To tralia and Asia. “We have multiple
metal stamping and metalworking, the customer, that means getting con- people on staff who can speak Spanish
and pharmaceutical and food.” Some- veyors to them fast. Customers can and can support Mexico and Central
times those lines are easily blurred. access an online configurator 24/7 to and South America with Spanish lan-
“So in food and packaging – if design a conveyor. guage fluency,” Jones says. “We have
you’re on the hygienic side of the wall The configurator will guide them regional managers strategically locat-
– everything has to be sanitary and through a series of questions about ed around the country, and that group
stainless steel and designed for daily the width, length, elevation changes, is growing. We have a network of dis-

Dorner Mfg. Corp. Midwest
25 percent in the last one-and-a-half years. We’re sending

a lot of conveyors out to companies across North Ameri-
ca. Where we’ve seen our biggest growth is in the United
States because customers know they can buy conveyors
from us and they will get them fast.”
The company has a network of regional managers
to provide local support and a substantial field service
group. “We’ll send service people globally if needed,”
Jones declares. “Most of our field service is done across
North America, but we just sent a person to Chile to do
some local support and product training.”
For the future, Dorner Mfg. plans to seek additional
business in Asia. “We have a very strong sales channel in
India,” Jones notes. “They are doing a nice job for us. Our
goal is to grow by adding new products. We have been on
lean manufacturing allows
dorner mfg. to ensure rapid a new product introduction trajectory for the last four or
lead times and juggle many
priorities each day. five years that saw us adding two new product platforms
year-over-year. This new product growth will help us de-
tributors that is located across the country and in key velop more customers in Mexico and Central and South
markets around the world, including Canada, Mexico, America, as well as in the U.S. and Canada.” mt
Chile, England, Germany, India and the Netherlands.”
Dorner Mfg.’s quick lead times have been made possi-
ble by its use of lean manufacturing techniques. “We’ve
embraced lean manufacturing since 2001,” Jones re-
calls. “That is what on the manufacturing side allows
us to hit these rapid lead times. We’re used to juggling
many priorities on a daily basis and ship dozens of con-
veyors every day.”
The company has more than 100,000 square feet of
manufacturing at its headquarters in Hartland, Wis. It
obtains rollers and motors from third-party suppliers
but roll forms the conveyor’s frames and tig-welds the
stainless steel frames. A competitive advantage is that it
makes its own pulleys and belts.
“We have a belt process that is exceptional, Jones
maintains. “It is really very unique in the conveyor indus-
try, how we’re doing it and supplying our own belting. We
receive raw material and we cut and splice that accord-
ingly.” Conveyor belts can be made of fabric belting or
plastic chain materials. “We have rolls of materials in in-
ventory and we take that and cut it to length,” Jones says.
“Doing the belting gives us more control, faster delivery
and better quality.”
Conveying Growth
Dorner Mfg. is experiencing significant growth. “We’ve
been growing nicely,” Jones says. “We’re constantly add-
ing new equipment. We’ve expanded our labor force by

Bachman Machine Co.
www.bachmanmachine.com / HQ: St. Louis / Employees: 105 / Specialty: Metal stamping, tool
Midwest
and die and plastics injection molding / Bill Bachman, CEO: “Everybody wants it quicker.”
bachman machine’s parts are

shipped within 300 miles of
its st. louis base, but its dies
are shipped worldwide.
Stamp and Mold sign of a progressive die that was built

overseas, which did not complete the
complex part. “After the part came off
sophisticated technology and skilled employees of the progressive die, it was either
keep bachman machine co. a leader. by russ gager four or five more additional single hits
where you placed the part in the die,
stroked the press and manually took it
Whether designing tools and dies phisticated tools with generations of to the next station,” Bachman recalls.
for stamping, machining parts, build- experience are needed to keep man- “We did away with all that. We built a
ing plastic injection molds or making ufacturing returning to the United progressive die that finishes the part
hundreds of thousands of plastic or States, and that is what Bachman Ma- completely when the part comes off
metal parts, Bachman Machine Co. chine Co. provides. “One of our com- the end of the die. That was a large la-
has brought experience, knowledge petitive advantages is designing a die bor savings. You don’t see those every
and flexibility to its customers for so we can make adjustments while it is day, but it’s kind of cool when you do.
three generations. in the press without having to pull it,” It’s one we’re really proud of. The cus-
“We just keep trying to improve Bachman says. “That’s probably the tomer is saving some money.”
quality with better tool design and main one. A second thing is that our dies Bachman’s dies are shipped to the
features such as sensors to check are easier to work on. You don’t have to United States, Mexico, England, Sau-
things for us while a die is running or take a lot of things apart to get to what di Arabia, South Korea and Japan.
warn us if there’s a problem,” CEO you need to replace or sharpen.” Most of the parts it manufactures are
Bill Bachman says. An example of the kind of work that shipped within a 300-mile radius of its
Well-trained employees using so- Bachman Machine does is its rede- St. Louis headquarters.

Bachman Machine Co. Midwest
On Time With Quality tion-molded parts. “Customers are wanting to use high-
Bachman Machine Co. prides itself on having good on- er and higher strength steel in their stampings, so we’re
time delivery and quality. The company reports defects having to learn how to work with stronger materials,”
in the range of only 4 to 5 parts per million and is certified Bachman notes. “It’s harder to stamp them if they’re
ISO/TS 16949 and ISO 9001. “We try to anticipate what stronger materials, but the customers are doing it to save
problems there are before you design and build a tool so weight. They can use thinner material but the part will
they do not become an issue,” Bachman says. “Our tool have the same strength.”
room is capable of and does special little projects for cus- With five in-house CAD designers, Bachman Machine
tomers – protoyping or very small quantities of parts that Co. can create dies or molds for customers or make sug-
just have tight tolerances or a lot of detail to them. Cus- gestions for manufacturability. Many of the designers
tomers give them to us and they don’t as a rule of thumb built tools first so they understand the importance of
have to worry about them.” simplifying designs for manufacturing.
The company has 15 horizontal CNC machining cen- Bachman Machine Co. hires interns from local trade
ters and five vertical machines in its 105,000 square feet schools for its manufacturing and design positions.
in St. Louis that includes its metal stamping and tool- “That source for younger employees gives us a chance
and-die facilities. Its nine punch presses have capaci- to look them over and them a chance to look us over,”
ties from 60 tons up to 1,000 tons. Volumes range from Bachman points out. For the future, Bachman plans to
50,000 to millions of parts annually, but lower volumes purchase a new servo stamping press that can operate at
are possible for certain parts. variable speeds and investigate opportunities in supply-
Bachman Machine Co.’s plastics injection molding sub- ing parts and dies to the medical industry. mt
sidiary can handle a few thousand to millions of parts an-
nually in its 24,000-square-foot facility. A three-axis ser-
vo robot was installed on an injection molding machine
recently to join the other automation the company uses.
Approximately two-thirds of the company’s work is for
Tier 1 and Tier 2 automotive suppliers, with average runs
up to 200,000 parts annually. The plastics subsidiary
runs three shifts and the machining and stamping depart-
ments run two.
“As more and more models of cars come out, the vol-
umes in a general sense are shrinking,” Bachman ob-
serves. “It’s pretty amazing what the domestic, Japanese
and German manufacturers have planned for the next two
or four years. The trend is more cars with shorter runs. As
a rule of thumb, you just learn how to reduce setup time.
“Everybody wants it quicker,” he continues. “You keep
watching how you do things and look for better, more ef-
ficient ways. The way you locate dies is different and fast-
er now than it used to be. It’s more organized and better
coordinated. I’ve been here full-time since 1975, and lead
times on tools probably are half what they were when I
first started. So everybody has gotten better.”
Higher Strengths
Bachman Machine Co. is experienced with a variety of
materials ranging from various grades of ductile and
grey iron, stainless steel, aluminum and plastic mate-
rials whether in castings, bar stock, forgings or injec-

Creative Automation Inc.
www.cautomation.com / Headquarters: Whitmore Lake, Mich. / Employees: 60 / Bernd Midwest
Walter, owner: “We are detail-oriented and take care of the customer throughout the process.”
tomation solutions to a diverse client

base around the world. In addition to
its 50,000-square-foot manufactur-
ing facility in Michigan, the company
has sales and service offices in China
and Mexico.
No matter what type of automation
solution its customers require in their
facilities, Creative Automation is fo-
cused on providing them with the sys-
tems that meet their exact needs, be
they turnkey or smaller subsystems.
This is made possible by the staff of
knowledgeable and experienced en-
gineers the company brings to each
project as well as the highly skilled
shop workers who bring the systems
to reality. This gives Creative Auto-
mation’s customers a degree of confi-
dence that wouldn’t be possible with
creative automation’s experience
in assembling custom-engineered
other providers. “We are detail-ori-
systems results in systems that
work together well.
ented and take care of the customer
throughout the process,” President
Peace of Mind Bernd Walter says.
Partnering For Success

many top manufacturers rely on creative Creative Automation’s experience in
assembling custom-engineered au-
automation’s solutions. by chris petersen tomation systems puts it at the top
of the industry, and results in sys-
For major manufacturers such as the company says its approach to de- tems that work together in harmony.
GM, John Deere and Hitachi, automa- veloping custom-engineered turnkey “While the individual components of
tion is what keeps their production fa- automation solutions has been key to an automation system are easily ob-
cilities operating at the levels needed its success. tainable, the true value comes in mak-
to maintain their positions as global The company was founded in 1994, ing them work together,” according to
leaders. These companies need a part- when owner Bernd Walter purchased the company. “With our solid back-
ner that provides automation solu- the U.S. material-handling division of ground as a systems integrator and
tions they can count on to bring maxi- an automation solutions provider. Al- 20 years of experience in automation,
mum efficiency and effectiveness. though the original focus in those ear- Creative Automation Inc. can provide
In many cases, these and other gi- ly days was on gantries and pick-and- a variety of applications, including
ants of the manufacturing world turn place systems, Creative Automation’s complete automation systems, con-
to Michigan-based Creative Automa- scope has broadened over the years, veyor system, machine tool loading
tion Inc. a RIA-Certified Robot Inte- adding robots, vision systems, RFID and unloading, and palletizing of
grator With facilities in the United and other technologies to its portfo- blanks, finished parts and packages.”
States, Mexico and China, Creative lio. Today, Creative Automation pro- Creative Automation has partnered
Automation has the global reach nec- vides equipment including robots, with some of the world’s leading pro-
essary to serve many of the world’s conveyors, palletizers, deburring sys- viders of other automation technolo-
most prominent manufacturers, and tems, dispensing units and other au- gies to become an experienced inte-

Creative Automation Inc. Midwest
Creative Automation is being proactive about keeping

its employees up to speed. Walter says the company has
established training programs aimed at educating em-
ployees about the newest developments in automation
technology, and, the company regularly sends employees
out for training from third-party providers.
Growing Through Technology

Incorporating new technology is another way in which
Creative Automation is working to stay on top of the
competition, and the company always is looking to build
on its past success. “We continuously improve our prod-
ucts, and therefore satisfy the requirements from the
customer,” Walter says.
Currently, Creative Automation is deepening its ex-
pertise as an integrator of vision systems, as well as RFID
technology and plasma treat systems. By adding to its ca-
pabilities, Creative Automation it putting itself in a bet-
ter position to serve its customers well into the future.
creative automation strives to
remain ahead of competition by
“We will grow with the business,” Walter says. mt
incorporating new technology.
grator of those products. For example, the company has

partnered with robot manufacturers including FANUC,
ABB and Denso. Working with partners such as Ger-
many’s Ro-ber GmbH, Creative Automation has added
palletizing to the list of solutions it can offer customers.
The company also has partnered with EFTEC Engineer-
ing GmbH to integrate robotic dispensing into its sys-
tems, and technology from WMS-Engineering GmbH
and Mannesman-Demag gives Creative Automation de-
burring system capabilities to remove burrs from preci-
sion-machined parts. It also provides advanced cleaning
technologies from its partner, trt oil-off GmbH.
By working together with a variety of leaders in au-
tomation such as conveyor systems supplier Altratec
Montagesysteme GmbH, allows Creative Automation to
bring the most sophisticated technology in the world to
its customers’ facilities.
Staying on Top
Given the highly technical nature of the equipment Cre-
ative Automation designs and builds, keeping up with
the ever-changing state of technology is the company’s
greatest challenge. Specifically, making sure the compa-
ny’s personnel are all kept up to speed on the latest tech-
nology is its top priority. Walter says, “You have to have
people trained for that.”

Airmaster Fan Co., a member of the Maico group
www.airmasterfan.com / Annual revenue: $175 million (Maico Global) / HQ: Jackson, Mich. / Midwest
Specialty: Commercial and Industrial circulation and ventilation fans /
“Our Airmaster brand is synony-

mous with quality, as we sell the best
fans in the business,” Laabs contin-
ues. “The end-user is not going to
have to re-buy the same fan every one,
two, three or five years. They trust
Airmaster. We have had fans in the
field operating in excess of 25 years.”
Airmaster products use superior
materials with higher-gauge metal.
“Other brands sell disposable, cheap
import fans,” Laabs declares. “They
use a lesser-gauge metal and inferior
components, all for the sake of reduc-
ing the price. For us, the best-quality
product is the only viable solution.”
This includes a heavier and wider ped-
estal base and high-gauge steel from
the Alro Steel Corp.
The amount of cubic feet per min-
“it is easier to explain price
once than to apologize
ute of air that Airmaster Fans produce
for quality forever,” vice
president ed laabs says.
is certified via the Air Movement Con-
trol Association (AMCA) lab. “Air-
Fan Favorite master can verify the performance of

our fans vs. the competition and this
is an advantage that our competition
airmaster fan is leading a paradigm shift in does not offer,” Laabs explains.
Airmaster also has an exclusive re-
industrial fan distribution. by jeff borgardt lationship with a vendor to produce
fan motors per their specifications.
When it comes to cooling hot fac- and understand the challenges that This separates Airmaster from other
tories, Airmaster Fan Co. doesn’t mess they face in the field,” Laabs says. “We fan manufacturers that all procure
around. “We provide the best-quality also work with the best professional similar low-quality motors, he says.
fan there is,” says Ed Laabs, vice pres- manufacturing representatives part- “This is a big competitive advantage
ident of sales and marketing. ners across North America. These for us because our fans do not look
“Our products are made in Mich- sales professionals are experts at de- like other brands and offer quality.”
igan and we also manufacture in veloping and nurturing relationships. Laabs states. “Our customers enjoy
China, using superior materials for Together, we provide solutions to our a lower cost of ownership because
optimal performance,” Laabs states. end-user manufacturers.” Airmaster Fans are built to last. The
“This, along with an excellent distri- Airmaster Fan also provides cus- end-user does not have to settle for an
bution network, allows us to man- tomized product training for distrib- inferior product to move air. End-us-
ufacture the best fan there is in the utors and representatives utilizing ers are willing to pay a little more for
industrial marketplace.” both online and live presentations. price, providing they receive a quality
“This format allows Airmaster to tar- product. This is exactly what they get
Relationships and Quality get specific industry applications and with by investing in the quality Air-
The Airmaster Fan Co. focuses on re- this makes our training relative to the master Fan offers.”
lationships and product quality. “We distributors and the market segment Airmaster supplies many custom-
partner with the right distributors where they do business,” Laabs says. ers in the automotive, agricultural,

