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ROBOTS
WIN
TE
R 2014
2001 Midwest Rd., Suite 106
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THE INTERNATIONAL MAGAZINE OF SPRING MANUFACTURE A Publication
of the Spring Manufacturers Institute / Vol. 53, No. 1NG
MANUFACTURE
Robots and the Spring Industry 19
SMI Fall Business Meeting is a Winner 32
Comforting Earthquake Victims 47
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2 / SPRINGS / Winter 2014
Passing the Gavel We all know the saying Time ies when you are
having fun! It is hard
to believe my term as your leader has come to an end and that
this is my nal Presidents Message. I can truly say it has been an
honor and an extreme privilege to serve as your president during
the past two years. I will always treasure and cherish this
time.
Leading the SMI has been a richly rewarding experience in so
many ways, but mostly because of the people. Ive been blessed to
work with such great folks and to meet so many others around the
nation and the world.
Over the past two years, we have developed a strategic plan with
the help of a broad representative base of SMI members. The specic
initiatives contained in this plan will help our members and the
entire North American spring industry improve its global
competitiveness. If you are an SMI member, I encourage you to
attend our annual conventions and join one of the many operating
committees who will help execute these specic strategic plans.
During my inauguration speech two years ago, I shared that
beyond my rst two passions (my faith and my family), that my next
two passions were manufacturing and relationships. During the past
two years, together we have achieved all seven of my goals for the
SMI under passion for manufacturing and four of my seven goals for
the SMI under passion for relationships. Without a unied team of
expert staff and dedicated volunteers, these goals could not have
been met.
I want to express my heartfelt thanks to an incredible list of
players who are responsible for the achievement of these goals and
the ongoing success of the SMI. No organization can sustain
excellence without a steady stream of dedicated, committed,
hard-working volunteers; at the SMI it has been my pleasure to work
with a wonderful executive committee, board of directors, committee
chairs and committee members who together have helped to make
excellent and sometimes challenging decisions to assure that our
organization continues to reach for excellence in all that it
does.
In addition to the great pleasure of working with all our
wonderful volunteers, I want to extend a very special thank you to
Lynne Carr, our executive director. Lynne is the glue that holds
this organization together; in all my years of working and
volunteering, I can honestly say I have never had the privilege of
working with someone more dedicated, more committed and more loyal
to an organization than Lynne is to the SMI. As members, we all
benet from this!
By the time you read this, I will have just passed the gavel to
our new SMI president Hap Porter. I am condent and enthusiastic
about Hap leading SMI over the next two years, not only because he
is such a wonderful person, but because of his great mind and
strong leadership skills. As I step out of the limelight, I wish
Hap and the SMI the very brightest of futures!
Forever Grateful,Steve
Steve MorelandPresident, Automatic Spring Products
[email protected]
SMI Executive CommitteePresident: Steve Moreland, Automatic
Spring ProductsVice President: Hap Porter, SEI
MetalTekSecretary/Treasurer: Mike Betts, Betts CompanyImmediate
Past President: Scott Rankin, Vulcan Spring & ManufacturingAt
Large: Steve Kempf, Lee Spring
SMI Board of DirectorsTom Armstrong, Duer/Carolina Coil Torsten
Buchwald, Kern-Liebers USA Ann Davey, John Evans Sons Mark
DiVenere, Gemco Manufacturing Chris Fazio, Diamond Wire Spring Kurt
Gillespie, Century Spring Richard Guimont, Liberty Spring Gene
Huber Jr, Winamac Coil Spring Miko Kabeshita, Ark Technologies
Charly Klein, Fox Valley Spring Bill Krauss, Vulcan Spring Don
Lowe, Peterson Spring Bill Marcum, MW Industries Richard
Rubenstein, Plymouth Spring Dan Sceli, Peterson Spring JR Strok,
Mohawk Spring Bill Torres, Gibbs Wire and Steel Jeff Wharin, Bohne
Spring
Springs Magazine StaffLynne Carr, Advertising Sales,
[email protected]
Gary McCoy, Managing Editor,
[email protected]
Dina Sanchez, Assistant Editor, [email protected]
Sue Zubek, Graphic Designer, [email protected]
Springs Magazine CommitteeChair, Richard Rubenstein, Plymouth
Spring Reb Banas, Stanley Spring & Stamping Lynne Carr, SMI
Raquel Chole, Dudek & Bock Ritchy Froehlich, Ace Wire Spring
& Form Bud Funk, Fourslide Products Bill Marcum, MW Industries
Brett Nudelman, International Spring Tim Weber, Forming Systems
Europe Liaison: Richard Schuitema, Dutch Spring Association
Technical Advisors: Loren Godfrey, Honorary Member Dan Sebastian,
Honorary Member
Advertising sales - Japan Ken Myohdai, Sakura International Inc.
