sustainable...precision manufacturing 3 features 16 shop profile: prototek engineering cutting new...
TRANSCRIPT
SUSTAINABLE- MANUFACTURING -
Reimagining the Processes to Gain a Competitive Edge
MAY / JUNE 2019
INSIDE THIS ISSUE:
ProtoTek Engineering Cutting New Pathways to Manufacturing Success
16 SHOP PROFILEBusiness Sustainability Use EOS to Maximize Your Company’s Profits
20 FEATURE
READ LUBE-TECH'S A
RTICLE
FLUID CHOIC
E
A Critical Component to
Making Shops
More Sustainable
PAGES 18-19
The look you get whenyou realize it comes with the machine.
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PRECISION MANUFACTURING 3
FEATURES16 Shop Profile: ProtoTek Engineering Cutting New Pathways to Manufacturing Success18 Feature: Fluid Choice - Critical Component to Making Shops More Sustainable 20 Feature Story: Business Sustainability Use EOS to Maximize Your Company’s Profits
COLUMNS22 Smart Shop: Why and How Using Oil Water Separators 25 Policy & Government: Youth Skills Training Building the Next Generation of Workers
ASSOCIATION NEWS4 Board Chair’s Letter5 Membership News & Upcoming Events7 President’s Letter15 Member Snapshots
INDEX
SUPPORTING MINNESOTA IN BECOMING THE WORLD LEADER IN PRECISION CONTRACT MANUFACTURING AND RELATED TECHNOLOGIES.
MAGAZINE STAFFEditor & Publications Manager: Nancy Huddleston - [email protected] Creative Director: Severyn Skoug - [email protected] Sales: Todd Cusumano - [email protected]
MPMA OFFICERSBoard Chair: Jesse Schelitzche, Imagineering Machine Inc.Vice Chair: John Madsen, Black Line GroupTreasurer/Secretary: Laurent Deconinck, Machining TechnologyTreasurer/Secretary: Rod Gramse, MRG Tool and DiePresident /CEO: Steve Kalina
EDITORIAL COMMITTEECharlie Hales - [email protected] Madsen - [email protected] Pascoe - [email protected] Reinschmidt - [email protected] Remillard - [email protected] Wilcox - [email protected] Wright - [email protected]
Precision Manufacturing (ISSN 0273-7523) is the only authorized, regular publication of the Minnesota Precision Manufacturing Association (MPMA). Opinions and conclusions expressed in the magazine are those of the individual writer and do not necessarily reflect the official position of the MPMA or its officers.
Precision Manufacturing is published six times per year by IntrinXec Management Inc., 5353 Wayzata Blvd., Suite 350, Minneapolis, MN 55416. Advertising rates provided on request. Correspondence regarding the magazine should be sent to Nancy Huddleston, c/o IntrinXec Management, Inc., 5353 Wayzata Blvd., Suite 350, Minneapolis, MN 55416. Electronic correspondence, including attached files in Word or plain text formats, may be sent to [email protected]. Unsolicited materials will not be returned.
POSTMASTER: Send address changes to: Precision Manufacturing, c/o IntrinXec Management, Inc., 5353 Wayzata Blvd., Suite 350, Minneapolis, MN 55416.
For more editorial or advertising information call (952) 564-3041.
MAY / JUNE 2019
8COVER STORY
Sustainable Manufacturing Reimagining the Processes to Gain a Competitive Edgeby Nancy Huddleston
Precision manufacturers are always looking for ways to be competitive in the marketplace, so could sustainable manufacturing provide the edge that leads to more opportunities for business growth?
PAGE 18PAGE 16
4 PRECISION MANUFACTURING
JESSE SCHELITZCHE Imagineering Machine
Bylaw ChangesYour Involvement Keeps Manufacturing Strong by Jesse Schelitzche
BOARD CHAIR’S LETTER
“The MPMA offers many reasons to
get out of the office or shop and spend
some time with industry peers.”
Many of our MPMA members participate in several of our association events throughout the year. From monthly programs focused on industry-specific topics to social hours and a golf tournament, the MPMA offers many reasons to get out of the office or shop and spend some time with industry peers.
Behind the scenes, there are countless hours put into these programs and events by many people, all with the intent to bring us together, grow the manufacturing industry, and keep the concerns of our members in front of lawmakers, business leaders, and the media.
An additional layer of dedication to the MPMA lies in those who volunteer on the Board of Directors and committees that continue to develop the organization and promote the strategy to keep manufacturing strong in Minnesota. One of the responsibilities of the Board is to follow the bylaws of the organization and update those bylaws as needed. In my message to the members of the MPMA, I will discuss a few changes that were recommended by the Executive Director, approved by the Board of Directors, and voted on by our members. (In no particular order of importance.)
� Affiliate member limits have been increased from 15 percent of the total Manufacturer/Associate membership to 20 percent of the total Manufacturer/Associate membership. Any one Affiliate category can make up no more than 20 percent of the total Affiliates.
ӽ Affiliate members include all of the outside resources interested in the manufacturing industry. These include many of the companies that assist our businesses on the back end – banks, lawyers, accountants, and IT services, just to name a few. These affiliates are extremely important to the MPMA and our members as they offer services many need, provide intelligent advice to our organization, and contribute to many of the events we hold each year. While we hold our manufacturing partners in the highest regard, these affiliates offer many great resources to keep the MPMA strong.
� Historically defined as the “President” and “Executive Director,” the President will now be the “Board Chair” and the Executive Director will now be the “President/CEO.”
ӽ As the Board looked at the titles and descriptions of both positions, it was clear that historically the “Executive Director” was performing the tasks of a traditional President and the “President” had the role of managing the Board of Directors. This name change clarifies those roles moving forward.
� Future role of Past Presidents within the MPMA
ӽ Historically, Past Presidents (now Past Board Chairs) were allowed to stay on as Directors as long as they met the attendance requirements. The new bylaws allow for no more than 30 percent of the Board of Directors to be made up of Past Presidents/Chairs, BUT allows any Past President/Chair to rejoin as a Director if approved by the current Board of Directors. In addition, the MPMA is creating a Past Presidents/Past Chairs Advisory Council that will meet twice a year to discuss MPMA issues and provide advice to the current Board and staff.