Airmaster Fan Co., a member of the Maico group Midwest
food processing and municipal sectors to be a member of a globally recognized which $2.6 billion is industrial circula-
with stocking warehouses across North industry leader. I like to tell our custom- tion fans. Yet much of the business flows
America. “We not only service the man- ers that Airmaster does not answer to a through big-box channels. “End-user
ufacturing and warehouse circulation/ corporation on Wall Street, instead as a manufacturers buy from independent
ventilation needs in North America, we family owned business we answer to our distributors because they trust them,”
also work with city/state and govern- customers on Main Street.” Laabs says. “We are seeing a paradigm
ment applications in North America. It also sells and markets through buy- shift as manufacturers begin to think
Airmaster also does business interna- ing groups. Laabs is active in both the outside of the big-box store and look at
tionally in Saudi Arabia and areas of Eu- Affiliated Distributors and NetPlus Alli- independent distributors for fan solu-
rope,” Laabs points out. ance Supplier Councils, and was recent- tions. The growth potential for Airmas-
Since Airmaster was acquired by the ly appointed to the board of directors for ter and our distributor partners offers a
German-based Maico Group in 2013, its the Industrial Supply Association. “Our bright future for fan sales.” mt
global profile has grown. The combined partnership with these buying groups
Alro Steel is a metals service center with 60 locations
companies have annual revenue in ex- has helped to drive our brand exposure in 12 states. Alro distributes metals, industrial supplies and
cess of $170 million. “The Maico Group with their industry-leading distributors. plastics. Alro offers cut-to-size metals and plastics with
next day delivery to over 25,000 customers in North Amer-
purchase brings additional new market Airmaster is also committed to the ISA ica. The metal inventory includes: aluminum, alloys, carbon
opportunity, fan innovation and prod- and the relationships that this organiza- steel, cast iron, stainless steel, tool steel, brass, bronze and
copper. Integrity. Loyalty. Honesty. These principals have
uct expertise to Airmaster,” Laabs says. tion brings to the industry.” guided Alro since our founding in 1948 by brothers, Al and
Robert Glick. Metals & Plastics, Cut To Size, Delivered Next
“Maico is also family owned so there are According to AMCA, the air circula- Day. Place your order today at www.alro.com.
excellent synergies and we are excited tion market is valued at $4.4 billion, of

Star International Holdings Inc.
www.star-mfg.com / Headquarters: St. Louis / Employees: Approximately 350 / Specialty: Com- Midwest
mercial foodservice equipment / Brian Kearins, president: “We’ll continue to be an innovative leader.”
Shining Star
star international has earned a reputation as a reliable
supplier to restaurant chains. by alan dorich
star international holdings

specializes in manufacturing
commercial foodservice equipment.
can pro-
After more vide a vari-
than 90 years, ety of solutions for toasting,
Star Interna- panini configurations, ventless hood
tional Holdings agement ex- systems and hot/cold holding due to
Inc. stands as a panded the product our incredible flexibility,” he says.
leader in its indus- line to include broilers, fryers and “Those restaurant chains are a
try, President Brian griddles. Star International acquired very important part of our tech-
Kearins says. “We are known for our Helmco Lacy in 1962, ToastMaster in nology development that provide
technology, innovativeness and value 1997, Holman in 2002 and Lang in solutions that address very specific
to our customer,” he says. 2007. In 2008, the Middleby Corp. needs to their cooking platforms,”
Based in St. Louis, the company purchased Star International and he says, noting that these customers
designs and manufactures commer- in 2009, merged Star International include a myriad of all the top chains
cial foodservice equipment, includ- with Wells Bloomfield. in the world.
ing griddles, char broilers, drawer Star International now employs The remainder of its clients con-
warmers, conveyor and convention over 375 employees in three manufac- sists of dealers that sell to restau-
ovens, and sandwich grills. Kearins turing facilities and has sales offices rants, schools, universities and are-
notes that Star International started in 15 countries. Star International is nas/stadiums. Those markets have
operations in 1923 as a small equip- just one of 50 Middleby brands re- “a high degree of interest [in] the
ment company. spected worldwide. latest and greatest technology, such
Jullian Burch, the founder of Star Today, restaurant chains comprise as panini grills, waterless hot holding
International began building elec- a large percentage of its business and and high speed toasters, which is pri-
tric popcorn poppers in 1923. Over it’s continuing to grow. “We are well marily what we’re known for,” Kear-
the years, Star International man- known in the QSR market because we ins says.

Star International Holdings Inc. Midwest
Being a Partner
Kearins joined Star International in March 2014. “My back-
ground is in general management and finance,” he says. He
credits the company’s success to its products and its parent
company, Middleby Corp.’s push for leading, cutting edge
technology. “Middleby’s innovativeness and technology are
unparalleled in the industry.”
For example, “Star has pioneered the technology of coun-
tertop cooking equipment from the standpoint of lower en-
ergy, cleaning and faster cycle times,” he says, noting that
these products are widely used by many national chains.
Under Kearins’ tenure, Star International has “essen-
tially adapted a new company vision of intertwining the
customer’s needs and over delivering on concepts and
prototypes. This makes for a very busy and sometimes
stressed out engineering department,” he says. “We’ve got
to be more of a partner with our dealers, reps and consul-
tants to be more of a solution to their cooking challenges.”
So far, “We’ve done a fantastic job of that and it’s showing
product-wise,” he says. “We’re working with several high
profile chains in the areas of advanced technology toasting
and customer solutions that are unique to them.”
Quality Investments
Star International concentrates on maintaining quality,
which has earned it an ISO certification, Kearins says. Its
quality investments have included testing equipment fix-
tures while they are “not at the end of the [manufacturing]
line, but in the line,” he says. “Because by the time some-
thing gets at the end of the line that’s incorrectly made, it’s
too late.”
Its recent state-of-the-art manufacturing investments
allow Star International to considerably ramp-up much
needed production and increase its lead time to custom-
ers due to a much more flexible and automated fabrication
area. It recently added a new fiber optic laser, a bender and
a deburring machine. All three machines “ultimately [im-
prove] the quality of the product exponentially because it’s
all automated,” he says. “There is no human factor that you
might have in a press brake.”
Star International has started training its employees in
the concepts of lean manufacturing. “We hope to be fairly
KG Machine It’s more than a piece of steel; with KG Machine it becomes endless
griddle plate possibilities. Producing over 1,500 different configurations of griddles
for nearly a quarter century, the company focuses on technology, experience, and a
strategic partnership with Star International Holdings Inc. to bring beauty and efficiency
to the centerpiece of residential and commercial kitchens around the globe. For more
information, visit www.kgmachine.com.

Midwest Star International Holdings Inc.
essential] are the proper working

star international holdings says
it places a lot of emphasis on conditions that enable the employee
building its products with quality.
to work in a safe environment.”
All in Place
Star International is disciplined when
it comes to its inventory. “We run our
business with an enterprise resource
system and rely heavily on our ven-
dors to support our production re-
quirements as well as planning labor
internally,” Kearins says. “Missteps in
accounting for inventory can only end
badly in meeting customer lead times
so it’s vitally important that compo-
nents are accounted for correctly.”
For example, “If there is scrap, [we
want to make sure] that fabrication
prod- removes it quickly so as to not allocate
u c t metal to a work order or that work-or-
right but ders are properly closed so our WIP is
maintaining accurate,” he says. “The key to inven-
lean principles tory management is to instill in every
such as house- employee that accurate and timely
well into the implementation by keeping, recordkeep- transactions are the key to proper in-
the end of the year as far as incorpo- ing and partnering with our suppli- ventory control.”
rating some of the lean principles,” ers,” he says.
Kearins says. “These are just a few of the items Looking Forward
“[We’ve trained] our folks that that contribute to the quality of the Star International encounters many
product quality is just not building the final product,” Kearins says. “[Also challenges in its industry, but the
Internet represents the largest one,
Kearins says. “It continues to add an-
Flexible Cooking other dimension to the industry that,
Star International Holdings Inc.’s products include its Pro-Max and Grill Express two-side grills. Both offer
users speed and the ability to grow menu options with minimal space commitments, the company says.
quite frankly, manufacturers are still
“These two-side grills may well be the most flexible piece of cooking equipment [users] will own, capable of trying to figure out,” he says.
delivering menu items for every [meal],” it states. Brick-and-mortar dealers are com-
The grills can cook pancakes, sausage and bacon, sandwiches, quesadillas and burritos, steaks and chicken peting strongly against e-retailers,
breasts. “Food even tastes better because everything cooks evenly, preserving its wholesale flavor by simulta-
neously searing it and sealing natural flavor on both sides,” Star International says.
Kearins says. Because of that, “Pric-
Several of the country’s leading restaurant chains use the Pro-Max grills, the company says. “They’ve dis- ing can become a very difficult item
covered the advantages of tremendous menu flexibility, portability, ease of use, minimal space required and to manage so that you’re not un-
no ventilation necessary in many instances,” Star International says. dercutting price for your customer
The grills are designed for high-volume use. They are “available with a smooth cooking surface, ideal for
base,” he says.
serving quesadillas or a breakfast menu second to none, or a grooved surface to deliver double-sided searing
that adds visual appeal while sealing in the natural flavor of meat, seafood or sandwiches,” the company says. Despite this challenge, Kearins says
“The time for Pro-Max is now,” Star International continues. “Customers want a wide variety of good food, he believes Star International’s out-
and the faster, the better. In fact, the fastest-growing segment in our business is quick-casual dining. look is positive for the foreseeable
“Today’s busy customer is willing to pay for pizzazz on the plate, and they don’t want to wait,” it adds.
future. “We’ll continue to be an inno-
“With Pro-Max grills, [restaurants] will deliver an endless variety of cuisine, quickly and with minimal counter
space.” vative leader and invest in our engi-
neering,” he says. mt

Vantage Plastics
www.vantageplastics.com / Headquarters: Standish, Mich. / Employees: 120 / Midwest
Specialty: Thermoforming packaging and recreational products
“We worked with a local compound-

er to come up with VanTech, which is
a unique blend of materials exclusive
to us,” Aultman explains. “We can
coextrude it to a sheet. It reduces the
amount of chafing of plastic material
particles that might get into the com-
ponent. That was a huge thing for us.
Having this as a proprietary compound
helps us control chafing and provide a
cost-effective, solution-based product
for our customers. We’re a very solu-
tion-driven company.”
Alternatively, urethane inserts are
placed in the trays. “You manually put
the inserts in between the tray and the
product that goes into the tray,” Ault-
man says. “It requires a lot of labor
and cost, because these get attached
by putting a hole in the tray and put-
vantage plastics says it
owes its success to the
ting an insert in there. So you create
strong team of people
working for it.
the same debris you don’t want as you
drill the hole in the tray.”
Solution Driven VanTech plastic can be coextruded

on both sides of a tray like a sandwich,
on top of another layer of plastic or
vantage plastics is capable of thermoforming it can be applied with adhesive in dif-
ferent places on a tray in the shape of
a wide variety of products. by russ gager buttons or strips. “VanTech is com-
patible with the tray material,” Ault-
Being a vertically integrated ther- LLC. Subsequent products such as man adds. “It can be ground up and
moformer enables Vantage Plastics trays have the shape of a component reused to produce new products with-
to create innovative products for its molded into them and are used to out contaminating the base materials.
customers. “We do not depend on off- package components and assemblies Urethane inserts have to be removed
site suppliers’ timelines to supply our for transport to production lines. from trays before they can be recy-
needs in extruded sheet,” President Some of the transported compo- cled or you create contamination and
Paul Aultman insists. “We buy the res- nents, such as automobile transmis- compatibility issues.”
in that we use, which allows our cus- sions, may have sharp edges which
tomers more value and us some mar- would normally chafe the plastic, cre- Pallets and Pools
gin opportunity vs. buying the sheets ating debris. This debris could cause Besides assembly trays, Vantage Plas-
from an outside source. This allows significant issues downstream. Van- tics also thermoforms interior auto
the flexibility of coming up with your Tech prevents this longstanding issue body components and underbody
own products and controlling them.” in a very cost-efficient and effective panels on consumer vehicles and light
One example of a product that is manner. Ensuring that components trucks for protective shielding from
exclusive to Vantage Plastics is a com- are delivered undamaged to the as- flying debris. Aultman estimates that
pound called VanTech. It is coextrud- sembly line is the task of the thermo- up to 55 percent of the company’s
ed on preproduction flat sheet by Van- formed packaging designed and man- volume is for the automotive market.
tage’s sister company, Airpark Plastics ufactured by Vantage Plastics. The company has diversified into pro-

Vantage Plastics Midwest
duction of pallets and recreational products, such as small

swimming pools for children and bases for ice fishing sleds.
The next largest market for Vantage Plastics after auto-
motive is material-handling products, such as pallets. “We
have a variety of standard plastic pallet tooling, and we can
sell to many different industry segments,” Aultman points
out. The pallets can be reused and then returned to Vantage
Plastics and recycled at the end of their useful lifetimes.
New Addition
Vantage Plastics is adding 36,000 square feet to its manu-
facturing space, due to be completed this spring, at its head-
quarters in Standish, Mich. This will bring total operational
space to more than 170,000 square feet. Extrusion lines will
be housed within this new addition, including a new line
that can produce a 120-inch wide sheet. The new machine
will join three other extruders that can produce enough
raw plastic sheet to feed the company’s 12 thermoforming
machines. Since one of these thermoforming machines is
among the largest in the world, and features a 10-foot by 20-
foot platen, a full spectrum of products can be produced.
This also provides the capacity to handle high-volume pro-
duction jobs.
That large machine can form a single large part or several
smaller parts in quantity. “If somebody wants a million piec-
es of a pallet, we might make six tools and put all six tools in
there to maximize the throughput and delivery time for the
customer,” Aultman says. The company also uses robotics
and CNC equipment in its manufacturing operations.
The company’s products are distributed internationally.
“We have a number of customers that are in Canada and
Mexico,” Aultman says. “We ship to Europe, and we’ve got
customers that are based in the Netherlands. However,
with the focal point of the auto arena still in the metro area
of Detroit, it is still a good, solid base.”
Vantage Plastics’ diversification into non-automotive in-
dustries was motivated by the Great Recession. “We have
over 400 customers, and I would say out of the top 10, five
or six are non-automotive,” Aultman calculates.
He attributes the company’s success to its hard-working
employees and to his being a person of faith. “We were one
of the ones that survived, but literally by a thread,” Aultman
recalls. “It was a very tough time. I attribute our success to
the dedication of the people here. We got way more efficient
and reduced our scrap rates. We really learned a lot about
ourselves and made some dynamic improvements. We did a
lot of training during that time and are a lot better company
today for that.” mt

