Page 25 - MetalForming December 2013

Excellence in Quality
Pentaflex, Inc., Springfield, OH, received the 2013 Wauke- sha Metal Products Excellence in Quality Award for its qual- ity-system improvements that have resulted in reduced PPM ratings. PPM went from 294 in 2011 to 67 in 2012 to 3 PPM through the first five months of 2013. Pentaflex is a contract stamper specializing in deep-draw heavy-gauge stampings and welded assemblies for the heavy truck market. It also services the automotive, agricultural, off-highway and defense industries.
Pentaflex’s attacked its PPM issues using formal problem solving and the use of the 8D process; availability of better data through its Plex ERP system; ongoing continuous- improvement efforts; and formal training through Six Sigma and lean. At the shop-floor level, the firm receives CARs from its customer base and posts them as quality alerts. It processes 8Ds with shop-floor input to provide corrective actions. In the case of Tier 2 supplier quality issues, it prepares internal CARs and sends them to the Tier 2 supplier for cor- rective action. Using the Plex ERP system, quality instructions are catalogued for operator use.
To enhance Pentaflex’s problem-solving techniques and directly attack lean-manufacturing opportunities, in 2013 the firm launched Six Sigma black- and green-belt training pro- grams. One black belt and two green belts completed train- ing; management expects all employees to receive formal lean-manufacturing training. To date, its lean-action teams have completed six projects, focusing primarily on 5S.
The introduction of Plex as a management tool has enhanced Pentaflex’s ability to generate correct and appropriate data in support of problem-solving efforts and definition of machine/tool/operator accountability. Plex also has allowed Pentaflex to better understand efficiency and utilization of company efforts by product and by employees.
The Quality Award, sponsored by Waukesha Metal Products, Sussex, WI, recognizes outstanding achievement by a manu- facturing company in the development and implementation of a company-wide quality system that effectively uses con- tinuous improvement. Pentaflex received a $1500 cash prize.
Excellence in Productivity
Pentaflex, Inc., Springfield, OH, also received the 2013 Zier- ick Manufacturing Corporation Productivity Award, for its production of stamped outer inlet chambers for a Class 8
truck exhaust-system converter package. Parts are stamped using a cell configuration comprising a blanking press, hydraulic press with a mechanical transfer system, and an inline washer system.
To facilitate a customer design change that increased blank thickness from 1.5 mm to 2.5 mm and weight from 21 to 35 lb., along with the related ergonomic issues, Pentaflex employs a new 880-ton blanking press to bring the blanking operation inhouse. This eliminated outside logistics and transportation costs, and created one-pallet flow from blank- ing press to stamping press.
To draw and form the parts, the firm employs a 1600-ton hydraulic transfer press, automated with conveyors to auto- feed from the press load station through four transfer stations, and then through a parts washer. The result: Pentaflex can run the cell with only two operators, compared to eight operators required to run the previously designed part on a hand- transfer press with an offline parts washer.
Productivity has been dramatically improved, as press cycle time has been reduced from 60 sec. to 30 sec. Reduced press cycle time resulted in an additional 20-percent gain in hydraulic-press capacity. This allowed Pentaflex to achieve a 1-yr. payback on its facilities improvements. And, its customer received a five-percent value-added cost reduction.
Last but not least, the new cellular process and tooling concept allowed Pentaflex to qualify for its first Research and Development tax credit—$20,000 for the 2012 tax year.
The Productivity Award, sponsored by Zierick Manufac- turing Corp., Mount Kisco, NY, recognizes outstanding achieve- ment by a manufacturing company in the development and implementation of programs and processes, and use of assets that lead to significant improvements in productivity. Pentaflex received a $1500 cash prize.
Excellence as an Educational Institution
Two programs shared the 2013 Clips & Clamps Industries Educational Institution Award: Hennepin Technical College (HTC), Minneapolis, MN, and Southwestern Illinois College (SWIC), Granite City, IL.
HTC received recognition for its M-Powered program, designed to help unemployed and underemployed individ- uals, those looking to start a new career and incumbents needing to upgrade their skills in the precision manufacturing industries. The program combines technical training with essential skills such as resume writing, interview techniques
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