Staying involved in the MPMA gives our members a great opportunity to continue to strengthen manufacturing in Minnesota. Volunteering on one of the MPMA committees or on the Board of Directors gives you a deeper appreciation for all the work being done to move this organization forward. When you see a staff member, committee member, or director at one of our events, please tell them how much you appreciate their work and what they do for the MPMA and manufacturing in Minnesota. It is well deserved. PM
PRECISION MANUFACTURING 5
UPCOMING EVENTSMAY
- 16 - Member program
JUNE- 4 -
Leadership Training Series #2
- 13 -Member Program
- 15 - MPMA Family Event
Minnesota Twins Game
JULY- 30 -
35th Annual Open Golf Classic
AUGUST- 6 -
Leadership Training Series #3
- 8 -Manufacturing Facility Tour
- 22 -MPMA Family Event – Top Golf
MEMBERSHIP NEWS
More information on MPMA events @ mpma.com.
35th Annual Open Golf Classic is July 30 Registration is open and sponsorship opportunities are available for MPMA’s 35th Annual Open Golf Classic on Tuesday, July 30.
This is a perfect opportunity to grab some customers, vendors, or co-workers and enjoy a great day of golf at Bunker Hills Golf Club at Bunker Hills Regional Park, 12800 Bunker Prairie Road, N.W., Coon Rapids. This challenging course is characterized by large greens, tree-lined fairways, and the unique characteristic of 75 bunkers.
Cost is $180 per person for the day, which includes lunch, green fees, and dinner. If you are not a golfer, come for networking/social time and the dinner, which is $60.
Sponsorship opportunities are also available and vary in price and package. Please contact Shelly Losinski at 952-564-3041 or email [email protected] for more details.
The schedule, registration information, and sponsorship details are available in the events section of www.mpma.com.
Rod Gramse Named President of MRG Tool and DieMRG Tool and Die is proud to announce that Rodney Gramse has been named president.
Rod has “officially” been with MRG since 1997 after he graduated from the University of Wisconsin Stout with a manufacturing engineering degree. Rod has worked in the shop, the press area, engineering, and quality assurance. Over the last seven years Rod has been operations manager and general manager. His father, Mike Gramse founded the company in 1979, and has served as MRG’s president for 40 years.
Rod envisions building upon what Mike has created over the last 40 years, noting that 2018 was MRG’s best year ever. “We are excited for the years to come, with the current relationships that will grow, and the new ones to come,” Rod said.
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PRECISION MANUFACTURING 7
When most of us think about sustainability, we naturally start thinking wind and/or solar energy, waste and pollution reduction, carbon footprint, etc. Then as small contract manufacturing companies, our blinders go up because most of that doesn’t seem to apply to us. In this edition, you’ll find a few ways that manufacturing sustainability does apply to you, in our cover story and several feature stories.
Another important part of sustainability is sustaining the business itself. With many MPMA member companies owned, led, and run by baby boomer entrepreneurs (in addition to those out in the shop), we no doubt are going to see a lot of change in the coming years. We are already seeing leadership shifts, mergers and acquisitions, and family transitions. These are events that are natural to any business and it’s important that all companies are actively preparing. My father always said you should run your business always striving to make the company worth more. Indeed this is great advice to ensure sustainability through recessions, transitions, or when an entrepreneur decides to cash in on their life’s work.
In preparation for these transitions, the key is to be always looking at value, leadership succession, ownership succession, and of course, personal wealth management. MPMA has a vast array of resources related to each of these topics and I encourage you to explore them. Don’t hesitate to reach out to me if you’re looking for a connection amongst your fellow members. The worst thing a business owner can do is to wait it out. These plans take years to successfully implement.
Specifically, I’d encourage any new or young leaders to use MPMA as a resource for everything from our monthly programs, training, and networking events, to our Leadership Councils. I personally benefitted greatly from being involved with MPMA at an early stage in my career, and I cannot begin to quantify the value of the relationships I’ve built. I’ve been lucky to learn a lot from those baby boomers!
Most manufacturers have told me they were busting at the seams in 2018, and in 2019 they are steady, but not overloaded. Now is the perfect time to re-invest in training, upgrades, personal development, and business strategies. MPMA’s third pillar in our Strategic Plan is all about workforce training – in particular to provide training support for technical positions, emerging leaders, and owners of member companies. We are currently working to:
� Establish MPMA as the one-stop shop to coordinate training resources for members.
� Be the facilitator of member training programs.
� Provide guidance in obtaining and implementing grant and apprenticeship resources.
� Partner with members that can provide automation integration resources to fellow members.
How are we doing this? One way is through our Leadership Councils, which are open to senior leaders to provide insight and guidance that you need to run a successful manufacturing business. We’ve also just introduced a Leadership Training Series, the second of which begins in June: “A Leadership Tune-Up for Experienced Leaders.”
Lynn Moline, who facilitates MPMA’s Leadership Councils (we currently have two groups), is leading the series. Her goal is to provide the insight, help, and guidance you need to run a successful manufacturing business in today’s ever-changing world.
Go to www.mpma.com and look under Leadership Councils for more information on these opportunities, and look under Events for specific information about the leadership series. You’ll be glad you did!
THANK YOU PAST PRESIDENTSRelated to transitions and generational changes, I wanted to take a moment to thank our Past Presidents
of the association. These individuals (and their organizations) have devoted a lot of time, energy, and resources over the years to make MPMA a success. Please visit our website to see the full list. PM
STEVE KALINA President / CEO
Minnesota Precision Manufacturing Association
Sustainable StrategiesSupporting You as Your Business Changesby Steve Kalina
PRESIDENT’S LETTER
“My father always said you should
run your business always striving to
make the company worth more.”
8 PRECISION MANUFACTURING
SUSTAINABLE- MANUFACTURING -
Reimagining the Processes to Gain a Competitive Edge
The U.S. Environmental Protection Agency (EPA) defines sustainable manufacturing as the creation of manufactured products through economically-sound processes that
minimize negative environmental impacts while conserving energy and natural resources.
Precision manufacturers are always looking for ways to be competitive in the marketplace, so could sustainable manufacturing provide the edge that leads to more opportunities for business growth?