New Era Converting Machinery Inc.
www.neweraconverting.com / Headquarters: Paterson, N.J. / Employees: 70 / Specialty:
Northeast
Custom web converting equipment
Web Masters
new era converting machinery inc. relies on its vendors to supply the quality
components it needs for its custom web converting machines. by jim harris
new era converting machinery

says it looks for suppliers
with superior quality, delivery
and pricing.
As a world-leading provider of manner in which we do assembly, so work of qualified or pre-qualified ven-

processing equipment to the web con- those are the most critical elements.” dors,” Pasquale says. The company’s
verting industry, New Era Converting The company meets with prospec- vendors are typically grouped based
Machinery Inc. regularly hears from tive vendors to review their capabil- on their areas of expertise, such as
potential suppliers eager to do busi- ities, then solicits bids to determine suppliers of high-precision compo-
ness with the company. pricing and delivery times. New ven- nents or providers of large fabrica-
When it comes to choosing pro- dors initially supply New Era with a tions and frames.
spective vendors, the company takes small quantity of non-critical path One long-time supplier, Simco-Ion
a highly considered approach. “We’re parts. If the vendor proves to be Industrial Group, provides pre-en-
looking at three things: quality, on- worthwhile, New Era then engages gineered static control devices for
time delivery and price,” President it in a deeper relationship including machinery. These devices are used in
Bob Pasquale says. “Quality for us is having the vendor develop and supply a wide variety of systems, including
first and foremost, and the ability to more critical parts. winding machines that prevent static
get components on time is extremely “We have many successful long- electricity build-up, Pasquale notes.
important because of the just-in-time term relationships with a large net- More than 95 percent of the custom

New Era Converting Machinery Inc. Northeast
fabricated components in New Era’s Both families agreed that the new
machines are produced in the United company would be better served work-
States or Canada. All parts received by ing as a customer-facing and research
the company are put through a rigor- and development-oriented company
ous inspection process and are tracked with testing and assembly capabilities
for quality purposes. “We buy a signif- instead of as a manufacturer of custom
icant amount of the parts we use from parts, Pasquale notes.
outside suppliers, so we use a software The company today designs and de-
package that allows us to track every tails components that are fabricated
part as well as every vendor who makes by vendors before being brought back
parts for us,” Pasquale says. “We con- to New Era’s 50,000-square-foot fa-
stantly review that list to make sure cility in Paterson, N.J., where they are
our vendors are meeting our quality tested, inspected and assembled into
requirements.” machines.
Equipment assembled by New Era
Custom-Built Solutions includes unwinding and winding ma-
Component suppliers have played a chines, coating machines, laminators,
central role in New Era’s operations embossers, calenders, dryers, drive and
throughout its history. The company control systems, roll-handling equip-
was founded in 1992 as a joint effort ment and web-handling systems. Ma-
between Pasquale’s family, which had chines produced by the company are
produced web converting machinery used in the production of packaging,
since 1946, and the Lembo family, a electronic media and reflecting sheet-
former “friendly competitor” that had ing products, among other products.
owned a company that manufactured “Our customers are converters who
similar machines since 1947. process materials in ‘roll to roll’
since 1992, new era has

provided custom web
converting equipment for a
variety of applications.

Northeast New Era Converting Machinery Inc.
New Era builds all of its machines to customer specifi-

cations. “We think our specialty is custom-built convert-
ing machinery,” Pasquale says. “We don’t have a standard
product line or machine offering – our business is engi-
neering solutions to meet customer-specific needs.”
This takes one of two forms. Customers either ap-
proach the company with a particular product they want
to make and rely on New Era’s expertise and experience
to develop a machine or concept to meet the require-
ments of manufacturing that product, or provide the
company with a concept or specification.
“I think our proudest achievement is our ability to pro-
new era provides turnkey duce highly customized large-scale machinery,” accord-
solutions for equipment
including installation, ing to Pasquale.
freight and start-up.
Pre-inspected parts are assembled and optically
or ‘roll to sheet’ format,” Vice President Paul Lembo aligned to high tolerances. Once parts are assembled,
explains. “The most common substrates our machines the machine is wired, piped and tested before shipment.
handle are papers, films, foils, fabrics and foams; howev- “Despite the fact that our equipment is usually one-off,
er, we also work with other materials like flexible glass, purpose-built machinery, our customers expect minimal
rubber and metals.” machine-related downtime and high-precision compo-
nents/manufacturing practices,” Lembo says.
New Era’s turnkey services also include installation,
freight and start-up services. Customers are also provid-
ed technical information including mechanical, electri-
cal and utility drawings.
“we don’t have a standard product

line - our business is engineering
solutions to meet customer-specif-
ic needs.” - Bob Pasquale
Steady Growth
The company in recent years has improved upon its ca-
pabilities by moving from a traditional two-dimensional
engineering and design software platform to a 3-D plat-
form. This upgrade prompted the company to purchase
new computer hardware, Pasquale says.
New Era also has hired more engineering, assembly
and electrical wiring technicians to meet an increased
demand for its services. “What we find is that our cus-
tomers are continuously trying to either improve upon
the process they use to make their products or develop
new products and enter new markets,” he adds. “Our
growth has been steady and progressive, with most of it
coming as our customer base continues to expand.” mt

Electri-Cord Mfg. Co.
www.electri-cord.com / HQ: Westfield, Penn. / Employees: 400-plus / Specialty: Wiring
Northeast
harnesses and assemblies / Dennis McDonald, VP and GM: “We are fast, responsive and consistent.”
Wired For Anything

electri-cord designs and produces custom electrical
wire harnesses and cable assemblies. by jim harris
electri-cord specializes
in contract electronics
manufacturing for a global
client base.
Electri-Cord Mfg. Co. is dedicated States, Mexico and Asia and maintain- facility in Northborough, Mass; a
to meeting the needs of its customers, ing inventory in local distribution and 53,800-square-foot manufacturing
regardless of where those customers sales facilities to provide products facility in Guadalajara, Mexico; and
are located in the world. “Our custom- “when and where our customers need a distribution center in Mendota
er service, and our ability to respond it,” he adds. Heights, Minn. An affiliated partner
and react to customer needs, set us The company can rapidly supply company, I-Sheng Electric Wire &
apart,” explains Dennis McDonald, samples and inspection data and Cable Co. Ltd., operates plants in Tai-
vice president and general manager of can offer international manufactur- wan, China, Vietnam and Brazil. All
the Westfield, Penn.-headquartered ing services to customers regard- of Electri-Cord’s facilities have engi-
operation. less of their location. Electri-Cord’s neering and quality departments with
The company takes what it calls a North American operations include sales representatives across the coun-
“Globally local©” approach to busi- a 55,000-square-foot manufacturing try to provide their customers with a
ness, which includes utilizing man- headquarters in Westfield, Penn; a world-class manufacturing partner.
ufacturing facilities in the United 15,000-square-foot manufacturing Electri-Cord’s strategically locat-
MAY/JUNE 2015 2015 manufacturing-today.com 139

Northeast Electri-Cord Mfg. Co.
responded to a reduction in military

spending by entering new markets
including the medical, life science
and industrial manufacturing sectors.
Electri-Cord took a big step in this
direction in 2014, when it acquired
Northborough, Mass.-based ORM, a
wire harness, panel and box build con-
tract manufacturer serving this grow-
ing business sector in New England.
The acquisition brings with it the
ISO 13485 certification for medical
device manufacturing. Electri-Cord’s
other certifications include ISO 9001,
ITAR, UL 508 and UL 698. The com-
pany is in the final stages of preparing
and auditing for the TS16949 approv-
al, which is expected by the end of
2015 to better serve its customers in
the automotive market.
“All Electri-Cord products car-
ry the appropriate certifications for
electri-cord’s strategic
markets include military, their industry and geographic market,
alternative energy, medical
and automotive. and meet or exceed all required safety
and quality standards,” the company
ed manufacturing plants allow it to Adapting to Needs says. “In addition, we have incorpo-
serve customers from one or more of Established in 1946 as a power cord rated automated systems in many ar-
these facilities. If a customer needs a company, Electri-Cord today special- eas that have resulted in fail-safe test-
quick-turn prototype it may be built izes in contract electronics manufac- ing on machinery.”
in one of the company’s U.S.-based turing including wiring harnesses, The company’s testing process-
facilities and moved to a lower-cost cable assemblies and electrical pan- es include its usage of the CT100
facility when the project reaches full el builds. The company also offers a Semi-Automatic Power Cord Tester,
production. Having multiple plants plethora of domestic and internation- equipment it designed. The CT100
also gives the business a contingency al power cords. tester is the most widely used pow-
plan if something were to happen at Electri-Cord’s strategic markets er cord tester in the world. “This is
one of these facilities, as each of the include military, alternative energy, the golden standard for power cord
others share the same capabilities. medical/life science and automo- testing, and many of the largest glob-
“Our customers’ business depends tive/transportation. The company’s al OEM companies require this test
on quality suppliers who consistently adaptability to multiple markets has on all power cords manufactured for
produce reliable products on time and allowed it to weather a number of eco- them,” Electri-Cord adds.
to their specifications,” the company nomic downturns and market chang-
says. “At Electri-Cord, our mission es and enabled it to outlast many of Product Life Cycle
is to meet the ever-evolving needs of its competitors. “We’ve been able to Electri-Cord’s manufacturing capa-
our customers by manufacturing a adapt by asking our customers what bilities include all aspects of wire and
broad portfolio of high quality elec- their problems are, and helping them cable assembly processes from cut-
tronics products and offering a range come up with solutions,” CEO Mitch ting, terminating, soldering, molding,
of custom capabilities that add value Samuels says. harnessing and testing for the sim-
and distinct advantages.” Most recently, the company has plest to the most complex of prod-

Electri-Cord Mfg. Co. Northeast
ucts, McDonald notes. The company manufactures systems

entirely to the specifications of its customers, which in-
clude 25 Fortune 500 companies. “We are fast, reactive and
consistent,” McDonald says.
Electri-Cord can tailor its production schedules directly
to customer needs, and can dedicate manufacturing cells to
a single customer if added specialization is needed. Prod-
ucts are designed in collaboration with our customers.
“With us, it’s a womb-to-tomb scenario,” he adds. “We can
take a product from early design through ramp-up and pro-
duction all the way to the end of its life. Many of our com-
petitors don’t do that.”
The company is assisted in its efforts by vendors includ-
ing ComTec Solutions, who provides comprehensive IT
solutions to Electri-Cord. “They know our business inside
and out, we consider them a strategic partner who helps us
optimize the use of our information systems to achieve ex-
cellence in the industries we operate in,” Samuels says.
Samuels and McDonald credit much of the company’s suc-
cess to its technical and manufacturing staff, many of whom
have been with the company for a number of years. “I’ve
given out a dozens of 40-year commemorative watches, and
I give out multiple perfect attendance awards each year,”
Samuels adds. “We’re a very good company to work for.” mt
electri-cord’s manufacturing
capabilities include all
aspects of wire and cable
assembly processes.

GM Toledo Transmission
www.gm.com / Headquarters: Toledo, Ohio / Employees: 2,028 / Specialty: GM transmissions /
Northeast
Joe Choate, plant manager: “Nothing is allowed to leave the workstation if it’s not right.”
Poised for Growth

gm toledo transmission operates a disciplined operation
with continuous improvement measures. by janice hoppe
gm toledo transmission GM Toledo Transmission has

manufactures and assembles
gm’s front- and rear-wheel- built a long-standing reputation for
drive transmissions.
quality, productivity and performance
over the past century and maintains it
today through a disciplined manufac-
turing system. “We are recognized
through an internal assessment by
GM as being one of four plants to re-
ceive its Built-In Quality Level Four
Award because of our discipline and
the involvement of our people,” Plant
manager Joe Choate says. “The To-
ledo facility is one of the highest as-
sessed plants in the corporation.”
The Toledo, Ohio-based plant was
founded in 1916 to produce truck
transfer cases and transmissions
for four- and six-wheel-drive mili-
tary trucks throughout World War
I. Today, the team manufactures
and assembles GM’s front- and rear-
wheel-drive transmissions in its two-
million-square-foot facility that sits
on 151 acres. “We are the largest trans-
mission manufacturer for GM, mak-
ing twice the products other plants
make,” Choate says.
Over the past nine years, GM has
invested more than $1.2 billion to
enhance Toledo Transmission’s op-
erations. In February 2006, $540
million was invested in its six-speed,
real-wheel-drive transmission capa-
bilities and another $323 million was
invested in May 2007 for six-speed,
front-wheel-drive transmissions. GM
invested $240 million for new eight-
speed transmissions in May 2011 and
$82 million one month later for en-
hancements to those transmissions.
Most recently, GM invested $30.6

GM Toledo Transmission Northeast
gm toledo transmission says its

entire workforce demonstrates
a sense of ownership and pride in
what they build.
million for six-speed transmission components and rebuild a brand new its process so parts can only be put
capacity increases at Toledo Trans- unit from the ground up.” together one way. If a piece fails er-
mission. “This investment signifies When Choate came to Toledo ror-proofing tests, the line will shut
a commitment to the men and wom- Transmissions 10 years ago, he helped down and alert a team member in
en of Toledo Transmission and their integrate a change of philosophy by the area to resolve the problem. “We
dedication to build the world’s best enhancing discipline within the man- have the lowest overall warranty cost
transmissions,” Choate notes. “The ufacturing system, the plant does associated with products coming out
entire workforce exhibits a sense of not allow anything manufactured to of here,” Choate notes. “Our abili-
ownership and pride in the trans- be repaired on the line. GM’s invest- ty is running 99.8 percent first-time
missions they build. This continued ments in new products, design and quality through processes. It’s that
dedication will lead Toledo Trans- equipment allowed Toledo Transmis- discipline that nothing leaves the sta-
mission with our shared vision of sion to build transmissions right the tion if it’s not right and our employees
continuous improvement and com- first time. “Everything has a formula taking ownership in the product that
mitment to quality, and ensure the that must be followed in a disciplined makes all the difference.”
success of our efforts.” format to ensure proper quality lev- The company does not have excess
els,” Choate says. inventory for any part of its manufac-
Disciplined Operations Toledo Transmission error-proofs turing processes. Components are
“Nothing is allowed to leave the work-
station if it’s not right,” Choate says.
“We adopted a policy that if the prod-
“i have worked at 13 gm plants and started out as a
uct is not right we take it out of the uaw employee. i have never seen a workforce meld
station, tear it down, get rid of the bad together like the one i have here.” - Joe Choate
Northeast GM Toledo Transmission
toledo transmission’s production

employees are referred to as
“quality operators” and there are
five levels in that position.
delivered by a supplier and within Clear Metrics ciated with a set of goals on the team
two hours they are in a transmission Toledo Transmission implemented a boards. When we add all the incre-
and leaving the plant. “We don’t have business plan deployment process to mental things together, it moves the
buffered stock lying around,” Choate continuously improve and measure plant needle towards improvement.”
says. “We have short lead times.” its success. GM provides the compa- To further improve its operations,
GM strives to work closely with and ny with annual targets that the Tole- the company implemented a through-
support its suppliers, Choate notes. do team interprets and uses to devel- put improvement process that fo-
“Suppliers can make or break you; op metrics for safety, people, quality, cuses on problem solving through
we need to truly be their partner,” he responsiveness to customers, cost real-time data. Toledo Transmis-
adds. “For example, one of our suppli- performance and the operation’s en- sion’s database monitors faults in the
ers overbilled and overbooked a bid vironmental performance. plant that often go undetected by the
on a product that was integral to our A performance board on the shop team. “If a problem occurs frequently
production. To assist this supplier, we floor indicates what needs to be done enough, the database flags it as a main
sent a task force to address the issues to accomplish the goals and the things issue that needs to be reviewed and
and aided the supplier in getting out that are blocking the company’s abil- resolved,” Choate says. “The database
of the contract. Simultaneously, we ity to meet the goals. “The things we tells us what’s really going on.”
were able to establish a new qualified are charting on the shop floor are not When Toledo Transmission began
supplier to continue providing these easy things to achieve,” Choate says. manufacturing eight-speed trans-
key products without impacting our “Working towards these goals will missions it could produce about 30
production. This is a great example of drive continuous improvement. Ev- in an hour. The company has since
teamwork across the board.” ery single member in the plant is asso- been able to increase production to

