Page 15 - MetalForming December 2016

Tops in Metalforming
Your winners of the PMA 2016 Awards of Excellence in Metalforming—each winner received a plaque, commemorative flag and cash prize. Note that no winners were selected for the Link Systems Process Control Award and the Pridgeon & Clay Excellence in Quality Award.
Higgins-Caditz Design Award
Federal Tool & Engineering, LLC, West Bend, WI
Pitcher Insurance Agency Safety Award
E&E Manufacturing Co., Inc., Plymouth, MI
Zierick Manufacturing Corporation Productivity Award
Tella Tool & Mfg. Co., Lombard, IL
Plex Systems Innovation & Technology Award
HK Metalcraft Manufacturing Corp., Lodi, NJ
Ulbrich Award for Competitive Excellence in Product Development
Pentaflex, Inc., Springfield, OH
A.R. Hedberg Training & Education Award
DeWys Manufacturing Inc., Marne, MI
Clips & Clamps Industries Educational Institution Award
Middle Tennessee State University, Murfreesboro, TN
Following the redesign, the company now stamps a single part, from Type 304 stainless steel, in a 165-ton press using a progressive die. The part is produced in a triple-hole version, with the ability to split the part into a single-hole and a double-hole bracket. Total process time has been reduced to 5 to 6 sec., so that a 2000-piece run takes 4 hr. Lead time was reduced from six to two weeks; the company has less cash tied to inventory; and annual “all-in” savings are estimated to be $155,000.
The new design has eliminated three press and post- press operations. Additionally, the original part was shipped to the customer, who then purchased and spot-welded two or three clips to it. Also, parts were stored in three separate bins. Now, the customer receives a complete part that requires no further operations, and it can be stored as a single part number until separation is necessary.
Created by the Worcester Pressed Steel Co., Worcester, MA, and sponsored by The Quarterly Club, the design award rec- ognizes a manufacturing company for outstanding achieve- ment in developing an innovative product design.
Excellence in Safety— E&E Manufacturing Co.
E&E Manufacturing Co., Inc., Plymouth, MI, received the 2016 Pitcher Insurance Agency Safety Award, for developing two types of safety stop blocks designed to eliminate a pos-
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MetalForming/December 2016 13
sible hazard due to lift- ing heavy stop blocks into presses. E&E man- ufactures heavy-gauge stamped metal fasteners, progressive-die metal stampings and high- value-added assemblies for Tier One, Tier Two and OEM clients in the automotive, heavy- truck, military and other industries.
The first style of stop
block, a flip-up style, is
referred to as the Easy
Set stop block. While
heavy, employees still
can flip the blocks easily
into position with the
help of gas springs and
shock absorbers to soft-
en the landing. E&E also
utilizes two safety
switches on these
blocks; these are auto-
matically disengaged when the block is in the upright posi- tion. The Easy Set is equipped with air-assist on the adjustable-screw portion of the stop block. The second type of stop block created by E&E, known as the Snake, allows employees to simply press a button to move the stop block in and out of a press. It was designed for presses using other systems and features, such as transfer systems, that prohibit the use of the Easy Set. The Snake has a spring-loaded air- cylinder pin device that holds the stop block in its home position or in its location under the slide. The pin is released with a manually operated air valve attached to the side of the stop block. The link construction and assembly methods enable the Snake not only to support but to very easily move the heavy stop blocks.
The Safety Award, sponsored by Pitcher Insurance Agency, Chicago, IL, acknowledges either an effective comprehensive safety program or a specific innovative idea in the context of an effective safety program.
Excellence in Productivity— Tella Tool & Mfg. Co.
Tella Tool & Mfg. Co. received the 2016 Zierick Manufac- turing Corporation Productivity Award for streamlining the packaging process on one of its high-volume production tools that produces more than three million parts per year. A cross-functional team was established to investigate and develop a more effective and efficient process. With locations in Lombard, IL, and Brownsville, TX, Tella Tool & Mfg. is a
Newly designed safety stop blocks can be placed easily into position without creating heavy-lifting hazards.