Yes, according to Monte Hilleman, Senior Vice President of Real Estate Development for the Saint Paul Port Authority (SPPA). “‘Reduce – Reuse – Recycle’ has been around for a long time, but that is a limited view of environmental sustainability and what it can mean for your business,” he explained,
“Understanding energy efficiency and pollution prevention are important because when businesses do these things, that increases their competitiveness in the marketplace.”
by Nancy Huddleston
PRECISION MANUFACTURING 9
COVER STORY
So, while recycling scrap from CNC machines, changing out light bulbs, turning off machines, and upcycling waste material to another business can lead to leaner operational costs, those measures can also make a difference to your bottom line, and to the big companies that need contract manufacturers to produce precision parts.
STARTING POINTThe first step is to reimagine
traditional recycling efforts and take them to a higher level that includes remanufacturing, recovery, and redesign.
Next, keep in mind that recycling is not a one-size-fit-all approach, especially in manufacturing. While a big company like 3M has the wherewithal to move to 100% renewable electricity in all its facilities around the world, small to mid-sized businesses typically can’t make that same level of commitment. And, every business has a different approach to striking a balance between production demands, environmental requirements, and safety.
The experts advise starting with a “Life Cycle Assessment,” which is thinking about manufacturing products and processes from a “cradle to cradle” perspective - with the ultimate goal of making environmental sustainability a normal part of doing business.
“Where do your materials come from?” asks Hilleman, “Could you source them locally, thus transporting
them less? Are there ways that you are using and making products that are restorative for the environment? Most manufacturers are hazardous waste generators – so think about the options that eliminate or minimize these.”
Mark Mattke, CSP, CIH, is the Director of Operations, Wisconsin, for OECS Workplace Safety
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[ continued on page 10 ]
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10 PRECISION MANUFACTURING
Experts, and said thinking “cradle to cradle” vs. “cradle to grave” provides manufacturers with a lot of opportunities that are already within their grasp. Examples include:
� Hire an intern to create an environmental program.
� Use the Small Business Assistance Group at MPCA, or other no/low cost services such as RETAP, MnTAP, and Waste Wise at the Minnesota Chamber of Commerce.
� Use the Minnesota Materials Exchange.
� Switch to companies that specialize in non-VOC solvents.
� Consider a solvent still for reusing spent solvent.
� Have an energy audit done by your utility company.
� Have a thermographic survey performed for energy reduction options and fire prevention.
� Have your backflow preventer valve maintained.
� Have a spill clean-up contractor available for large spills.
� Practice good Storm Water Pollution Prevention (SWPP) measures – cover dumpsters, avoid outdoor storage in order to qualify for “no exposure designation.
� Train employees not to pour liquids down the drain, not to toss wet products into dumpsters, and not to hose spills to the drain.
FINDING HELPThe list of ideas to strengthen
environmental practices is endless, so knowing where to look for help is vital. One of the best places to start is with the Minnesota Technical Assistance Program – better known as MnTAP.
It is “an outreach program at the University of Minnesota that helps Minnesota businesses develop and implement industry-tailored solutions
that prevent pollution at the source, maximize efficient use of resources, and reduce energy use and costs to improve public health and the environment.”
MnTAP provides “no-cost, confidential, industry-tailored technical assistance” to reduce waste and increase efficiency, to “save on disposal and raw material costs and decrease regulatory compliance burdens.”
MnTAP is funded in part by a pass-through grant from the Minnesota Pollution Control Agency’s (MPCA) Resource Management and Assistance Division to the University of Minnesota School of Public Health, Division of Environmental Health Sciences. Other grants come from partners including the Minnesota Department of Commerce, Division of Energy Resources, Metropolitan Council, counties and other local units of government, EPA Region 5, and energy utilities. Also important to note: MnTAP is part of the University, so it has no regulatory responsibilities or obligations.
COVER STORY
BACKGROUND: Smith Foundry worked with a Minnesota Technical Assistance Program (MnTAP) intern in 2017 to find a means to improve air quality inside and outside of the foundry. Opportunities included switching to a greener binder system for core-making to reduce volatile organic compounds (VOCs), hazardous air pollutants (HAPs), carbon monoxide (CO), and particulate matter (PM), and prolonging sand life and reducing silica exposure by optimizing silica sand handling. In addition, the intern performed initial calculations for implementing new technologies to reduce operation costs and waste such as the Furness-Newburge Sonoperoxone Blackwater system and Mull-to-Energy system.
RECOMMENDATIONS *• Switch to alternative binders – annual savings, $900• Install blackwater system – annual savings, $30,000• Install mull-to-energy system – annual savings, $8,400• Optimizing piping design for new silica sand – annual savings, $2,600• Switch from pneumatic to electric tools – annual savings, $17,200
* Note: MnTAP interns only make recommendations. Companies make the decisions regarding implementation. All proprietary information is confidential.
FOR THE FULL REPORT, GO TO: www.mntap.umn.edu/interns/pastprojects/
SUCCESS STORY- SMITH FOUNDRY -
PRECISION MANUFACTURING 11
COVER STORYCOVER STORY
MnTAP is one of the many organizations that Mattke recommends to businesses that seek environmental compliance services from OECS. And the Minnesota Materials Exchange, a “free service that links organizations that have reusable goods they no longer need to those who can use them,” is one of his favorites.
In the “Waste Not Classifieds,” businesses, industry, nonprofits, and institutions can buy, sell, rent, seek, and provide services. There are rules and regulations to abide by, of course, but Mattke said it’s a great way for manufacturers to upcycle waste materials. The ultimate goal of the Exchange is to “prevent usable materials from becoming waste and save users money.”
To illustrate that goal, Mattke shared a story about a company that was searching for a better method to get rid of alcohol that it used in one of its processes. Previously, it had to obtain a waste water permit in order to legally pour large quantities of waste alcohol into the storm sewer system. Then, OECS helped the company find a buyer that could take their waste alcohol and use it for a different process.
Hilleman said examples such as that are the “Holy Grail” in industrial ecology. “Manufacturers can share their inputs and outputs,” he said. “Your waste product might be used by someone else for their product. It’s reusing instead of producing industrial waste.
“It can be difficult, because your waste product has to meet another company’s specifications, but creating a closed-loop system and continuing to use resources without creating waste” is becoming more important in the business world, Hilleman pointed out.
Tim Peterson, CHST, Vice President of Operations for OECS, said creating a closed-loop system is an important aspect of an environmental sustainability plan, which in turn, gives manufacturers a competitive edge.