GM Toledo Transmission Northeast
60 transmissions per hour because of To achieve a level three status, quality wards. “We are all in this thing together
its continuous improvement processes. operators are required to have a working and I think we are probably demonstrat-
“Fixing a lot of small things made a dif- knowledge of all the positions within the ing that more now than ever,” Choate
ference to realize throughput and effi- team’s area. Level four quality operators says. “The leadership coming out of that
ciency gains,” Choate explains. are capable of performing diagnostic solidarity is making us work together
work and the only eligible level to apply and build that bond to make us stronger.
Five Grades to be a level five team lead. Once a qual- We work arm-in-arm with each other.”
Toledo Transmission’s production em- ity operator reaches level five, the em- Moving forward, Toledo Transmis-
ployees are referred to as quality oper- ployee is required to attend leadership sion believes its hard work and processes
ators and within that position are five training. “I am most proud of the people have poised it to take on an “explosion of
levels – with the fifth level being the here,” Choate says. “I have worked at 13 product evolution” that Choate says will
highest and a team lead position. New different GM plants and started out as be coming soon from GM. “I think that
quality operators are required to attend a UAW employee. I have never seen a evolution will lead to product changes
Toledo Transmission’s training that it workforce meld together like the one I and allow us to start taking advantage
provides alongside UAW Local 14, the have here.” of the flexibility we have built into our
employee union. “We go through how Toledo Transmission prides itself on manufacturing process,” he adds. “We
the teams operate, responsibilities and the relationship it has with the UAW built a lot of capabilities in our manufac-
expectations,” Choate says. “Training team. The company believes it is im- turing system that we haven’t yet been
is one week and led by the union leader, portant for its quality operators to see able to take total advantage of, and that
personnel director and myself.” one leadership and direction to work to- will present itself soon.” mt

The Plastic Forming Co. Inc.
www.pfccases.com / HQ: Woodbridge, Conn. / Employees: 50 / Specialty: Double-wall, blow-
Northeast
molded plastic cases / John Womer, president: “We are a lower-volume, high-service producer.”
Among the products packaged in

the company’s double-wall cases are
professional hand and power tools,
portable test instruments and me-
ters, microscopes, surveying transits
and other optical devices, heart mon-
itors, medical instruments and edu-
cational kits.
“Our machinery is designed es-
sentially to make rectangular flat
parts,” Amatrudo says. “Most of the
blow-molding world is bottles. Our
machines were designed with the
tooling in mind, and the tooling is tai-
lored to fit the machines to allow very
fast changeovers and very little down-
time. The core of our business is now,
and always has been, what the indus-
try considers short runs. We routinely
set up and make 300 to 500 complete
each of the plastic forming
units, and those volumes are not
co.’s machines makes between something that typical commercial
450 and 550 parts per shift.
machinery is well-adapted to.” Adds
Case by Case Womer, “We are a lower-volume,

high-service producer.”
The Plastic Forming Co. uses a
the plastic forming co.’s proprietary molders continuous extrusion method. “In
addition to quick changeovers, con-
help it best serve clients. by russ gager tinuous extrusion gives us a lot of
flexibility in terms of part weight dis-
Secure transportation of delicate The reverse also is true. “Our pro- tribution using comparatively simple
instruments is always a challenge, and prietary machinery has really been hand tooling, but the trade-off is that
one of the best ways to do that is with designed for manufacturing cases it tends to be a slower process than
a dedicated double-wall, blow-mold- – especially in comparatively lower using an accumulator head like those
ed carrying case with either a foam volumes – with quick mold and col- used on bottle-blowing machines,”
insert or an integral molded interior. or changes,” President John Womer Womer says.
Manufacturing that durable, dou- adds. “If you want to make bottles or
ble-wall case – sometimes in a single auto parts in high production, there Machine Design
shot of blow-molded high-density are better ways than using our propri- Three in-house designers work on the
polyethylene – is the niche of The etary machinery.” company’s production machines and
Plastic Forming Co. Inc. Nevertheless, the company also molds. “We start with commercial ex-
“Our machinery – all built in-house blow molds other molded products, truders and commercial granulators,
– was designed specifically to make such as buoys for oil containment and pretty much everything else is
cases,” says Gary Amatrudo, vice booms and various tanks and trays. designed and built by us,” Amatrudo
president of customer and product The company fabricates foam and says. “That said, the bulk of our design
development. “Typical blow molding thermoformed inserts and trays for and machine shop efforts are focused
machines don’t make cases as effec- its cases when an integral blow-mold- on mold-building.”
tively as a purpose-built machine.” ed interior is not the best choice. The company’s blow-molding ma-

The Plastic Forming Co. Inc. Northeast
chines last approximately 20 years, large inventory of 60-plus case siz-

and the last one that was designed and es for immediate shipment within 48
built was in 2000. “In 2005, we adapt- hours. In addition, the company has
ed an older design to incorporate more proprietary tooling to make more than
modern controls,” Amatrudo says. “In 180 different exterior sizes and config-
some of our rebuilt machinery, we have urations in all.
incorporated more sophisticated pro- “Part of our strategy has been to fo-
grammable controls, with more opti- cus on offering a proprietary line of
cal and less physical sensing. Also, the case exteriors to sell as both off-the-
positioning accuracy is much higher, shelf items and as customized prod-
which allows us better control so that ucts,” Womer says, “That has allowed
we can make more consistent parts.” us to sell our cases to smaller manufac-
The continuous extrusion method turers who want cases specifically de-
speeds changes between jobs. “In our signed for their products without the
industry, we are pretty much the short- cost and complexity of having to create
run specialist, so we’ve designed and a custom mold from scratch.”
built everything around being able to
do short, very customer-specific runs,” Two Locations
Amatrudo maintains. Most of the company’s case man-
ufacturing is performed at its
Cycle Time 30,000-square-foot plant in Massil-
The typical cycle time required to lon, Ohio. The 30,000-square-foot
make a blow-molded case is approxi- headquarters in Woodbridge, Conn.,
mately 70 seconds, the time it takes to houses large part manufacturing, the
extrude a tube of molten plastic called design and engineering departments,
a parison that is then transferred into the machine and mold shop, sales, cus-
the mold. “And while we’re blowing tomer service and all other back-office
one part in the mold, we are creating operations.
the parison for the next part,” Ama- Besides the company’s manufac-
trudo explains. “Over the years, we’ve turing flexibility, quick changeovers
adjusted our cycle times to better uti- and ability to do short runs, another
lize the production staff. It’s a balance competitive advantage is its design
of machine time and man-hours, and capabilities. “All of our products are
we’ve slowed the part cycle down to completely designed and made in the
better utilize the staff.” USA, so shipping lead times are short-
“While one part is in the mold and er,” Business Development Specialist
the parison is being formed for the Jacquie Gilmore stresses.
next part, the machine operator is de- Womer attributes the company’s
flashing and performing various sec- success to the employees’ commit-
ondary operations on the part that just ment, their 25 percent stock owner-
came out of the mold,” Womer adds. ship and being very customer-focused.
Each machine makes between 450 “Something that we pride ourselves on
and 500 parts per shift. “So a 500-piece is the duration of our customer rela-
run of a case molded with both halves tionships,” he says. “On any given day,
at once would be a one-shift run,” we are shipping to customers that we
Amatrudo calculates. The company have been supplying for 30-plus years.
operates 12 molding machines in total. As their products change, we supply
The Plastic Forming Co. keeps a them with new packaging.” mt

Hadco Metal Trading Co.
www.hadco-metal.com / Headquarters: Philadelphia / Employees: 180 / Specialty: Aluminum,
Northeast
stainless steel, magnesium, engineering plastics, aerospace grades, specialty metals
chitectural and construction, semi-

conductors, energy and more. The
company is positioned to service
customers almost anywhere in North
America and around the world from
its locations in New England, New
York, Pennsylvania, Florida, Califor-
nia and South Korea, and with the
support of its global partners within
the Scope Metals Group.
Even though the company has a
large footprint, Fishman says, Hadco
is always available to its customers.
Combined with the company’s exten-
sive capabilities as a service center,
Hadco has what it takes to remain
successful for a long time, and the
company’s recent growth has been
proof of that.
Proven Partner
Although Hadco operates all over the
hadco metal trading co. is world, it’s still relatively small com-
a global provider of metal
products including aluminum pared to some of its larger competi-
and stainless steel.
tors. However, Fishman says that’s far
Fast and Agile

from a negative for the company and
its customers. “We’re not one of the
industry’s giants,” Fishman says. “I
think that makes us work harder for
hadco metal trading co. offers full solutions our customers, be very agile and very
and responsive service. by chris petersen quick. We give full and professional
answers followed by delivering on
Manufacturers frequently depend chased by the Scope Metals Group. what we promised to our customers.
on metal to be rigid and inflexible, but Fishman says that under the new It requires us to have an exceptional
those are two words that could never owners’ direction, Hadco evolved team of people that takes responsibil-
be used to describe Hadco Metal Trad- from a company specializing in alumi- ity, and pride in their job, as every sin-
ing Co. CEO Gilad Fishman says the num extrusions on the East Coast to gle person at Hadco makes an impact
company stands apart from its com- what it is today. on the business and the customers.”
petitors by being agile and responsive What Hadco is today is a global Fishman says the organizational
to its customers’ requests, and this is provider of metal products including structure within Hadco is very flat,
a major part of the reason why Had- aluminum, stainless steel, magne- making it possible for the compa-
co stands out as a leading provider of sium, engineering plastics and other ny to determine pricing, terms and
metal products to customers in North related alloys. The company offers operational solutions for custom-
America and around the world. these metals in sheets, plates, bars, ers without having to pass through
Hadco has been servicing the alu- tubes, pipes and extruded shapes, and numerous levels of management.
minum industry since the 1980s, but although it has a strong focus on the This has proven to be important in
the company as it is known today truly aerospace market, it services many empowering the sales teams to be
took shape in 2006, when it was pur- other industries such as defense, ar- successful, being sensitive to cus-

Hadco Metal Trading Co. Northeast
many more,” the company says. “Our

long-term commitment with producers
ensures availability of stock, reliability,
continuity and quality.”
The company adds that its ability to
supply these materials on a just-in-time
basis makes Hadco a valued partner to
its customers. “We offer total inventory
management, releasing our customers
of the need to hold stock and thereby in-
creasing their efficiency.
hadco is relatively small
compared to some competitors,
but that helps it remain agile
and fast. Saw Systems, Inc. has been a proud supplier of Hadco
Metals for 20 years. Mr. Lou Kruk (330-414-6033) is always
tomers’ special requirements and “Hadco is a one-stop shop, holding available with a recommendation on blades, coolant, or
technical assistance to solve any cutting problem. Our goal
needs, and making decisions on the go. tens of thousands of SKUs in stock from is to continue to keep Hadco producing their high quality
It allows quick feedback from the cus- a wide range of metals and alloys pro- metal products economically and efficiently. With Hadco’s
expansion and wide range of saws, Saw Systems is in the
tomers, prioritization, and operational duced by leading manufacturers such unique position to provide the auxiliary products to keep
support with quality product and on as Alcoa, Kaiser, Aleris, SAPA, NAS, the inventory of various shapes, sizes, and types of material
ready for Hadco to ship to you the customer!
time delivery. Valbruna, Universal Stainless, ATI and

Northeast Hadco Metal Trading Co.
Growth Ahead
Hadco plans to continue its growth
in the coming years. In fact, Fishman
says, the company’s success has pre-
sented it with a new set of challenges.
“I think the greatest challenge for us
is keeping up with our growth. Had-
co has a culture of what we call “con-
stant change,” striving to improve
and better every aspect and process
in the company all the time while
growing rapidly. We believe that if
you do not grow, you die. The energy
and commitment to deal with these
challenges makes Hadco a better and
more efficient company all the time”
he says.
Hadco has experienced double-dig-
it growth almost every year since its
acquisition by Scope Metals Group,
and Fishman says the company is hard
at work making sure it has the capac-
ity it needs to service new customers
to keep pace with its ongoing double-digit growth, hadco has increased hiring, training and without losing focus on the strengths
automation at its facilities, and is moving its headquarters to a much larger space.
that made it successful in the first
place. “As we grow quickly, we are in-
vesting constantly in order to contin-
ue that type of growth while still give
the same high level of service to our
customers,” Fishman says.
Among the initiatives Hadco has
taken on to keep up with its growth
are increased hiring, training and au-
tomation at its facilities. The compa-
ny also is moving its headquarters in
Philadelphia from a 160,000-square-
foot facility to one that measures
more than double that at 380,000
square feet.
Hadco’s logo is “Our Service – Your
Success,” and this approach seems
to be working well for the company.
Fishman says Hadco is excited about
the opportunities it sees on the hori-
zon over the next few years. “We see
this growth continuing, as long as we
keep our customers successful we will
do just fine,” Fishman says. mt

Nitta Corporation of America
www.nitta.com / Headquarters: Suwanee, Ga. / Specialty: Industrial belting, hydraulic hoses
Northeast
and tubing / Kim Millsaps, president: “We focus on the end-user to update their technology.”
Driven Innovation
nitta provides engineered belting solutions to a
wide range of customers. by chris petersen
In 1885, Nitta Corporation en-

tered the Japanese manufacturing
market with its first product, a pow-
er transmission belt made of leather.
Although simple belts such as this
initial product remain the company’s
core competency today, Nitta Corpo-
ration has built a strong reputation
as an innovator. That reputation fol-
lowed it into the United States market
in the 1970s and the establishment of
Nitta Corporation of America (NCA)
in 1980.
Based in Suwanee, Ga., NCA con-
tinues to serve industrial customers
throughout North America with the
same commitment to quality and in-
novation as its parent company. Pres-
ident Kim Millsaps says the company
has a global reach but is one of the nitta corporation of
few global manufacturers of power america serves numerous
industrial markets with
transmission solutions that can offer engineered solutions.
North American customers a direct

connection to its products. to the commodity level. The markets not in what we would call the com-
“We at the Nitta Corporation back in which NCA has its strongest posi- modity realm.”
in 1988 in the United States made the tion include textiles, paper manufac- NCA delivers these solutions
decision to become the only manufacturing and printing, although it does thanks in large part to its focus on the
turer in the United States that made serve other markets. The company’s end-user rather than only concerning
flat power transmission belting,” Mill- primary product line is industrial itself with meeting the requirements
saps says. Having its production facili- power transmission belting, but it of its OEM customers. This focus is
ty based in the United States is one of also produces hoses, tubing and fit- referred to within the company as
NCA’s chief competitive advantages tings, and wipers. “The Nitta Advantage,” and involves
when serving the North American working closely with end-users’ man-
market, and it has many more to help Full Solutions agement and technical teams to iden-
set it apart in the industry. No matter what it produces for any of tify the right product for each applica-
NCA serves numerous industrial the market segments it serves, Mill- tion. “We don’t just go to the OEM, we
markets with engineered solutions saps says NCA concentrates on pro- focus on the end-user to update their
that meet each customer’s specif- ducing engineered solutions that are technology and improve their overall
ic needs. Millsaps says this puts the more than a one-size-fits-all product. efficiency,” Millsaps says.
company at an advantage over man- “These are what we call engineered The company’s presence in the
ufacturers whose products are closer products,” Millsaps says. “They are United States helps make this pos-
MAY/JUNE 2015 2015 manufacturing-today.com 151

