Page 24 - MetalForming December 2014

2014 Awards of Excellence in Metalforming
benefits to the customer: cost savings and a slight weight reduction. Production parts run on a 400-ton automated transfer press.
The Product Development Award is sponsored by Ulbrich Stainless Steels and Special Metals, Inc., North Haven, CT, acknowledging a manufacturing company that demonstrates outstanding innovation in developing and manufacturing a product that best uses metal in place of a nonmetal com- petitive material, or that develops a product using flat-rolled material that was previously manufactured using more cost- ly manufacturing processes. Trans-Matic received a $1500 cash prize.
Excellence in Safety
Pentaflex, Inc., Springfield, OH, received the 2014 Pitch- er Insurance Agency Safety Award for its outstanding safety and health program. The company is a contract stamper spe- cializing in deep-draw, heavy-gage stampings and welded assemblies for the heavy-truck market. It also services the automotive, agricultural, off-highway and defense industries.
When rebuilding its workforce after the economic down- turn of 2009, Pentaflex experienced an increase in injuries. Recognizing the need to address its worsening safety record, Pentaflex recharged its safety program and the results have been significant. From the fourth quarter of 2012 through 2013, the company experienced zero lost-time injuries, a 75 percent DART rate reduction and a 50 percent decrease in OSHA recordable injuries. In 2014, despite increasing employ-
ment by another 20 percent, Pentaflex continued to experi- ence a reduction in injuries.
Key program elements include elevating safety awareness, correcting potential safety issues and training employees in safe practices. Safety training begins in a 90-day preem- ployment period, and within those 90 days new operators are scored on their performance and safety record and either rewarded with full-time employment or returned to the temporary services company for reassignment.
The Pentaflex safety program is led by a steering com-
mittee that meets monthly to address ongoing safety pro- grams, make plans to address new regulations, review oppor- tunities identified by team members and establish champi- ons and a timeframe for implementing new ideas. The committee comprises top management, production super- visors and selected associates from the stamping, assembly and tooling areas.
Safety is the first item addressed at weekly senior staff meetings. A “war room” also has been established in con- junction with the Pentaflex lean-action program, with open safety items tracked on an assignment board and reviewed daily. Safety metrics are posted on performance boards in the plant and highlighted by the president to all employees monthly.
A key safety topic also is addressed weekly at an all- employee gainsharing meeting. During these meetings, employees are encouraged to ask questions and relay safe- ty issues to management. This is consistent with the company culture and goals emphasized from day one: that all Pentaflex employees go home safely every night, while providing cus- tomers with quality parts on time and treating each other and the organization with respect.
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. Pentaflex received a $1500 cash prize.
Excellence in Training and Education
Pentaflex, Inc. also received the 2014 A.R. Hedberg Train- ing and Education Award. Since 2009, Pentaflex’s employment level has doubled. With Ohio’s unemployment rate dropping to less than six percent, it has become increasingly difficult to find qualified employees, and those that are hired require significant training. Key elements of the company’s education and training system include communication, problem solv- ing and employee self-improvement and advancement.
Pentaflex attacked productivity issues by providing employees with formal education regarding lean manage- ment and problem-solving techniques. It uses the 8D process to investigate customer-reported issues and internally report quality issues.
To enhance the company’s problem-solving techniques, 6-sigma black-belt and green-belt training programs were ini- tiated in 2013, with one black belt and two green belts hav- ing completed formal training to date.
At the end of the classroom phase of training, the firm holds graduation exercises to reinforce the importance of lean skills. Cost-saving projects have included 5S die-change improvement and assembly-cell cycle-time reductions. In 2014, 21 employees completed the class, with seven lean projects generating nearly $100,000 in savings.
As an additional resource to Pentaflex’s lean efforts, for-
22 MetalForming/December 2014
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