“Environmental improvements not only save you money in regard to your overall operational costs, but it is also recognized by other companies that you do business with,” he pointed out.
For instance, most large manufacturing companies have ISO 14000 certifications. But the cost of that certification is often out of reach
for small to mid-sized companies. The solution? Create an Environmental Management System Program (EMSP) for various requirements such as certification, recertification, and required audits.
“The bottom line is that you can still take some of the elements of ISO 14000 to reduce your environmental footprint, and use the thoughts and processes” to reduce, reuse, and recycle
which oftentimes matches up with the ISO 14000 standards used by larger companies, Peterson said.
TAKING ACTIONMichelle Gage, an engineer for
MnTAP, said one of the easiest ways to start a manufacturing sustainability plan is by enlisting the help of employees
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12 PRECISION MANUFACTURING
to form “Green Teams” that create benchmarks to measure production metrics against resource costs and get feedback on resource usage.
“There is a real value in talking with the operators and workers on the floor,” she explained, “They have good ideas and they might have a better way to do something you’re already doing – so a Green Team provides an opportunity for change.”
Trained MnTAP staff members work with businesses to form an internal team that can tackle energy and waste-related issues. Once a team has been formed, MnTAP trains members about effective brainstorming and investigation techniques, as well as pollution prevention and energy efficiency strategies.
“What we’re doing is facilitating the conversation,” said Laura M. Babcock, Ph.D., Director of MnTAP. “We’re providing ways for businesses to record their results, record good ideas, and get the facility staff to rank and prioritize these items. MnTAP provides the background and experience, and gives
them a reason to meet, which helps with accountability.”
Another opportunity to address waste reduction and energy efficiency projects is to hire a MnTAP intern. Businesses
contribute a nominal cost share for the project, and on site supervision. MnTAP pays the interns, mentors the interns, and provides technical support. A full report and presentation of recommended action is provided, and all proprietary information at the facility is kept confidential.
At the Port Authority’s MinnPACE program, manufacturers can save money by investing in renewable energy and energy efficient upgrades. Qualifying equipment includes big ticket items like solar, wind, and geothermal, but also upgrades to HVAC systems, lighting, motors, and compressed air, as well as purchasing new manufacturing equipment.
With 100 percent financing and no payments due until the following year, MinnPACE is positioned to eliminate some of the barriers associated with significant capital investments and often go hand-in-hand with energy audits. The SPPA works closely with utility companies, and quite often, if a project qualifies for rebates, it should qualify for MinnPACE as well.
COVER STORY
“Understanding energy efficiency and pollution
prevention are important because when businesses do these things, that increases their competitiveness in the
marketplace.”
Monte HillemanSenior VP of Real Estate
DevelopmentSaint Paul Port Authority
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MnTAP ‘s mission is to strengthen Minnesota businesses by improving effi ciency, while saving money through energy, water, waste reduction.
Some of the confi dential services we provide at no cost to the business include:
• Site visits to identify reduction opportunities• Demonstrations and research• Internal team facilitation• Navigating regulatory issues• Industrial water effi ciency evaluation• Finding safer solvents
MnTAP also off ers a low cost summer intern program.
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PRECISION MANUFACTURING 13
“We work with companies to get proposals, and MinnPACE provides the financing,” Hilleman explained, “The goal is a positive cash flow with energy savings that are greater than the debt service on the payment.”
MinnPACE also works with city and county governments to facilitate property assessments.
“MinnPACE offers 100% financing with no payment due until May of the following year, as part of the property assessment. This gives commercial building owners six to 16 months to reap the financial rewards of lower utility costs and ultimately stay ahead of the loan. That’s the magic of PACE,” he said.
SEEING THE LIGHTThe Center for Energy and
Environment (CEE) “helps businesses cut energy use through better tracking and understanding, and by reducing barriers to efficiency improvements and other resources.” Two of its commercial programs that are designed to make efficiency improvements straightforward and affordable are the
One-Stop Efficiency Shop and Energy Intelligence. Both are sponsored by Xcel Energy and delivered by CEE.
“It can be as easy as looking at the nonproduction times for a machine that’s left on or in idle, lights that are left on, or an air compressor that is feeding system leaks,” said Nicole Kessler, Program Manager for Energy Intelligence. “We urge manufacturers to look at their start up and shut down procedures to see where they can save energy.”
CEE helped Mack Engineering understand its energy use and find ways to save money. A pulse output board was installed on the electric meter, which allowed the visualization of daily electric data to show how the electrical demand changed throughout the day.
Once the assessment was completed, Mack Engineering took action to reduce the overnight baseload, align the morning startup of equipment and business operations, and turn off idle equipment during production hours.
“When we go in we say, ‘you know your facility,’ and we encourage them to do
a walk through at the end of the shift on Fridays (if they shut down for the weekend) and see what gets left on,” Kessler said.
Manufacturers might point out that they can’t turn certain pieces of equipment off, or else they will lose programming. To answer that concern, CEE encourages business owners to go back to their distributor to ask if machines can be turned off or put into an energy-savings mode without the loss of programming information. If so, that could result in big energy savings.
Another opportunity for cost savings comes with the way manufacturers use compressed air. “We ask them to think about how it’s used and if there are ‘non-ideal’ uses,” Kessler said. “For instance, it can be a pretty expensive broom.”
Compressed air is often referred to as the “hidden utility” or “fourth utility” because it is viewed as “just air,” but it’s actually an expensive tool. CEE advises manufacturers to repair leaks in the hoses and connectors to save energy,
COVER STORYCOVER STORY
U.S. Environmental Protection AgencyEnvironmental Management Systems (EMS)
www.epa.gov/ems
Minnesota Pollution Control Agency (MPCA)www.pca.state.mn.us/living-green/pollution-prevention-
cleaner-production-and-products
Minnesota RETAP (Retiree Environmental Technical Assistance Program)
www.pca.state.mn.us/quick-links/minnesota-retap
Small Business Assistance Group at MPCA www.pca.state.mn.us/smallbizhelp
Minnesota Technical Assistance Program (MnTAP)www.mntap.umn.edu
MnTAP Intern Programwww.mntap.umn.edu/interns/business/
MnTAP Green Team Programwww.mntap.umn.edu/services/teams/
Saint Paul Port Authoritywww.sppa.com/energy-financing/minnpace
OECS Workplace Safetywww.oecs.com
Minnesota Materials Exchangemnexchange.org
Center for Energy and Environment (CEE)www.mncee.org
Minnesota Waste Wisewww.mnchamber.com/grow/waste-wise
Tech Dumpwww.techdump.org
SUSTAINABLE MANUFACTURING- RESOURCES -
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14 PRECISION MANUFACTURING
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COVER STORY
and implement a process to service the system regularly.