Northeast Nitta Corporation of America
toire, this one imported from its par-

ent company’s production in Japan.
The PolySprint line of polyester-core,
finger-spliceable belting requires no
adhesives to join, making it an easi-
er-to-install and easier-to-service al-
ternative to belting products typically
used in the printing and graphic arts
sectors. Vice President of Operations
Kent Simpson says production of
PolySprint has quadrupled in recent
years, thanks in part to NCA’s con-
tract with the U.S. Postal Service.
Millsaps adds that the PolySprint
line has given NCA a much broader
customer base in the United States.
“It gives us a completely new opening
into the printing industry that we ha-
ven’t been able to enter in the past,”
manufacturing in the Millsaps says.
united states helps nca
better serve its customers
throughout north america.
Foundation for the Future
sible, and Millsaps says the compa- product lines in 2000, when the com- It’s very likely that NCA will contin-
ny has concentrated on adding new pany introduced its first aramid-cord ue to add to its business in the near
product lines ever since it entered machines in the U.S. future, as the company recently re-
the North American market. These In the past six years, NCA has added ceived the green light from its parent
include PolyBelt, the company’s ny- another new product line to its reper- company to nearly double its foot-
lon-core skive-splice belt that is typ-
the company has added new
ically used for power transmission product lines to its repertoire
in the last few years, including
belts, carrier belts and machine tapes. its polysprint line.
The company says PolyBelt offers su-
perior resistance to fatigue and can
be joined together quickly for greater
efficiency. NCA is the only vertically
integrated domestic manufacturer of
nylon core belting, providing custom-
ers with greater price stability, faster
delivery and greater flexibility.
Millsaps says the company also
is proud to be the leading domestic
manufacturer of flat aramid-cord
products, which it manufactures
under the Carryflex brand. Encap-
sulated in urethane and rubber, Car-
ryflex offers a flexible but rugged
design that resists fraying and will
not stretch even at above-average
lengths. NCA added Carryflex to its

Nitta Corporation of America Northeast
the company says its

product lines also include
industrial tubing and
hosing solutions.
“130 years in existence is going to

be a very significant milestone for
nitta globally.” - Kim Millsaps
print in the United States. Simpson says the company will
soon add more than 85,000 square feet of warehouse, office
and production space to its facilities in Georgia. This will
allow NCA to begin domestic production of PolySprint by
late 2016.
“Our mindset right now is local production for local con-
sumption,” Simpson says. Millsaps says NCA’s new manu-
facturing capabilities will make the company more capable
of providing customers with quick reaction times across all
product lines.
As Nitta Corporation marks its 130th anniversary this
year, NCA is gearing up to celebrate the event by spreading
the word to its distributors and end-users that its global
connections and innovation are its greatest strengths in
North America as well as the rest of the world. “130 years in
existence with continual improvement to our product lines
is going to be a very significant milestone for Nitta global-
ly,” Millsaps says. mt

New England Miniature Ball
www.nemb.com / Headquarters: Norfolk, Conn. / U.S. employees: 25 /
Northeast
Specialty: High-quality precision and semi-precision miniature balls
Precision Products
new england miniature ball’s products are used for a range
of applications, including ball bearings, valves and pens.
new england miniature

ball’s products are utilized
in a variety of commercial
and industrial applications.
After 50 years, New England Min- slides, ball and thrust bearings, test its employee policies and safety reg-
iature Ball (NEMB) stays success- equipment, pumps, ball screws and ulations. From there, “We have cus-
ful by keeping flexible, President valves. The company started opera- tomers in Singapore, the Philippines,
Pat Demarco says. As a supplier of tions in 1965, and today, it has opera- Thailand, Vietnam, Malaysia and do-
high-quality precision and semi-pre- tions stateside and offshore. mestic China,” he says.
cision miniature balls, the company In the United States, its facility in “We’re a specialized ball compa-
constantly copes with changes within Norfolk operates with a staff of 25 ny,” he notes, adding that customers
its business. that handles its high-precision prod- can refer to the company’s website at
“We’re always adjusting the size, ucts, Demarco says. “We produce www.nemb.com for specifics.
the surface and the roundness,” he de- items that have to be U.S. manufac-
scribes. “We have to adjust constantly tured plus standard industrial prod- Production Pride
to meet those demands.” ucts,” he says. NEMB takes pride in its manufactur-
Based in Norfolk, Conn., NEMB It also has an operation in Shanghai ing process, Demarco says. “We take
supplies miniature balls for a variety that is a mirror image of what NEMB raw wire, we form it, we massage it
of applications, including industrial does in the United States, including and we make it into a very lustrous,

New England Miniature Ball Northeast
Customer Favorite
After all these years, Demarco is proud of NEMB and its
staff. “I think the fact that we run so lean and mean and
service our customers to a point where we don’t lose
them is something to be very proud of,” he says.
This has enabled NEMB to retain customers that have
used the company for at least 20 years. “The work force
excels very nicely,” he continues. “We’ll get people who
ask us to do miraculous things. We don’t quite do that,
but we’ll get close to that.”
Sometimes, “The weather’s against us,” he says. “[But]
these folks get in here and get the [machines] running.”
Demarco sees a strong future for NEMB. “We did a
forecast this morning and we’re shooting for eight per-
cent growth,” he says.
He adds that the company recently moved into provid-
ing balls for linear slides. “That’s a new arena for us, both
in the U.S. and foreign,” he says. “[It involves us] provid-
nemb’s staff has enabled it
to retain customers that ing a ball to a different specification and grading that’s
have stayed loyal for at
least 20 years. required for linear slides, versus a ball bearing.” mt
high-precision product,” he says. “We’re proud of the

end item.”
But to ensure it produces a quality product, NEMB has
implemented an internal, continuous improvement pro-
gram. The company is certified ISO NQA and is presently
pursuing TS 16949 in its China operations.
“We have specialized equipment for measuring sur-
faces, the roundness of shapes and size variance in ac-
cordance with ABMA standards,” he says. “We provide
products through the AMS and ASTM standards.”
Lean and Small

NEMB runs a very lean operation, according to Demarco.
“Each and every manager carries more than one responsi-
bility,” he explains. For example, the company’s produc-
tion manager also serves as its purchasing agent as well as
its fire inspector.
“We have trained operators that are capable of con-
trolling more than one machine,” he says. “We have
equipment on the floor to satisfy our output and minimal
to run it.”
NEMB also strives to keep its wire and finished goods
inventory minimal, Demarco says. However, “If we have
an overrun, we have a luxury,” he notes.
“We can reduce the ball to another size,” DeMarco
explains, noting the benefits for customers. “So there’s
ways to save some pennies and materials.”

Masline Electronics Inc.
www.masline.com / Headquarters: Rochester, N.Y. / Employees: 32 / Specialty: Electronic
Northeast
components / Jim Gerling, sales manager and co-owner: “We’re willing to invest into inventory.”
masline electronics has

been providing electrical
components for more than
80 years.
Family Business tors, terminal boxes, circuit break-

ers and relays, capacitors and wire.
“Our strength is in stocking our
masline electronics plans to continue its legacy products,” Jim Gerling says. “We’re
with e-commerce initiatives. by alan dorich willing to invest into inventory for
our customers.”
Its client base includes several
After more than 80 years, fami- At first, it specialized in repairing Fortune 500 companies. “It’s anyone
ly owned Masline Electronics Inc. radios and television sets. When doing manufacturing of electrical
thrives by focusing on ethics and in- Masline died in 1964, his wife, Winona components,” he says, naming Xerox
tegrity, Sales Manager and co-owner Masline, took leadership of the com- Corp. and Welch Allyn as examples.
Jim Gerling says. “At the end of the pany and transitioned it into OEM Masline Electronics also has
day, we may take a little longer to electronic component sales in 1990. grown by helping its customers
make a decision, but we make sure it’s Masline passed away in 2011. “She through vendor reduction and logis-
a sound decision,” he asserts. worked until she was 98,” Gerling re- tics programs. “Our customers are
Based in Rochester, N.Y., the com- calls, noting that he shares ownership trying to reduce their supplier base,”
pany provides electronic compo- with his mother, Sheila Gerling, and Gerling explains.
nents, including custom assemblies, his uncle, Glenn Masline. “We’re doing a lot of sourcing of
kitting, lead-forming and final in- products to help them meet their fi-
spections. Gerling’s grandfather, Ed Customer Focused nancial objectives,” he continues,
Masline, started Masline Electronics Masline Electronics continues to adding that Masline Electronics looks
in 1932. sell components, including resis- at its clients’ buying programs to get

Masline Electronics Inc. Northeast
them products at better prices. “That’s been a huge area “when we learn something new from
of growth for us since 2000.”
a company, then we continually edu-
Online Initiatives cate each other.” - Jim Gerling
Like many companies, Masline Electronics’ business
has been impacted by the Internet and the rise of e-com- “When one team wins, then the whole team wins,” he
merce. “People are doing more with less people,” Gerling says, noting that its workers do a great job educating each
says. “[Buyers also] want to buy online and don’t want to other. “When we learn something new from a company,
interface with people. then we continually educate each other and use those
“It’s really tough for a small company to invest into wins to go approach other customers.”
e-commerce and websites,” he says, adding that Masline Gerling predicts that more changes are ahead for
Electronics plans to have its own e-commerce presence Masline Electronics’ industry. “Regional distributors will
soon. “It should be done by the start of the third quarter. have to expand into different marketplaces to survive,
We have to adjust the final logistics of it.” even though they may not want to,” he states. “I see a lot
The company has upgraded its infrastructure so that of regional distributors dying by acquisition and some
its employees can work from home. This also serves as a larger distributors trying to get into specific markets.”
way to attract top talent, Gerling says. But e-commerce will continue to be strong, as it gives
For example, if an Iowa-based job candidate with in- customers the ability to receive products in 24 to 48
dustry contacts wanted to work from home, New York- hours. “Our customers will want to have [this] resource
based Masline Electronics could accommodate his or her of product at their fingertips,” Gerling says. mt
request. “I could figure out a way for him to work remote-
ly,” Gerling states.
Coping with Costs

Gas prices have dropped, but transportation costs still
represent one of Masline Electronics’ largest expenses as
a company. “It’s one of the biggest challenges we have,”
Gerling admits.
The company copes by buying smarter and in larger
volumes. “We’re consolidating our shipments,” he says.
“We used to have lines that were shipped to us every day.
Now we have them shipped three times a week.”
This is similar to the services Masline Electronics pro-
vides to its own clients. “It lowers transaction costs and
give us a larger volume so I don’t have to buy them so
often,” Gerling says, noting that the company also tries
to buy from one manufacturer when it can “so we have
more buying power.”
The company also looks at long-term projections. “If
our customers are looking at six-month windows, we
look at 12-month windows,” he says.
Win-Wins
Gerling joined Masline Electronics in 1990 after working
for a manufacturing rep firm for three years. “I wanted
to understand the industry before I came into distribu-
tion,” he says, noting that he considers the company’s
staff to be family.

D&K Engineering Inc.
www.dkengineering.com / HQ: San Diego / Employees: 520 / Dan O’Leary, vice president
West
of manufacturing operations: “It is all about exceeding client expectations.”
d&k engineering is a global

leader in end-to-end
research and development
and manufacturing services.
The Extra Mile For example, the company holds

internal mini-kaizen events, which
results in minimizing steps in the
d&k engineering’s streamlined processes make it manufacturing line. This focus has
easier for clients to go to market. by jeff borgardt also led to increased capacity for large
products such as producing ecoATM
Everybody in manufacturing has “We use a lot of the typical terminol- kiosks, which are machines placed
heard about kaizen, lean manufac- ogy and methodologies you have heard at shopping malls and grocery stores
turing, Six Sigma and continuous im- of before such as lean and kaizen, but that purchase used electronics and
provement philosophies. But what do we seek to demystify them,” says Dan smartphones from customers.
they really do? O’Leary, vice president of manufac-
At D&K Engineering, the company turing operations. “We utilize these Global Leader
utilizes the latest in manufacturing tools in a way that everybody can ap- Founded in 2000, D&K Engineering
theories in a practical way, day-to-day, ply them. Anybody can attend a kaizen is a global leader in end-to-end re-
so everybody can understand. event. We go a little further than that.” search and development, product

West D&K Engineering Inc.
more than 90 percent of

products designed and de-
veloped by d&k engineering
have been taken to market.
development and manufacturing services for high-inno-

vation content, hardware-based products and equipment,
the company says. With world-class research, development
and manufacturing talent, state-of-the-art product realiza-
tion processes and a global infrastructure and supply chain,
D&K Engineering helps companies become leaders in their
industries by designing and manufacturing breakthrough
hardware-based products that lead to profitable, enduring
lines of business.
Clients in diverse, economically significant industries
recognize D&K Engineering’s value and expertise. D&K En-
gineering has developed special market-leading expertise
in the following markets:
> Industrial/commercial
> Self-service kiosks
> Printing
> Medical/life sciences
> Military
“we are selective about who we

choose, including assemblers and
operators. we have a very compe-
tent, super manufacturing staff.”
D&K Engineering’s 130,000-square-foot facility in San
Diego employs more than 350 people. The company also has
an R&D and manufacturing location in Singapore.
“We are a relatively large organization but we keep the

D&K Engineering Inc. West
hierarchy very flat,” O’Leary says. “This facilitates better

communication throughout the organization so when im-
provements need to be made, things happen very quickly.”
Management also is very accessible, without multiple
layers of bureaucracy. “Management is very approachable.
We don’t have lots of layers and staff to go through to make
decisions and implement improvements,” O’Leary says.
Happy Workforce, Happy Clients

D&K Engineering has developed hundreds of patents on be-
half of clients. The company’s established, proven relation-
ships with qualified domestic and international suppliers
help it stay ahead of the curve, keeping up with the explo-
sive demand for leading-edge products in the medical/life
science, printing, kiosk and military markets.
More than 90 percent of D&K Engineering’s commercial
products designed and developed have been successfully
taken to market. The company prides itself on its timely, re-
peatable, predictable and high-quality performance. It also
offers competitive pricing, the company says.
All of this results in a happy workforce. “One of our cli-
ents was in here the other day and remarked that we have
the happiest assemblers he has ever seen,” O’Leary relates.
Part of the reason for this is that senior managers “know
their names and have social events to connect with them,”
O’Leary says. “The owners spend time on the manufactur-
ing floor.”
With a core set of best practices and industry knowledge
that spans the entire product development lifecycle, D&K
Engineering mobilizes the right people, processes, tools
and infrastructure to create and deliver sustainable busi-
ness value to organizations seeking to outsource the de-
sign, development and manufacturing of their equipment
or products.
Culture of Collaboration
The team is carefully selected for optimal performance. “A
lot of the folks we get in here are referrals from current em-
ployees,” O’Leary explains.
“We are pretty selective about who we choose, includ-
Monoprice is a leading e-commerce retailer that specializes in offering more

than 6,500 high-quality, affordable electronics and accessories to professionals and
consumers worldwide. Monoprice is a proud supplier of charging and power cables to
D&K Engineering. With the help of Monoprice products, D&K Engineering continues
to innovate in the kiosk manufacturing space and stay ahead of technology changes.
Established in 2002, Monoprice has built a stellar reputation for product excellence and
customer service through providing premium products at a fraction of marketplace
prices with incomparable speed and service. For more information, email Eric Krause at
eric.krause@monoprice.com or visit www.monoprice.com.