22-11 Harimacho1-Chome, Abeno-ku Osaka 545-0022 Japan Phone:
+81-6-6624-3601 Fax: +81-6-6624-3602E-mail: [email protected]
Advertising sales - EuropeJennie Franks, Franks & Co.63 St.
Andrew's Road Cambridge United Kingdom CB41DHPhone/Fax:
+44-1223-360472 E-mail: [email protected]
Advertising sales - TaiwanRobert Yu, Worldwide Services Co.
Ltd.11F-B, No 540, Sec. 1, Wen Hsin Rd. Taichung, TaiwanPhone:
+886-4-2325-1784 Fax: +886-4-2325-2967 E-mail:
[email protected]
Springs (ISSN 0584-9667) is published quarterly by SMI Business
Corp., a subsidiary of the Spring Manufacturers Institute: 2001
Midwest Road, Suite 106, Oak Brook, IL 60523; Phone: (630)
495-8588; Fax: (630) 495-8595; Web site www.smihq.org. Address all
correspondence and editorial materials to this address.The editors
and publishers of Springs disclaim all warranties, express or
implied, with respect to advertising and editorial content, and
with respect to all manufacturing errors, defects or omissions made
in connection with advertising or editorial material submitted for
publication.The editors and publishers of Springs disclaim all
liability for special or consequential damages resulting from
errors, defects or omissions in the manufacturing of this
publication, any submission of advertising, editorial or other
material for publication in Springs shall constitute an agreement
with and acceptance of such limited liability.The editors and
publishers of Springs assume no responsibility for the opinions or
facts in signed articles, except to the extent of expressing the
view, by the fact of publication, that the subject treated is one
which merits attention.
Do not reproduce without written permission.
Cover art created using images from: iStockphoto.com/3alexd
President's MessageFrom Steve Moreland
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SPRINGS / Winter 2014 / 3
Intelligent Process& Quality Control
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4 / SPRINGS / Winter 2014
Contents
FEATURES
19 Robots and the Spring Industry By Gary McCoy
27 FlashbackIntroduction to Robotics
By G.C. Macri
32 SMI Fall Business Meeting is a Winner
35 SMI Hosts International Standards Organization (ISO) TC-227
Meeting in Nation's Capital
36 Peterson Spring Celebrates 100 Years
40 Heart and Soul By John Passante
45 JSSE Semi-Annual Lecture Meeting and Awards
47 Comforting Earthquake VictimsMichio Takeda
19
47
COLUMNS
13 Be Aware Safety TipsOSHA Inspections: How You Were Chosen and
What to Expect
By Jim Wood
15 IST Spring TechnologyCautionary Tale: Stainless Steel Turns
100 Years Old
By Mark Hayes
DEPARTMENTS
2 Presidents MessagePassing the Gavel
7 Global Highlights
10 Regional Spring Association Report
51 Springmaker Spotlight Leading His Team to Victory:A Profile
of Norm Rodriques and Springfield SpringBy Gary McCoy
57 Book Corner
59 Inside SMI
61 New Products
63 Advertisers Index
64 SnapshotJim Callaghan
27
51
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SPRINGS / Winter 2014 / 5WWW.RKTRADINGUSA.COM 847-640-9771
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06615Tel 203.386.0038 Fax 203.502.6681 www.zapp.com
For over 25 years, Zapp has been providing
the spring industry with the highest quality,
best performing products which far exceed
the industry standards. Our state-of-the-art
mill facility located in Dartmouth,
Massachusetts, offers a convenient supply
chain that insures continuity and reliability.
At Zapp, no matter how we slice it, our
precision quality and outstanding customer
service always shine through.
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SPRINGS / Winter 2014 / 7
North AmericaOn November 1, 2013, Lapham-Hickey Steel
Corporation purchased the assets of Industrial Spring Steel.
Industrial Spring Steel, located in Philadelphia, Pa., was founded
in 1958 and is a supplier of high carbon tempered and annealed
spring steel primarily throughout the East Coast.
Lapham-Hickey Steel is a family owned and operated full line
service center that was founded in 1926 in Chicago, Ill. The
acquisition of Industrial Spring Steel will strengthen
Lapham-Hickeys presence and coverage on the East Coast, and as a
leading provider of high carbon tempered and annealed spring steels
throughout the country.