Programmable thermostats are another low-cost upgrade that can result in a lot of energy savings. Although specific temperature and humidity settings are necessary for certain manufacturing processes, generally thermostats can be set back when work is not taking place, resulting in cost savings.
And last, but not least, the energy savings from upgrading to LED lights can’t be emphasized enough, according to Kessler. While there is a cost up front, the energy savings will typically pay for that within two or three-years’ time.
$$$$$So how can manufacturers pay for
all of this?“There is a business cost for
environmental altruism,” Hilleman pointed out. “But you can make a difference by looking for opportunities in transportation, closed-loop distribution, and by getting out of the regulatory world with pollution prevention measures.”
Whenever businesspeople inquire about environmental challenges, they inevitably ask how to pull the biggest lever to get the most savings. By and large, according to Hilleman, the biggest lever is carbon emissions from HVAC units and lights – which contribute 40% to the carbon emissions in the U.S.
“That’s a shockingly large number, so we must deal with our facilities. We must improve energy efficiency to reduce our carbon emissions. We have an obligation to look at those negative effects,” Hilleman said.
Realistically, the experts acknowledge that one of the biggest barriers to implementing an environmental sustainability program is the capital investment. Here are some ideas on how to get started:
� Begin incorporating energy efficiency changes into the facilities improvement budget, a little at a time.
� Change to “green cleaning” products.
� Look at the supply management chain to lower transportation costs.
� Look into low-cost options, such as fixing leaks in the compressed air system.
� Fix leaky faucets, toilets and water spigots and switch to low-flow fixtures.
� Get an energy audit done by your utility company.
And remember, “sustainability is a process,” according to MnTAP. “Businesses may not be ready to make a capital investment or to reorganize systems. You can go from small changes to big changes,” Gage advises.
Getting started is the key. “Energize your staff about the low
and no-cost options and you’ll see a big impact on materials, water, and energy use,” Gage said, “It’s very motivating to see those cost savings, which can provide the motivation to go to the next level.” PM
NANCY HUDDLESTON is the editor and publications manager for Precision Manufacturing Journal. She can be reached at [email protected].
PRECISION MANUFACTURING 15
MPMAMEMBER
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16 PRECISION MANUFACTURING
ProtoTek Engineering has embraced the modern arena of high-end CNC software. If any manufacturer in Minnesota, Wisconsin, or the Dakotas wants to purchase the No. 1 CAD/CAM software in the world, they call ProtoTek, because they are the sole entity responsible for the sales, support, training, and presentation of Mastercam.
WHAT IS MASTERCAM?Mastercam is CAD/CAM software
that helps businesses improve production speed and efficiency in their manufacturing processes, saving time and money. It is used by global, industrial conglomerates as well as small, regional shops, plus everything in between to advance programming and machining capabilities. As manufacturing needs evolve with the development of Industry 4.0, Mastercam is being developed in step to support smart manufacturing initiatives on a worldwide scale.
Mastercam is the most widely-used CAD/CAM software in the world beating out its closest competition by an extremely wide margin. As a matter of fact, Mastercam sold its 250,000th license last July. No manufacturing software protocol comes even marginally close to that number. There are obvious reasons.
But for those in the upper Midwest, perhaps one very important reason why Mastercam prevails is the product-passionate, highly-experienced, engineering-savvy, and steady minds of the professional crew behind ProtoTek Engineering.
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PRECISION MANUFACTURING 17
each Mastercam customer receives is a very well-planned and highly-functional service team that completely supports the product, trains every user, teaches, assists, and walks every customer through each subject, one-on-one or in their award-winning group training classes. No Mastercam user is ever truly alone when you consider the availability and desire to help that exists within each ProtoTek support professional.
One of the best reasons to consider Mastercam is how the company is in a true continuous improvement mode. Every year, Mastercam provides a new, more innovative way to perform manufacturing functions. Streamlining, efficiency, time-saving, tool-wear improvement … the list goes on and on.
SALES, SUPPORT, SERVICE, TRAINING
Sales, support, service, and training are the pillars of the ProtoTek Engineering business model. Discover much more by reviewing www.prototek-engineering.com.
And now, with the release of Mastercam2020, the world of premier CAD/CAM software enters a new evolution, all designed to help manufacturers prosper, exceed customer requirements, become more effective, and build a stronger legacy for years to come. PM
The staff at ProtoTek Engineering are eager to answer any questions you may have.
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SUCCESS STORYNot long ago, Mastercam introduced its Dynamic Motion technology.
Say you’re a low to medium-volume job shop running many repeat jobs with numerous set ups. The short to medium-run jobs continually turn over. To meet this demand, the company expands from two CNC machines to 12, including two new vertical machining centers, one being a large 5-axis machine with 141-inches of travel in the X. Your large 5-axis machine may be dedicated to producing parts of differing lengths and configurations for a multi-year specialty project. The new 5-axis machine allows the company to take on more jobs creating a need for strong, reliable CAD/CAM software. Mastercam CAD/CAM software will immediately help in reducing set-up times and overall workflow, especially when programming for any specialty-contract customer who sends its orders for three-dimensional parts in various formats, such as a STEP format.
You may need to deal with a lot of stringent documentation requirements. Mastercam can help with that, too. And, although the parts may be very complex, Mastercam allows them to be programmed efficiently, and its simulation feature assures that there will be no interferences that could cause damage.
The ability to cut expensive materials to exacting specifications with reduced cycle times will give your company a distinct advantage. Perhaps, many of the parts this company is called upon to manufacture start as mono-material billets which large amounts of material must be removed. In some applications, a 200-pound block of steel may be whittled down to 40 pounds. Maybe there is one 3,000-part job that starts out as an 85-pound block of high-strength steel and ends up weighing a mere 14 pounds at the end. Another project starts out as a 10-inch round disc that ends up being a 6-by-7-inch piece that is not quite square. This company’s bearings can rough out these parts efficiently using tool paths incorporating Mastercam’s Dynamic Motion technology. The program keeps the tool continuously engaged with the material so there isn’t a lot of jumping or air cutting. And, the Mastercam Dynamic Motion tool paths can utilize the entire length of the tool to cut, rather than just the tips.