West D&K Engineering Inc.
ing assemblers and operators. We have a very compe-

tent, super manufacturing staff.”
The culture of collaboration also includes D&K’s
expert engineers who design the many products that
D&K develops. The D&K engineering staff is one of the
d&k engineering’s departments are constantly collaborating to ensure
optimal performance for its customers.
most-seasoned groups of engineers, with decades of ex-

perience and hundreds of patents. This experience set
has been honed through numerous development pro-
grams that have gone to market. This expertise fosters
close collaboration across all functions. “Everyone gets
to know the guys on the manufacturing floor because of
the culture of collaboration here,” says Diane Law, vice
president of marketing.
The culture at D&K allows for optimal performance.
“We are constantly collaborating so everybody can pro-
vide feedback and input,” O’Leary describes. “That is

D&K Engineering Inc. West
what I mean when I say we ‘demysti- and subsequently obtain delivera- uling and cost, but also teamwork.
fy’ lean manufacturing. All that lean bles ranging from concept designs “It is all about exceeding expecta-
stuff is great, but you can also get a and analysis and prototypes to a ful- tions,” O’Leary says. “Going the
long way with simple transparency ly manufactured product.” extra mile is how you keep clients.
between departments with active The key is not only quality, sched- That’s what we do every day.” mt
and fluid communication.”
In addition to its internal dynam-
ics, the company also supports the
larger manufacturing industry. D&K
Engineering supports National Man-
ufacturing Day, an open forum for
manufacturers to open their doors
and show what today’s manufactur-
ing is and what it is not.
Product Plans
D&K Engineering’s product-real-
ization plan is its process for suc-
cess. “We have a clearly documented
product-realization plan D&K has
developed,” O’Leary states. “It is our
design recipe to take a product from
whiteboard to the end-customer. It
goes from designing on a napkin to
delivering a complex device.”
The internal, state-of-the-art
product-realization process is the
DNA of the D&K culture. Each pro-
gram goes through specifically de-
signed steps as it moves through
commercialization. The steps have
specific, clearly defined delivera-
bles. These items are reviewed and
checked off before the program
moves on to its next deliverables.
“The whole process increases the
viability of a product, getting it to
market faster,” Law says.
“D&K Engineering delivers end-
to-end product development and
manufacturing services as well as
focused projects to address a spe-
cific client need anywhere along the
product development lifecycle,” the
company says. “Start-ups to multi-
billion-dollar corporations engage
D&K Engineering at various points
in the product development process

MTI Metal Technology
www.mtialbany.com / Revenue: $5 million - $10 million / Headquarters: Albany, Ore. /
West
Employees: 18 / Specialty: Reactive and refractory metals
Industry
Pioneers
mti’s new manufacturing
capabilities enhance
its customer service.
by janice hoppe
Metal Technology (MTI) has de-
veloped a reputation for reliability
and quality over the past 44 years be-
cause of its innovative approach to
precision forming processes using re-
active and refractory alloys. “We have
always focused on high-temperature,
corrosion-resistant alloys that are
produced here in Albany, Ore.,” Di-
rector of Sales Steve Smith says. “Ni-
obium, titanium and zirconium are
some of the alloys used heavily in pro-
pulsion systems for rocket and aero-
space applications.”
Albany has a rich heritage of met-
allurgy dating back to the early 1940s
when President Franklin D. Roosevelt
tapped the Albany branch of the U.S.
Bureau of Mines to develop a process
to produce these metals, Smith says.
MTI began as B-J Enterprises in
mti says the fact that it is
1971 and quickly grew in size and ca- diversified has helped it
weather the ups and downs
pabilities. Today, MTI specializes in in the economy.
the precision fabrication and custom
manufacturing of high-temperature, MTI works with diverse markets cause when one industry is down an-
corrosion-resistant alloys. “We have and industries, including aerospace, other is up.”
developed our processes to include defense, chemical processing, coat-
CNC machining, water-jet cutting, ings, high-energy physics and nucle- New Techniques
and deep-draw forming and forg- ar medicine. Customers range from Custom manufacturing is a major part
ing,” Smith notes. “The deep-draw national laboratories to space-travel of MTI’s business and the company
process is our claim to fame.” Over prime contractors that rely on the prides itself on being AS9100 and ISO
the years, the company has accu- company to deliver. MTI meets that 9001:2008 certified. “We have a pro-
mulated an impressive inventory of challenge daily and in 2014 achieved cess-based approach that focuses on
tooling for its press operations. Each a 93 percent on-time delivery rate. continual improvement and meeting
tool is machined in-house and then “One thing to note about our busi- customer requirements,” Smith ex-
heat-treated to harden before being ness is that we are diversified,” Smith plains. “Our calibration systems are
used in production. says. “We can weather downturns be- designed to standardized equipment

MTI Metal Technology West
and tooling to MIL-STD-45662 requirements – meeting but with lower environmental impact and workplace
the high standards set by the National Institute of Stan- hazards. “We have gone green in our metal-cleaning pro-
dards and Technology.” cess and in doing so we have saved ourselves time and
Staying true to its roots, the company continues to in- it’s healthier for our employees,” Deep Draw Supervisor
novate by developing new manufacturing techniques that Gary Warnock says.
enhance its customer service. “In 2014 we began our ad- In a different green initiative, the company has made
ditive manufacturing initiative and developed techniques another improvement to its deep-draw process that also
for producing quality parts from powder metal,” Director provides safety benefits to its 18-person manufacturing
of Engineering Jason Stitzel says. “We’re now leveraging staff. “Over the years, we have used a proprietary lubri-
that knowledge to produce parts that we refer to as ‘hy- cant in our draw process that was acetone-based and we
brid,’ in that we can produce parts that incorporate both are switching to a water-based lube,” Warnock explains.
additive and traditional manufacturing methods.” Moving forward, MTI plans to continue focusing on
MTI can capture the benefits of additive manufactur- exotic metals and alloys as it has since day one because it
ing for highly complex geometry of a component and has become a specialist in those materials over the years.
then transition to traditional CNC methods for less “These metals are not something a lot of other compa-
complex portions. “The hybrid approach is available to nies work with because of their high cost and properties
our customers and we’ll prescribe it – if it represents the that make them a challenge to manufacture,” Smith says.
most economical way to manufacture their component,” “MTI has 40-plus years working with them and we’ll con-
Marketing Manager Matt Crateau says. tinue developing techniques to produce high-precision
In 2014, MTI 3-D printed density trials in a key alloy products in the most economical way.” mt
required for space travel. C-103 is a niobium-based alloy
that contains about 10 percent hafnium and one percent
titanium and is used in space applications because of
its formability, cost, weight and reliability, the compa-
ny says. MTI became the first to use a powder-bed laser
additive manufacturing system to produce solids from
C-103. “In 2014 we ran trials with C-103,” Crateau notes.
“We are now partnering with a space propulsion compa-
ny for the second phase of development.”
In phase one, MTI’s goal was to determine the right pa-
rameters between the laser power and speed that the 3-D
printer uses. “We learned where we need to be to achieve
density of C-103,” Smith explains.
In another recent development project, MTI began
hot-forging molybdenum. The process uses CNC-con-
trolled force and depth on the company’s largest hydrau-
lic press to create a near-net shape that can then be preci-
sion machined to meet final dimensions. “We’re excited
about moving ahead with hot-forging. Our team includes
experts in forming alloys in a way that maximize the per-
formance in finished parts,” Smith said.
Going Green
MTI is also focused on developing and implementing en-
vironmentally sound practices. Most recently, it made a
process change to drastically reduce its strong acid use
in chemical finishing by converting to an automated pol-
ishing process. The process delivers a superior product,

Core Health and Fitness
www.startrac.com / Headquarters: Vancouver, Wash. / Employees: 400 / Specialty: Fitness
West
equipment / Dustin Grosz, COO: “Service in our view is our biggest differentiator.”
Schwinn, Spinning and Nautilus

brands. The company acquired the
Nautilus license in July 2014 along
with the former Nautilus manufac-
turing facility in Independence, Va.
The Star Trac and StairMaster
brands were initially run as separate
entities following their acquisition.
“We had great brands, but didn’t have
any systems to unite them at the very
beginning,” adds Grosz, a former ex-
ecutive for Bowflex Inc. – Nautilus’
corporate parent – who joined the
company in 2009 and consolidated
the businesses in 2011.
Operational Flexibility
The commercial fitness market
makes up the bulk of Core Health
and Fitness’ business. The compa-
core health and fitness’
equipment brands operate
ny’s customers include large chains
on an open platform that
allows customization.
such as Equinox, L.A. Fitness, Any-
time Fitness and 24 Hour Fitness, as
Bulking Up well as YMCAs, hotels, universities,

high schools and park districts. Core
Health and Fitness operates distri-
customer service distinguishes core health and bution centers in Virginia and Cali-
fornia serving the United States, and
fitness within its industry. by jim harris in the Netherlands, China and Brazil
serving 65 international markets. The
The StairMaster and Star Trac fit- sell Schwinn indoor cycling bikes to company also maintains a sales and
ness equipment brands have helped the commercial fitness market from service presence in the United King-
people improve their fitness and lives Nautilus, which at the time was be- dom, Germany and Spain.
for more than 20 years. However, at ginning to focus its marketing efforts All of Core Health and Fitness’ cus-
the height of the “Great Recession” in entirely on home fitness equipment. tomers can expect a high level of ser-
2009 to 2011, it was the brands them- The following year, Core Health vice. The company’s ability to provide
selves that desperately needed to get and Fitness acquired the Star Trac this service allowed its once-troubled
into shape. brand. “We had already taken a strug- brands to turn around their business,
Michael Bruno, a veteran of the bi- gling brand, StairMaster, and turned Grosz says.
cycle and fitness equipment manufac- it around very quickly,” says Dustin “Our brands are immediately
turing industry, saw an opportunity Grosz, COO of the Vancouver, Wash.- recognizable, but service in our view
to improve the StairMaster brand in based company. “We repeated that needs to be our biggest differentia-
2009, when he acquired it from Nauti- success with the Star Trac brand, which tor,” he adds. “Our focus is on build-
lus Inc. Bruno at the time established was in need of a financial turnaround.” ing an infrastructure with systems
Core Health and Fitness Inc. as the Today, the company manufactures, and processes that allow us to best
new corporate owner and operator markets and owns the StairMas- support our customers, who are de-
of StairMaster. The company also ac- ter and Star Trac brands and holds manding when it comes to warranty
quired the rights to manufacture and the commercial market licenses the expectations and turnaround times.”

Core Health and Fitness West
“our focus is on building an infrastructure

with systems and processes that allow us to
best support our customers.” - Dustin Grosz
The company uses Salesforce’s service and user flexibility has earned
customer relationship management it a number of accolades from its cus-
(CRM) software platform and is tomers. The company in 2014 won
launching EcoFit network wireless de- “Vendor of the Year” awards from
vices to communicate with and gain Gold’s Gym and GoodLife Fitness,
visibility into equipment on custom- Canada’s largest fitness club operator.
er sites. The EcoFit networked device
will notify the club operator and Core A Varied Approach
Health and Fitness when equipment Core Health and Fitness’ manufac-
needs maintenance, and also tracks us- turing operations include fabrication,
age. “In the past, the industry was very welding, powder coating and assem-
reactionary,” Grosz says. “We now have bly. The company partners with other
the ability to utilize a much more proac- manufacturers for components and
tive system that allows us to see what’s injection molding operations.
going on in the club so we can work best Products are manufactured based
with customers to keep equipment run- on demand and sales forecasts, which
ning 99 percent of the time.” are tracked through the use of mate-
The equipment manufactured and rial requirements planning (MRP)
marketed by Core Health and Fitness software. All machines are checked for
also operates on an open platform that quality along each step of the manufac-
allows customers to configure them as turing and assembly process.
they see fit, as opposed to a closed or The company is influenced by sever-
proprietary platform. Machines can al different operational philosophies.
be configured for use – via Bluetooth “We have multiple principles we view
device – with multiple mobile fitness as necessary to improve our business,”
apps including Mapmyfitness and Fit- Grosz says, citing lean and Six Sigma as
bit. “We have very few customers to examples. “We don’t feel that just one
whom we provide 100 percent of the philosophy completely fits what we
equipment they run in their club,” do, so we try to take variations of those
he adds. “We created our products to and apply them to our operations to
work in an open platform scenario, achieve desired results.”
which allows operators to use them in Core Health and Fitness regularly
any way they need.” refreshes its product lines and adds
The company’s machines can also complementary products annually.
accommodate multiple smartphone or The company also continues to seek
tablet devices for viewing during work- new growth opportunities.
outs. “A lot of companies are focused “We’re always looking at different
on entertainment into their products, acquisition possibilities,” Grosz says.
but the way ours is set up allows oper- “We’re looking to acquire companies
ators to use the products they’re most and brands that can improve our sup-
familiar with, which will show up on ply chain and our product line, or bring
our screen,” Grosz says. us into a different market category
Core Health and Fitness’ focus on such as medical and rehab.” mt

Gruber Industries
www.gruber.com / www.gruberpowerservices.com / www.grubertechnical.com
West
Revenues: $25 million / Headquarters: Phoenix / Employees: 200
fresh coat of factory-matched paint

is applied. Our units leave our depot
in like-new condition.”
‘A Service Organization’
Quality and reliability have been
main focuses of Gruber Industries
for more than 30 years. “Since 1984,
Gruber Industries has provided un-
paralleled customer service and qual-
ity,” Korda says. “We strive every
day to manufacture or supply to our
customers the best products and ser-
vices available in today’s global mar-
ketplace. We consider ourselves first
and foremost a service organization
that sells solutions, not just products;
it’s the services we provide that drive
the products we produce and sell.”
Each of Gruber’s divisions special-
focusing on quality and reliability,
each of gruber’s divisions specializes
izes in a different aspect of the criti-
in a different aspect of the critical
power and data center industries.
cal power and data center industries.
In addition to its UPS refurbishing
Critical Thinkers work, the Gruber Power Services

division also sells and services all
makes, models and sizes of critical
gruber industries provides products that keep power equipment including battery
cabinets, maintenance bypass equip-
its customers running at all times. by jim harris ment and generators.
Gruber Power Services also man-
Product quality and reliability cy lighting and life support equip- ufactures high-performance batter-
are absolute necessities for Gruber ment on at data centers, hospitals ies for stationary applications. “Our
Industries’ customers. “We cater to and small businesses in the event of maintenance-free, valve-regulated
the critical backup power and data a power outage. Gruber Power Ser- lead-acid (VRLA) absorbed glass
center industries, where failure is not vices – one of Gruber Industries’ material batteries are specifically de-
an option and time is not free,” says three operating divisions – is the signed for UPS applications and engi-
Eric Korda, director of manufactur- largest UPS refurbishing company neered to out-perform all of our com-
ing operations for the Phoenix-based in the United States. petitors, which is why we back them
company. “The products that we “We use state-of-the-art equip- up with an industry-best four-year
manufacture, refurbish and sell are ment, load banks and processes to limited warranty,” Korda notes.
typically critical to the performance ensure that every unit that leaves The Gruber Communication Prod-
and/or protection of our customer’s our facility is 100 percent function- ucts division manufactures data ca-
networks and facilities.” al and capable of supporting its rat- bling and networking products as well
Thousands of uninterruptable ed load,” Korda says. “We also send as a full line of metal products for the
power supply (UPS) systems refur- every refurbished unit through full telecommunications industry includ-
bished and sold by the company are cosmetic treatment, where units are ing server/equipment racks, shelves,
utilized around the world to keep es- thoroughly cleaned inside and out, panels and other wire management
sential computer services, emergen- every nut and bolt is checked, and a products. Products are manufactured