By using the entire tool length, tool wear and breakage is reduced, providing even more time savings and lowering manufacturing costs. Using Mastercam is a real win-win scenario.
That is the kind of story and benefit everyone in the manufacturing industry can relate to, and only Mastercam can provide these better manufacturing protocols to follow. And only ProtoTek Engineering can help each customer discover their new pathways to manufacturing success using the most widely-used CAD/CAM software in the business, Mastercam2020.
18 PRECISION MANUFACTURING
Sustainability and the environment often go hand-in-hand. While the environment is a huge part of sustainability, other factors such as efficiency, waste, and production are important metrics that factor into the big picture. Fluids and fluid performance play a key role in all of these factors, and fluid choice is critical to making your shop more sustainable.
HIGH-QUALITY FLUIDSHow can spending more on fluids make
you and your customer happier? Won’t that increase costs? The truth is, sometimes the old adage, “you have to spend more to make more,” holds true, especially when it comes to industrial fluids.
Consider this example: A few years back, the Department of Defense awarded a grant to study the energy efficiency of grinding fluids. The group chosen to head up the study identified various fluids to evaluate, then installed a black box on the tool spindle to measure energy consumption.
What they found was that high-quality f luids, as well as better additive packages, resulted in significant energy savings, something that not only
affects a shop’s bottom line, but helps the environment by using less energy. Some other benefits of using high-quality f luids are longer f luid life in the sump, which means less f luid used and less down time, and higher speeds and higher feeds. All of these equate to a more efficient machine and more efficient production, which trickles down to the customer as cost savings and product satisfaction.
BASE FLUIDS, ADDITIVES, BLENDS
The fluids a shop uses may be up to 95% base oil, but that other small percentage, 5 - 15% of the blend, are additives. They make the fluid “work” by enhancing it with extreme pressure, lubricity agents, and other specialty chemistries that control wear, oxidation, moisture, and a myriad other things.
A more expensive additive package that contains, for example, a higher level of extreme pressure additive, or more effective biocides and emulsifiers, can result in longer fluid life and better performance, creating less re-work and less waste. Take this example: a high-end
metalworking fluid coolant concentrate can range from $20 - $30 per gallon, and these fluids will routinely last two - three years in the system when cared for properly. On the other hand, a “price-driven” purchase of a lesser (per gallon concentrate cost) metalworking fluid at $10 per gallon might only last three months, regardless of sump maintenance. The difference is most likely in the quality of the preservative and emulsifier package that allows the fluid to have a longer circulation or “sump” life.
Another thing to consider in regard to metalworking coolants is water. Water makes up 90 - 95% of a metalworking coolant, and water quality plays a large factor when it comes to metalworking coolants and their performance and service life.
RENEWABLE FLUIDSFluids such as vegetable oils, esters,
and others not derived from petroleum are considered “renewable fluids.”
Vegetables are good for us, and they can be good for your machine, too. Vegetable and ester-based fluids can provide improved lubricity over mineral oil options because of their increased polarity for the metal surface. However, if not formulated correctly, vegetable-based fluid service life may be half that of a petroleum-based fluid due to lesser oxidative and hydrolytic stability. It is critical to verify if the vegetable-based fluid you choose has a comparable life cycle under heat, water, and stresses of your manufacturing environment.
So, is using twice as much fluid sustainable? The good news on this front is there have been a lot of advances in fluid technology and vegetables and esters could compete with traditional fluids in fluid life and oxidative stability in the near future.
EXTENDING CHANGEOUTSIt’s common knowledge that
maximizing fluid life can enhance both cost savings and efficiency. But did you know that lab analysis can be used to determine when a fluid needs to be
Fluid ChoiceCritical Component to Making Shops More Sustainable by Michelle Brakke and Jim Urquhart
FEATURE
PRECISION MANUFACTURING 19
changed from a performance standpoint vs. when the calendar says it needs to be changed? This involves educating machine operators on how to keep fluids clean and the importance of taking regular samples.
Proper filtration and new technologies, such as rare earth magnets that improve traditional filtration by pulling microparticles out of the fluid, help keep fluid clean. Cleaner fluids will also help achieve better surface finishes, minimizing micro abrasions that result from swarf and particulates in the fluid.
Of course, the quality of fluid figures into this as well, with high-quality fluids typically lasting longer. The result is more run time, less expense, and a better product for the customer.
RECYCLINGUsed petroleum products are not
just considered burner fuel anymore. Despite originating from a mixture of base stocks and quality, the re-refining process will often yield a higher quality base f luid and can even result in a
higher quality f luid than first time use Group I base stock.
There are two general types of used oil – crankcase old and industrial oil. Each type presents a unique set of recycling challenges.
Cutting lubes, way lubes, machine oils, and other machining fluids (used to cool and lubricate tooling as it works the metal during the machining process) are the main sources of industrial used oil. When industrial fluids reach the end of their lifespan, their disposal becomes a challenge. Unlike crankcase applications, industrial oils are typically emulsions (chemically stabilized water and oil mixtures). In order to be recycled, this emulsion must be broken and the water removed. Some manufacturers choose to do this on-site with an evaporator, which basically boils off the water into the atmosphere — leaving the oil and other waste accumulated from the manufacturing process to be recycled.
Re-refining prepares used oil for use in an engine or other machine, the same as originally intended. This process
includes vacuum distillation to remove volatile contaminants (fuel) and hydro treatment to remove impurities. One gallon of used oil typically results in a half-gallon of recycled base stock.
When it comes to utilizing recycling services, shops have two choices in regard to sustainability – the first is to choose an oil collector that recycles fluids with the most up-to-date technology. The second choice is considering using fluids blended from re-refined base oils.
The bottom line is, with the availability of recycling services there is no reason a shop should be considering any other route, especially with the looming threat of EPA fines and, perhaps worse, having your shop end up in the news as an EPA violator. PM
MICHELLE BRAKKE is the Industrial and Distribution Product Development Manager at Lube Tech and can be reached at 763.417.1256.
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“High-quality fluids, as well as better additive packages, result in significant energy savings, something that not only affects a shop’s bottom line, but helps the environment by using less energy.”
20 PRECISION MANUFACTURING
You’ve worked hard to build a successful company that provides for its employees and is well thought of by its customers and partners, but with success, your company has become increasing complicated, complex, and unwieldy and you feel as though you no longer have complete control over its future. Each day presents more challenges and you’re working longer and harder just to maintain the status quo.
As a business owner, does this sound familiar? You’re not alone, because many successful business owners struggle with getting what they want out of their business. Luckily, there is a solution that has worked for many small businesses: The Entrepreneurial Operating System (EOS).
WHAT IS EOS?Founded by lifelong entrepreneur
Gino Wickman, EOS is a set of simple concepts and practical tools that helps
business owners get what they want out of their company by focusing on six key business components: Vision, People, Data, Issues, Process, and Traction. By focusing on these key business components, business owners can create a foundation on which the countless stresses and headaches of running a business seemingly melt away.
Vision: Where are we going? This starts with the leadership team. Everyone needs to be riding the same bus in terms of where the company is going and how it’s going to get there. There can’t be multiple buses traveling in multiple directions. All of the company’s energy needs to be focused in the same direction. When the leadership team is not riding the same bus, employees become confused and hesitant to move forward.
People: You cannot achieve a great vision without great people. Not only is
it important to have great people, but it’s equally important to put those people in the right seats. Often times a company’s leadership tolerates the wrong people because of their productivity, while at the same time those people are chipping away at the company’s foundation and management’s vision.
Data: Run your business using objective, real-time data. Too many businesses run on opinions and egos. In order to have a pulse on the business and shine a light on the issues, you need predictive data.
Issues: As a business owner, you and your business face a constant barrage of obstacles and challenges. By way of putting the right people in the right seats, successful business owners empower their employees to solve issues and make decisions. Do not shy away from a decision; any decision is better than no decision.
Process: The most successful companies run on systems. Systemize your business so that it becomes more efficient, more effective, more manageable, and ultimately more profitable. Process creates calmness among employees and alleviates the need to re-create the wheel. Process also allows leaders to be more strategic in their thinking because they spend less time getting bogged down in details.
Traction: Traction means daily execution of the company’s vision. This is all about getting things done, being disciplined, and holding people accountable. If there’s no traction, the company’s vision is purely a hallucination.
If you’re experiencing underwhelming business success and feel out of sync with your leadership team, it could be signal that your business needs re-tooling, and EOS could be the solution to your problems.
Business SustainabilityUse EOS to Maximize Your Company’s Profits by Brandon Reinschmidt
FEATURE
There are all kinds of books and templates available to help your company implement EOS, or you can bring in a facilitator to help.
PRECISION MANUFACTURING 21
IMPLEMENTING EOSThere are all kinds of books and
templates available to help your company implement EOS, or you can bring in a facilitator to help. Regardless of the implementation method, there are important lessons EOS can teach you about business.
Accepting ChangeJust like phones or computers,
businesses operate according to core internal systems. When you receive update notifications on your phone or computer, you accept those updates because you want them operating at peak performance. Businesses are the same way; they need ongoing updates and development in order to operate at peak performance.
Setting ExpectationsThe daily grind can be overwhelming,
and customer obligations usually take priority over all else. Nevertheless, it’s important to take time to define your vision, values, process, roles, and responsibilities to your employees. By doing so, you guarantee you’re all riding the same bus! If employees aren’t meeting expectations, make sure the expectations have been clearly defined and communicated before assuming it’s due to lack of effort.
Accountability EOS is designed for small growing
businesses, but at some point your business will plateau or become less profitable and more inefficient because it doesn’t have the right structure of roles and responsibilities. Regardless of your company’s size, your company should have an organizational chart where roles and responsibilities are clearly defined. This provides accountability and ensures a high level of performance.
DelegationAs a small business owner, it’s often
hard to distinguish between ownership and leadership. Many small business owners are used to wearing a variety of hats and overseeing all facets of their company’s operations. However, by
delegating some of their responsibilities, business owners create a stronger, deeper leadership team that is more capable of maximizing the company’s resources.
STILL UNSURE?There are many books worth reading
if you’re looking for more information, including the popular “Traction: Get a Grip on Your Business” written by Gino Wickman. You also can search online and find a variety of EOS tools as well as certified EOS implementers that can help you get started. PM
BRANDON REINSCHMIDT CPA, ABV is an Audit Senior Manager at SDK CPAs and a member of MPMA’s Communications Committee. He can be reached at 612.332.9369 or [email protected].
Founded by lifelong entrepreneur Gino Wickman, EOS is a set of simple concepts and practical tools that helps business owners get what they want out of their company by focusing on six key business components:
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Contact SDK for all your accounting needs
� Vision
� People
� Data
� Issues
� Process
� Traction
22 PRECISION MANUFACTURING
Compressed air produced by any oil flooded piston, rotary vane, rotary screw, etc. compressor has contaminants in the compressed air itself. After the compressed air is cooled by the heat exchanger in the compressor and the refrigerated dryer, the contaminants including water and oil condense and become a liquid. To properly dispose of this liquid, the oil needs to be removed from the water so that the water can be disposed of in the traditional manner to the municipal sewer system. This purification process can be easily achieved through the use of oil water separators.
If you do not use an oil water separator and you dispose of the liquid condensate from your dryer by dumping it into your municipal sewer system, collecting it in a bucket and dumping it outside, or doing some other non-
Why and HowUsing Oil Water Separators by Tom Chellberg
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PRECISION MANUFACTURING 23
environmentally friendly method, you may be liable to a citation from the EPA, or the authority having jurisdiction for wastewater purity. Some industrial buildings are built with an oil water separator sump, built in to the floor drain system when the building was originally built. Inquiry should be made if this is sufficient to satisfy the local code requirements.
The Federal government’s “Clean Water Act” states that water drained into the municipal system must have not more than
40 PPM (Parts Per Million) or less of oil in the wastewater. Liquid that is dispensed from the receiver tank, air dryer, and the pre-filtration and post-filtration filter housings usually contains approximately 300 PPM of oil to water, so you can understand that this is a very valid liability concern. For more information, check out:
� The Clean Water Act – EPA
� Code of Federal Regulations – Part 279, Title 40
HOW DO THEY WORK?Each brand of oil water separators
operates a little bit differently, but they all use the underlying principle of adsorption.