Gruber Industries West
in Gruber’s 35,000-square-foot manu- ber Technical Services, specializes in pipeline, and Gruber Communication
facturing facility in Phoenix. the design and construction of data Products was born.”
Most of the company’s products are centers including cooling, critical pow- The company has plans to introduce
assembled by hand, with automation er equipment, access floor, structured new products, including an expansion
used only on processes that do not af- cabling and consulting and design. of its GPS Elite line of batteries, initially
fect the form of the end-product. “For launched in 2010. “We are actively work-
example, we use an automated process Future Opportunities ing on expanding the line to include
to measure, strip, cut and otherwise Gruber Industries has a history of batteries for solar applications,” Kor-
process raw wire and fiber, which is growth within its product and service da says. “We also hope to someday be
then hand terminated and pneumati- lines, which it continues to build on. the first battery manufacturer to bring
cally crimped,” he adds. “This strategy “Many years ago, Gruber was primarily lithium ion and copper fusion technol-
allows us to be extremely flexible in our an installer of data center structured ca- ogy into batteries and cables for critical
manufacturing process while maintain- bling and networking equipment,” Kor- power applications.” mt
ing a reasonable degree of efficiency.” da says. “We suddenly lost a key suppli-
All of Gruber Communication Prod- er and found ourselves unable to meet Leoch Battery Corporation has a full line of UPS
Critical High Rate Batteries. All of our UPS batteries have
ucts’ cables and other products are our commitments. Instead of losing a 10-15 year design life and are IEC, UL and ISO certified.
custom-made. “Although many of our our contracts or scrambling to find new Leoch has sales offices on both the East and West coasts
in order to serve all of our customers with their battery
products are closely related, few are suppliers, we began manufacturing the needs. Leoch is rapidly expanding and is now publically
identical,” Korda says. cables and patch panels needed to com- traded on the Hong Kong Stock Exchange with a value in
excess of $1 Billion.
The company’s third division, Gru- plete the installation jobs we had in the

Spectra Logic
www.spectralogic.com / 2014 revenue: $100 million / Headquarters: Boulder, Colo. /
West
Specialty: Data storage solutions
Long-Term Solutions
spectra logic helps its clients preserve and access their data
with storage solutions made to last. by chris petersen
spectra logic’s data storage

systems have been utilized by
a wide variety of customers
in multiple sectors.
Technology is always changing, age solutions for their data has made its customers. With the recent an-
and for a company specializing in data the company a trusted provider for nouncement of its BlackPearl cloud-
storage solutions like Colorado-based clients ranging from McDonald’s to based data storage solution, Spectra
Spectra Logic, keeping up with the ad- the Discovery Channel to some of the Logic is poised to meet the next gen-
vances in technology can keep even a world’s leading research laboratories. eration of demands from its custom-
company with decades of experience The company is used by the National ers, but Starr says the company un-
on its toes. Chief Technology Officer Center for Supercomputing Applica- derstands that the work is never done.
Matt Starr says the company succeeds tion’s Blue Waters Archive Project.
because it never stops working to Even though the company faces Big Requirements
stay on the cutting edge of data stor- some stiff competition from some Starr says Spectra Logic’s customers
age technology. “We’re a 30-year-old of the world’s biggest names in com- typically have very large data require-
start-up,” Starr says. puting technology, Starr says Spectra ments, and they want to keep those
Spectra Logic’s dedication to pro- Logic remains a leader in long-term terabytes of information permanent-
viding customers with the most ef- data storage because of its strong ly. “We are hyper-focused on archive
fective and efficient long-term stor- commitment to its technology and storage,” he says.

Spectra Logic West
The solutions Spectra Logic provides for its custom- “i look at our customer base and how
ers include tape libraries, disk-based systems and cloud-
based storage. Starr says the company has a techno-
often we’re touching our customers,
logical advantage over its competitors, but the way the and i think that gives us a competitive
company deals with its customers means just as much in advantage.” - Matt Starr
most cases.
“It sounds kind of corny, but I look at our customer
base and how often we’re touching our customers, and I solutions like BlackPearl are how Spectra Logic is using
think that gives us a competitive advantage,” Starr says. advanced technology to help customers keep the costs
Spectra Logic operates under the belief that customer related to this storage flat or trending downward. “I’d say
intimacy is just as important as the technology it deliv- the biggest challenges across the board are how fast the
ers, and places a strong emphasis on listening to its cus- industry is moving,” he says.
tomers about their data storage needs and working with No matter how Spectra Logic serves the storage needs
them to find solutions that will serve those needs not of its customers in the future, Starr says the company is
only for the present but also well into the future. dedicated to continuing to manufacture in the United
States. Although some of its competitors have tried to
Private Cloud keep costs down by manufacturing overseas, quality suf-
One of the company’s most recent innovations was the fers as a result.
introduction of its BlackPearl Deep Storage Gateway. “It may cost more up front, but in the long run it’s much
Starr says this new product addresses many of the issues better for what we need to do,” Starr says. mt
involved in storing data indefinitely. He says many of the
company’s customers want to store their data essentially
forever, and cloud storage has been a popular method of
achieving this. However, the cost and complexity of uti-
lizing public cloud storage to the extent many customers
need to, has been a major hurdle for many.
Starr says the BlackPearl system alleviates these issues
by using a public cloud protocol to allow customers to
build their own private cloud that can transition smooth-
ly to tape storage systems. Most of the cost involved in
cloud storage comes from paying cloud operators to host
data. “It’s like renting to own, and it starts costing too
much money,” Starr says.
By providing customers with their own local cloud-
based solution, the BlackPearl Deep Storage Gateway
gives Spectra Logic’s customers all the benefits of cloud
storage without the need to rely on outside cloud opera-
tors. “They can store petabytes of data in their own cloud
for pennies per gigabyte,” Starr explains.
Spectra Logic is moving towards more of these types of
private cloud products, Starr says, as customers’ focus is
changing. Whereas in the past customers were primarily
concerned with backing up important data, now they are
looking to archive all of their data permanently.
Future Needs
The amount of data companies need to store perma-
nently has been increasing exponentially, and Starr says

Konnexio
www.konnexio.com / Revenue: $3.5 million / Headquarters: London, Ontario / Employees: 15 / Specialty: Auto-
International
mated machines / Konrad Konnerth, president: “It’s a paradigm shift in how people think, but it’s important.”
konnexio designs and builds

machines for automated
assembly and test processes
for a variety of customers.
New Tradition
change in two to five years because the
machine was difficult to change over.”
After more than 27 years of expe-
rience in manufacturing, Konnerth
konnexio’s automation separates it from every discovered an untapped market and
other manufacturer. by janice hoppe developed a technology that will
change the industry. Konnexio de-
Konnexio is revolutionizing the the needs of North American manu- signs and builds machines for auto-
world of machine automation with a facturers. Prior to starting Konnexio, mated assembly and test processes
first-of-its-kind technology that ac- Konnerth worked as the director for for automotive, consumer goods
commodates product changes more engineering for a German machine and medical device industries. “Our
easily and can be reused for future company’s plant in Canada that man- greatest desire is that our customers
product variances. “Instead of build- ufactured high-speed, rigid machines. enjoy the experience of working with
ing one large, rigid machine we have “We used to build machines that us on their machine-building project,
been focusing on making each process were high-speed assembly machines accomplishing their automation goals
its own machine and linking them to- with one-second cycle times,” he ex- and receiving the best return on in-
gether,” President Konrad Konnerth plains. “These were very good, rigid, vestment possible,” Konnerth says.
says. “It’s a paradigm shift in how peo- durable machines, but the problem
ple think, but it’s important.” is that they are rigid and you can’t A Niche Market
Konnerth founded the London, change them over. Most manufac- Konnexio’s adapto is a unique and
Ontario-based company in 2003 with turers don’t have the volume to jus- innovative assembly automation and
a goal to develop automation ma- tify that machine and the biggest testing machine system comprised of
chines that could easily change with drawback is when you have a product modular smart cells. The smart cells

Konnexio International
“this is a concept that no one else provides world- Inner Workings

Manufacturing an adapto system is spe-
wide. it is innovative and somewhat new, so we need cific to each customer and starts with
to educate people on how it works.” - Konrad Konnerth project casting and outlining prelimi-
nary steps. Once the order is received,
Konnexio begins engineering each cell
can be employed individually as stand- in one system. If something changes followed by developing control panels.
alone assembly and testing machines we can reconfigure these cells making The system also includes a number of
able to perform multiple operations or it much easier to change and adapt to pre-developed components. “We have a
may further be linked together to cre- product upgrades.” standard base machine concept and use
ate a highly complex assembly line per- The main motion within Konnexio’s that to build custom applications,” Kon-
forming any number of assembly and adapto system is servo-driven, meaning nerth explains. “We build on the reli-
testing functions. everything is programmable and can
Proax Technologies Ltd. For over 50 years, Proax
“If you think of a large machine that easily be changed, Konnerth explains. Technologies Ltd. has been a leading Technical Automation
is designed and developed specifical- “This is a concept that no one else pro- Distributor, offering innovative product solutions for
machine automation, motion control and machine safety
ly for one product, once you build that vides worldwide,” he notes. “It is inno- needs. Proax is proud to partner with Konnexio providing
machine that’s the way it is,” Konnerth vative and somewhat new, so we need innovative product solutions, and in-house local technical
support. Proax has 10 locations across Canada and
says. “What we have been doing is build- to educate people on how it works. We represents world-class leading manufacturers in the auto-
mation industry. Please contact Proax for your industrial
ing a machine by looking at each individ- are still doing that and it is our biggest automation needs! 1-866-592-1240
ual process and bringing them together challenge and task.”

International Konnexio
livery times because – as opposed to

the large, rigid machines that have to
be built in a linear fashion – Konnex-
io’s individual cells can be built paral-
lel to each other.
Konnexio keeps inventory of its
standard base components so it can
react quickly and build a new cell in an
emergency. “We can react quickly and
that’s the beauty of this system,” Kon-
nerth says. “It’s a standardized sys-
tem, so we can reuse components.”
Future Efficiency
The key differentiator of the adapto
system comes into play after it is built
and when the customer has a product
change or new component that needs
to be implemented in the line. “In the
past, we had to go onsite to work on
the machine to try and accommodate
the change by installing new tooling,
rewiring it and get it running again,”
Konnerth explains. “That could take
one to six weeks on the customer’s
floor during which our customers
cannot run production.”
That drawn-out process is no longer
necessary because Konnexio can build
a new cell in-house then ship it to the
customer and swap out the old cell
with the new one in a day or two. “It’s a
tremendous time saving and increase
in productivity,” Konnerth notes.
Moving forward, Konnerth’s dream
konnexio’s adapto system is to build automation machinery that
saves time and money
because its design allows has 80 percent standard components
for easy replacement.
and 20 percent custom components.
Konnexio plans to continue devel-
ability and the success rate of our Konnexio performs in-house testing oping more systems and subcompo-
pre-engineered subsystems.” that can last one day to one week – nents as it grows. “We want to achieve
Cells are built individually and depending on how long the customer 80 percent standard components
specific to each customer’s tooling wants to test the machine. with only a few parts that are custom
requirements and then brought to- Once the machine is approved, it to help us bring down delivery time
gether as a complete line. Quality is then disassembled, shipped to the and improve the quality of our ma-
control measures are taken to ensure customer and reassembled on the chines,” he adds. “These are the types
a high-quality, high-performance ma- customer’s floor. Another major ben- of things we are working on and will
chine is delivered to its customers. efit to the adapto system is quick de- develop overtime.” mt

Systemes LMP
www.lmpinc.ca / Headquarters: Laval, Quebec / Employees: 20 / Specialty: Refrigeration systems /
International
Jeff Gingras, vice president of sales: “We take every project very seriously.”
vice president of sales jeff

gingras says systemes lmp
offers the best cooling
technology available.
Cool Customers installs refrigeration systems used in

supermarkets, warehouses and most
recently, an ice rink. The company
systemes lmp’s carbon dioxide cooling systems specializes in manufacturing sys-
offer customers energy efficiency. by jim harris tems that use carbon dioxide (CO2)
as the main source of cooling instead
of CFCs or HFCs. “Our goal from the
In 1987, the United Nations ratified are closer at hand and in the case of beginning was to reduce the amount
the Montreal Protocol on Substances the 2015 date set for the reduction of of HFCs and CFCs used in refrigera-
that Deplete the Ozone Layer as an ef- HCFCs, already here. tion,” Vice President of Sales Jeff Gin-
fort to reduce the production and use For more than 15 years, Systemes gras says. “We have probably the best
of chlorofluorocarbons (CFCs) and LMP has prepared for the phase-out technology on the market today for
hydrochlorofluorocarbons (HCFCs). of CFCs and HCFCs by developing supermarkets.”
The protocol establishes a timeline alternative technologies. The compa- Systemes LMP was established in
to gradually phase out CFCs except ny also seeks to reduce the use of hy- 1998 as an affiliate of Lesage Refrig-
for very limited uses, and sets a date drofluorocarbons (HFCs), or “super eration Inc., a maintenance and in-
for the reducing the consumption and greenhouse gases,” which were intro- stallation company founded in 1953.
production of HCFCs. duced as a replacement for CFCs but Lesage’s owners founded Systemes
At the time of the protocol’s rat- have since been linked to the phenom- LMP in response to the growing need
ification, the timeline for both ac- enon of global warming. for new refrigeration technology
tions seemed very distant. Now that The Laval, Quebec-based manufac- brought on by the Montreal Protocol,
28 years have passed, those dates turer develops, builds, markets and Gingras adds.