Adsorption, different from Absorption, is the process in which atoms, ions, or molecules from a substance (it could be gas, liquid, or dissolved solid) adhere to a surface of the adsorbent. Adsorption is a surface-based process where a film of adsorbate is created on the surface, while absorption involves the entire volume of the substance permeating the penetrable absorbing substance.
By directing the compressor system condensate from the tank, dryer, and filtration units into an oil water separator, this piece of equipment collects the oil on impermeable polypropylene fibers and then purifies the water through activated carbon media. The water is then dispelled and can be safely drained into the public sewer system. The oil will be collected and stabilized on the polypropylene fibers and disposed of correctly when doing the scheduled compressed air system preventative maintenance task. PM
TOM CHELLBERG works for Fluid-Aire Dynamics, an MPMA member company, which is based in Burnsville. He can be reached at [email protected] or 952.486.2623.
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PRECISION MANUFACTURING 25
Youth Skills Training Building the Next Generation of Workers by Amy Walstien
POLICY & GOVERNMENT
Manufacturing is one of the top industries in Minnesota, producing 16% of our state’s Gross Domestic Product (GDP) and employing over 320,000 workers directly in manufacturing and even more in industries related to manufacturing. Precision manufacturing is an important part of Minnesota’s manufacturing story because our members link the supply chain – MPMA members turn the Iron Range steel that is processed in our foundries into key parts for Minnesota’s defense companies, medical device companies, recreational vehicle companies, and others.
All of this work requires skilled, technically-trained workers. And they are in short supply.
We have a two-part challenge in getting skilled workers into our shops:
attracting talent to our industry and developing skilled workers on the shop floor. MPMA’s new strategic plan is oriented to solving these challenges, not only from a tactical viewpoint, but also from a policy standpoint.
So how does MPMA impact education and workforce policy? We listen to members, and then we work to solve policy problems by advocating for you at the State Capitol.
Justin McPhee, Mold Craft; Teagan Cyr, Red Wing High School; Reed Lohr, Red Wing High School; Rep. Barb Haley; Michael Wendland, Red Wing High School Instructor; Rep. Jim Davnie; and Amy Walstien, MPMA.
[ continued on page 26 ]
26 PRECISION MANUFACTURING
ADVERTISERS' INDEXAll Elements - allelementsinc.net ................................................... 23Ballard Spahr - ballardspahr.com ................................................. IBCD&B Plating - d-bplating.com........................................................... 9Federated Insurance - federatedinsurance.com ...................... 24, 26Fluid-Aire Dynamics - fluidairedynamics.com ............................... 22Kurt Manufacturing - kurt.com ...................................................... 6Lubrication Technologies, Inc. - lubetech.com ........................... FCMars Supply / Walter Hammond - walterhammond.com ............ 11MDI - mdi.org ................................................................................... 19Midwest CAM Solutions, Inc. - midwestcamsolutions.com .......... 14MnTAP - mntap.umn.edu ................................................................. 12MRG Tool and Die - mrgtoolanddie.com ........................................ 23On Time Delivery - bontime.com ................................................... 12Petro Choice - petrochoice.com ...................................................... 25 Productivity Inc. - productivity.com .............................................. IFC ProtoTek Engineering, Inc. prototek-engineering.com ................................................ 16-17,OBCSaint Paul Port Authority - sppa.com ............................................. 9SDK - sdkcpa.com ............................................................................. 21TCF Bank - tcfbank.com ................................................................... 19
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POLICY & GOVERNMENT
The new Youth Skills Training (YST)program is a key example of MPMA’s advocacy in action. One of the major issues getting in the way of attracting students to manufacturing was that we simply couldn’t get kids under 18 into our shops to see what we do and try it out for themselves. So in 2017, MPMA worked with the Legislature to pass a bill that lets students experience manufacturing, health care, IT, agriculture, and automotive careers through “Youth Skills Training” (YST) programs.
YST programs do two things really well. First, YST introduces students to careers by connecting high school students with internships and apprenticeships in respective industries, which enables student learners to participate in industry experiences. Second, YST fosters the creation of local partnerships between high schools and local employers to meet training needs – with the flexibility to create programs that fit the community.
In 2017, the Legislature appropriated $500,000 for five pilot programs. Over 50 local partnerships formed and applied for those pilots, which is a strong indicator of the demand for skilled training programs throughout the state.
This year, we went back to the Capitol to ask for additional funding from the Minnesota workforce development fund, a portion of the employer tax set aside for workforce programs.
Our bill - SF 1265 (Sen. Paul Anderson, Plymouth) was first heard in the Senate Jobs Committee on February 27. Prior to the committee hearing, we conducted a press conference to talk about the bill and why it’s necessary to expand the program to reach more students. Willie Lubahn from MPMA member company Fastenal testified on why the Winona REACH YST program is so important for building skilled workers for manufacturing.
The companion bill in the House - HF 1504 (Rep. Jim Davnie, Minneapolis) - was heard in the House Jobs Committee on March 14, where students from Red Wing spoke about their experiences in the program. Justin McPhee from Mold Craft spoke about why their company got involved in offering externships through the White Bear Lake Gen Z Connections YST program.
YST is a great example of how MPMA can use advocacy to solve a problem - like getting students under
18 onto manufacturing floors. We also work on other policy issues related to education and workforce at the Capitol:
� We are supporting additional scholarships targeted to students entering manufacturing programs at Minnesota technical colleges.
� We are weighing in on making funding more flexible for Career and Technical Education (CTE) programs.
� And we are helping navigate the expansion of student-run manufacturing programs, like Tiger Manufacturing in Hutchinson and Saints Manufacturing in St. Francis.
MPMA also works with other advocacy groups, like the Minnesota Chamber of Commerce, on taxation, transportation, health care, and other issues that are important to Minnesota manufacturers.
MPMA members with policy issues, questions, or ideas can reach out to us at any time, and we’re always welcoming new members to MPMA’s Government Relations Committee. PM
AMY WALSTIEN is the Director of Government Relations for the MPMA. She can be reached at [email protected] or 651.238.9264.
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