International Systemes LMP
the company says it aims

to build systems that are
energy-efficient as well as
easy to use.
Innovation First Systemes LMP eases the transition – which will phase out the use of R-22
Systemes LMP’s systems offer bene- to CO2 for its customers by supplying by 2020 – awarded the warehouse a
fits to clients beyond their environ- documents and schematics as well as large grant to replace its system, Gin-
mental advantages. Systemes LMP’s offering courses in the equipment’s gras notes.
refrigeration units are designed to be use prior to installation. “We want Systemes LMP is switching the
energy efficient and easy to operate. to reassure our customers and make warehouse system’s evaporators
“We try to have our systems resemble sure their projects happen without over to the ice slurry system at night
traditional HSC/CFC systems,” Gin- any issues whatsoever,” he adds. “We to avoid interrupting activities there,
gras says. take every project very seriously.” he adds.
The most significant difference One recent technology developed The company also holds patents on
between a CO2-based system and by the company is a chilled water ice energy-efficient heat reclamation, air
a traditional system is the pressure slurry that can be used as a secondary circulation, defrosting and dehumid-
they operate under. While a non-CO2 fluid in refrigeration systems in place ification technologies. “Our systems
system typically uses 250 to 350 psi of of R-22 refrigerant. Systemes LMP enable our customers to achieve the
pressure, a typical two-stage boost- is in the process of installing a com- lowest operating costs on the market
er system using R744 as a refrigerant bination ice slurry/CO2 system in a and get the quickest return on their
could reach pressures of 1300psi. warehouse in Quebec. The province investment,” according to Systemes
LMP. “Our outstanding reliability
equates to less maintenance and few-
“our systems enable our customers to achieve the er repairs than on any other systems.
lowest operating costs on the market and get the We offer a range of modular solutions
quickest return on their investment.” to replace synthetic refrigerants

International Systemes LMP
a partnership with leading

manufacturer hussman will
allow systemes lmp to enter
the u.s. market.
that are harmful to the environment with natural second-

ary fluids.”
Systemes LMP continues to develop new technologies
to save its customers energy. “About 60 percent of a super-
market’s costs are related to energy, so any way we can help
them reduce their consumption will allow them to be more
profitable,” Gingras says.
Expanding Capabilities
The use of CO2 in refrigeration systems continues to grow
in Canada as well as in other parts of the world including Eu-
rope, Australia and New Zealand. To address this demand,
the company recently expanded its reach across Canada
and also took steps to grow across North America.
Systemes LMP in 2014 entered into an agreement with
Hussmann, one of the world’s leading manufacturers of
display cases and refrigeration systems, to license its CO2
refrigeration technology for products sold overseas and in
the United States. “Hussmann is the main catalyst for the
sale of our products in the United States,” Gingras says.
When the demand for transcritical systems exceeds Syste-
mes LMP’s capacity, Hussmann will build transcritical refrig-
eration systems developed by Systemes LMP in its manufac-
turing facility in Swanee, Ga. Systemes LMP manufactures
systems for the Canadian market in its facility in Laval.
The company builds roughly 45 refrigeration systems for
customers per year. Every system is designed to meet a cli-

Systemes LMP International
orders compressors on a just-in-time basis. “We have a

number of suppliers who help us,” Gingras says. “We try
to use suppliers who offer us the best products at a com-
petitive price.”
All of the company’s refrigeration systems undergo
strict testing. This includes pressure testing to prevent
leaks, as well as “dry runs” that ensure electrical com-
ponents work properly. Systemes LMP operates an in-
house lab and testing facility. All the technologies and
components used on our systems have been tested be-
fore going to market. “We don’t use our clients as Guinea
Pigs,” he adds.
Systemes LMP’s installers and employees are all high-
ly knowledgeable about the company’s technology. “All
our employees and certified installers are up-to-date
with the technologies on the market today,” the compa-
ny says. “We make sure that all our installers are taught
the right way to work with CO2, and ensure they are
aware of the dangers and safety requirements that must
be followed.” mt
systemes lmp’s manufacturing

functions include welding,
cutting and assembly.
ent’s specific needs. “Our shop is 100 percent custom,”

Gingras says, noting that system sizes and capacities vary
by location, but the main technology used is the same for
all systems.
Systemes LMP’s manufacturing functions include
welding, cutting and assembly. The company also has
plumbing and electrical capabilities. The company
keeps some components such as valves in inventory, but

AV&R Aerospace
www.avr-aerospace.com / Headquarters: Montreal / Employees: 120 / Specialty: Aerospace automation /
International
Jean-François Dupont, CEO: “Innovation is part of our DNA.”
to use robots. That is extremely pop-

ular right now. The size of our system
– you could compare it to a refrigera-
tor. It’s not that big, but there’s a huge
portion of software in our systems.
Basically, it’s a small system using
robot cameras and lasers to give feed-
back. It’s just a simple system when
you look at it that we improved over
the years. The size will vary depend-
ing on the type of application.”
AV&R Aerospace has 80 engineers
on staff. “We do all the concepts,”
Dupont says. “We send out to our two
different workshops the fabrication
of the equipment, and we do the inte-
gration in our workshop and the final
testing.” After customer trial and ap-
proval, the machines are shipped to
the customer.
av&r aerospace offers automation
integration services with tools such
as its robotic blade profiling system.
Onsite Commissioning
Commissioning the equipment at
‘Critical Parts’ the customer’s site can take from two

weeks to two months. “Two months
is a big startup for us,” Dupont main-
av&r is selling custom automated systems to tains. “Usually, two weeks is enough.
On some of the machines, we just
the global aerospace industry. by russ gager have to plug in the cord and that’s it.
Other systems are shipped in differ-
Little things like tiny imperfec- and to use that recognition to explore ent containers or trucks and we do the
tions on the surface of critical jet other market segments. We succeed- assembly onsite, but most of the time,
engine parts can affect the engine’s ed pretty well, so now the company is we don’t have a lot of things to do on-
efficiency in a big way. Similarly, con- well-known inside of the OEMs. On site, which is good, because we work
centrating on a small portion of a very top of that, we have established R&D actually in 12 different countries. So
important and expensive market can partnerships with Rolls-Royce, Pratt we don’t want to send a complete
result in big growth. That is the strate- & Whitney and GE Aviation.” team to our customers’ sites. It is very
gy that AV&R Aerospace has adopted. AV&R Aerospace designs and con- expensive for us. Most of the time,
“What we do is provide robotic tracts for the manufacturing of au- only one engineer is enough to start
solutions for part finishing, surface tomated machines that finish the jet the system.”
inspection and painting,” CEO Jean- engine parts. A popular product is a Among those 12 countries are the
François Dupont explains. “We focus system that creates the profiles on the United States, Canada, Mexico, the
our effort on the critical parts inside jet turbine’s blades. United Kingdom, Germany, Italy,
the jet engine. We decided in 2008 “The requirements now for the per- France, Singapore, China and Russia.
to focus our energy in that particular formance of the new engines requires Dupont estimates that approximately
market. It’s not a big market, actually, an extremely accurate profile on these 30 percent of AV&R Aerospace’s reve-
but the goal of the company was to be blades,” Dupont points out. “It’s not nue is from Europe, up to 35 percent
recognized as the leader in that area possible to do it manually, so you have from the United States and Canada,

AV&R Aerospace International
and the rest from Asia. Approximately The company has doubled in size quired a robotic vision system. We de-
70 percent of the company’s revenue since last year, and Dupont is expecting cided to narrow our expertise, and we
is from the aerospace market and up to that growth to continue in upcoming succeeded.
10 percent from the energy industry. “A years. “We’re excited with what’s com- “We have a mandate to diversify our
natural-gas-fired generator is essential- ing on for 2016, 2017 and 2018,” he de- market,” Dupont adds. “We’re looking
ly a jet engine on the ground,” Dupont clares. “They are going to be big years to deploy our technology in the ortho-
points out. for us, and we expect a lot of volume in pedic industry. We are doing some trials
The rest of AV&R Aerospace’s revenue our manufacturing cells. The average on knee, shoulder and hip replacement
is derived from the general automation age of our employees is 32 years old, so parts for the human body that require
industry. “In our local integration mar- it’s a very exciting culture, and our em- surface polishing and inspection, the
ket, we find something that we could ployees like to be challenged. We ap- same kind of technology as jet turbine
replicate, and it will become a market preciate their work. Innovation is part blades but in a different market.” mt
segment for us,” Dupont explains. “We of our DNA. We put a lot of money into
Proax Technologies Ltd. For over 50 years, Proax
will invest more and more to become a R&D every year so we come with new Technologies Ltd. has been a leading Technical Automation
leader in that area.” solutions. We are playing with robots, Distributor, offering innovative product solutions for
machine automation, motion control and machine safety
cameras, computers – it’s pretty cool.” needs. Proax is proud to partner with AV&R providing
Future Growth Dupont attributes the company’s suc- innovative product solutions, and in-house local technical
support. Proax has 10 locations across Canada and
AV&R Aerospace has two locations in cess to its specialization. “In the past, we represents world-class leading manufacturers in the auto-
mation industry. Please contact Proax for your industrial
Montreal. It plans to establish regional were generalists,” he explains. “We were automation needs! 1-800-557-7386
offices internationally in the near future. doing every automation project that re-

Picard Ovens/Sipromac
www.picardovens.com / www.sipromac.com / Headquarters: Saint Germain De Grantham, Quebec,
International
Canada / Employees: 71 / Vincent Tourigny, CFO: “Our plan is to acquire a company every 18 months.”
portunity for two like-minded com-

panies to come together.”
The union of the two companies
will enable both to gain market
share and attract large high-end gro-
cery chain customers such as Whole
Foods, which has started to use the
ovens in some of their bakeries.
Expansion into the restaurant mar-
ket – including the $35 billion U.S.
pizza industry – is also a priority.
“Restaurants who have postponed
their expansion plans since the Great
Recession are now in an expansion
mode, which creates great business
opportunities for us,” Tourigny says.
Picard Ovens’ location in Saint
Germain de Grantham, Quebec, was
also important to Sipromac, which
wanted the newly unified company
to remain Canadian-based. Picard
will retain its name and continue
manufacturing products under that
brand, Business Development Di-
rector Thomas Hinton says.
“We buy steel from the United
States or Canada, and all the major
components of our machines are
made in North America,” he adds.
all of the major components
“One of the key points of the acqui-
of sipromac’s and picard sition was keeping all of our produc-
ovens’ machines are made in
north america. tion here.”
A Unified Force A Legacy of Quality

Founded in 1957, Picard Ovens has
become known in the foodservice
sipromac’s recent acquisition of picard ovens industry for its unique products,
which include the Revolution re-
will allow it to widen its market. by jim harris volving tray oven. The company is
also the first to develop and market
A recent merger between two bakery and pizza oven manufactur- a baking stone conveyor oven used
Quebec, Canada-based food indus- er. “We were attracted to Picard be- in pizza making.
try equipment suppliers will enable cause of its history and the unique An updated version of the oven,
both operations to expand their products it has developed,” explains known as the Hot Rock, was recent-
market reach. Sipromac, a 30-year- Vincent Tourigny, a shareholder in ly introduced to the market. “Cook-
old food packaging and processing the unified company who also serves ing directly on the stone allows for a
specialist, in March 2014 acquired as its CFO. higher quality of pizza, which many
Picard Ovens, which is a 60-year-old “We saw this merger as a great op- of our customers are looking for,”

Picard Ovens/Sipromac International
Tourigny says. “The oven is also easier and faster to use

than mesh conveyor ovens.”
The company’s other products include rotisserie and
industrial ovens. “Our ovens are known for their com-
pact size, versatility, performance and economical cost
of usage,” the company says. “Our products can be quick-
ly adapted to clients’ needs.”
Sipromac was founded more than 30 years ago by M.
Maurice Lenoir. The company is today partially owned
by Dave Couture, who serves as its president. In addi-
tion to Couture and Tourigny, the company is also par-
tially owned by Andre Francoeur and Yoann Frechette.
The four shareholders are closely involved in the day-
to-day operations of Sipromac/Picard. Couture and Fre-
chette oversee production and engineering, Tourigny is
responsible for finance and administration and Fran-
coeur oversees administration and development of the
Sipromac brand, the company says.
Sipromac offers food industry customers a complete
line of food packaging and processing equipment includ-
ing vacuum packaging machines, heat shrink tunnels and
dip tanks, tray sealers, thermoformers, injectors, tum-
blers, massagers, smokers and cryogenic freezers. “Day
after day, Sipromac draws on its knowledge, experience
and expertise to build sturdy, reliable and highly special-
ized machines adapted to the most stringent needs of the
food sector for the packaging and processing of poultry,
meat, seafood, deli meat, cheese and other food prod-
ucts,” the company adds.
A staff of engineers ensures the continuous develop-
ment and quality of Sipromac’s products. The company
also offers customer installation and support services.
“Our goal is to have the best customer service in the in-
dustry,” Tourigny notes.
Future Investments
Sipromac’s acquisition of Picard Ovens will allow the
Picard brand to take advantage of its parent’s engineer-
ing expertise. Sipromac will benefit from Picard Ovens’
marketing reach.
The unified company is investing in the existing dealer
network. “We want to recruit reps and service partners
to cover the whole North American market,” he adds.
For Sipromac, adding Picard Ovens to its capabilities is
just the beginning of an overall growth strategy. “We’re
looking for acquisitions in both Canada and the United
States,” Tourigny says. “Our plan is to acquire a company
every 18 months.” mt

LAST PAGE | MAY/JUNE 2015
Quick Turns
proto labs inc. has “reinvented the manufacturing process to be more
cost-effective and efficient with low volumes,” according to president
and ceo victoria holt. see page 24 for more information.
F U N D E M E N TA LS
I MPROVEMENT
B UY AMERICAN
A CCOUNTING
M ARKETING
A LFAB INC.
C ONTENTS
L AST PAGE
E CONOMY
D IALOGUE
N EWS

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MAY/JUNE 2015 manufacturing-today.com 1

MAY/JUNE 2015 manufacturing-today.com 3

48. Space Vector Corp.

52. Space Information

54. LaserStar Technologies

Saf-T-Cart has grown to sell its products to

clients throughout all 50 states, Canada and

4 manufacturing-today.com MAY/JUNE 2015

88. Custom Coils Inc.

91. Bonterra Builders LLC

94. UEC Electronics

98. Setpoint System

100. Barnes International

105. Thermwood Corp.

108. Poly-Wood Inc.

113. Control Gaging

MAY/JUNE 2015 manufacturing-today.com 5

116. Acieta LLC 130. Star International 142. GM Toledo Transmission

6 manufacturing-today.com MAY/JUNE 2015

158. D&K Engineering Inc.

164. MTI Metal Technology

168. Gruber Industries

170. Spectra Logic

175. Systemes LMP

MAY/JUNE 2015 manufacturing-today.com 7

S PACE TECH CONFERENCE 2015

manufacturing-today.com MAY/JUNE 2015

Clearing the Cloud alization – bargain. It’s entirely possi-

S PACE TECH CONFERENCE 2015

MAY/JUNE 2015 manufacturing-today.com 9

S PACE TECH CONFERENCE 2015

Connect the Dots Thanks to advanced breakthroughs in

10 manufacturing-today.com MAY/JUNE 2015

increased, while the need for invento- importer, to be handed directly to an

12 manufacturing-today.com MAY/JUNE 2015

The Big East

This will be the 34th year of EASTEC,

which will showcase the latest tech-

nologies in the industry, from addi-

14 manufacturing-today.com MAY/JUNE 2015

ern economy and SME has found that momentum is gath-

EASTEC also will highlight its Bright Minds Program,

MAY/JUNE 2015 manufacturing-today.com 15

18. Linear Mold & Engineering

16 manufacturing-today.com MAY/JUNE 2015

MAY/JUNE 2015 manufacturing-today.com 17

linear mold & engineering

18 manufacturing-today.com MAY/JUNE 2015

among the markets linear

MAY/JUNE 2015 manufacturing-today.com 19

DMLS machines from its longtime

20 manufacturing-today.com MAY/JUNE 2015

MAY/JUNE 2015 manufacturing-today.com 21

throwing away 75 percent of ma- “Our dedication to serving our cus-

go,” Tenbusch states. This includes most up-to-date technology, additive

depth engineering cooperation. industry. In today’s global market,

22 manufacturing-today.com MAY/JUNE 2015

at manufacturing over the next cou-

cus on the 3-D printing technologies

proto labs says it has reinvented

THE NEW WAY model and the industrial engineer.”

24 manufacturing-today.com MAY/JUNE 2015

build it back up, asking ourselves whether something is re-