We couldnt be more excited to welcome Industrial Spring Steel
their employees, customers and all partnerships to the
Lapham-Hickey family, said Brian Hickey, who will assume the
responsibilities of general manager for Industrial Spring Steel in
Philadelphia. Lapham-Hickey has a rich history with the Spring
Manufacturers Institute and its member companies and we look
forward to increasing our service levels to this industry.
David Devoe, operations manager and general manager of Plymouth
Spring Company, Inc. in Bristol, Conn., was presented with the
annual Quality Recognition Award sponsored by the Hartford Section
of the American Society for Quality (ASQ) in June.
Devoe was recognized for his contribution in helping establish
Plymouth Springs Lean Journey in 2011 and his achievement results
since. During that time, Plymouth Spring has increased their
on-time delivery by 20 percent, while keeping reject rates below
expectations, and at the same time increasing sales growth by 10
percent.
The Hartford Section of ASQ honors individuals and teams with
this award annually for their contributions to their associations
and businesses. The American Society for Quality is a
108,000-member professional association headquartered in Milwaukee,
Wis. that advances individual, organizational, and community
excellence worldwide through quality improvement, learning, and
knowledge exchange.
More information on the Hartford Section of ASQ can be found on
the sections website www.asqhartford.org.
Kern-Liebers Pieron (KLP) has manufactured precision springs and
wire parts in Farmington Hills, Mich. for more than 10 years. On
September 7, 2013, they celebrated the opening of a new 25,000
square foot facility near Grand River and Drake, only a few miles
from their previous location. The new facility has doubled the
production oor space as their previous building, and will allow for
business growth into new markets. KLP is excited to be a continuing
part of the Farmington Hills community, and proud to be producing
quality products competitively in Michigan.
Chicago-based Rolled Metal Products has appointed Steven E.
Pearce as general manager. Before joining Rolled Metal Products,
Pearce served in a similar capacity for A.M. Castle and Ryerson,
Inc., both major processors and distributors of metals. He
previously held progressively more senior positions with a global
manufacturing company. Pearce holds a bachelors degree in
engineering from Lehigh University and a masters degree in business
administration from the University of Chicago.
Im pleased to contribute my 30 years of management experience to
leading Rolled Metal Products to the next level of business growth
in our markets, said Pearce. We will succeed by offering excellent
customer service and delivering high value and high quality to our
customers at all times.
Vulcan Spring and Manufacturing Co., a leading designer and
manufacturer of at steel springs and related assemblies for diverse
global markets, has hired Jon Racis as its regional sales manager.
Racis will be responsible for eastern U.S. sales for both Vulcans
industrial and point of purchase markets.
Global Highlights
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/DNY59
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8 / SPRINGS / Winter 2014
Jon adds an exciting amount of drive and experience to our
growing sales organization, said Don Jarvie, vice president of
sales. He will help Vulcan Spring better serve our clients and to
nd new opportunities that will align with Vulcans strengths.
Originally from Wilmington, Del., Racis earned his bachelors in
sports management from Wilmington University. He comes to Vulcan
Spring from Fastenal Industrial Supply in Delaware.
Connecticut Spring & Stamping (CSS), a manufacturer of
precision parts for the aerospace, medical, rearms and defense
industries worldwide, announces its capabilities for producing
compression springs for rearms from shaped and stranded wire. CSS
development and prototyping assistance for both military and
commercial rearms helps OEMs accomplish the right spring design,
and ensures the springs are durable enough to sustain repeated
use.
Using its 70-year history and diverse expertise in developing
stranded wire and shaped wire springs, and its knowledge of design
formulae for spring rate and equivalent direct (tensile or
compressive) stresses, CSS helps OEMs design recoil compression
springs that can perform properly in the extremely limited space
available in most rearms.
CSS services includes consultation on stranded versus shaped
wire, careful selection of wire base material, assistance with wire
manufacturing stranding specications to achieve accuracy, as well
as extensive development and prototyping to assist the customer
accomplish the right spring design.
For further information, please visit www.ctspring.com or call
860-677-1341.
Decatur, Ga.-based Newcomb Spring Corporation has named Daniel
(Dan) Tetreault as the new general manager of its New England
facility, Newcomb Spring of Connecticut. In this position,
Tetreault will oversee day-to-day operations at the plant, lead new
business development and assist customers in the manufacture of
custom springs, wire forms and stamped metal parts. Tetreault was
previously employed at WAFIOS Machinery Corporation, where he
served as vice president.
My past experience has been a valuable asset here at Newcomb
Spring of Connecticut, said Tetreault. I have an in-depth
understanding of CNC, verti-slide and multi-slide forming
machinery, and Ive been able to apply those skills so that Newcombs
very modern machinery is utilized to its maximum potential.
Tetreault was appointed general manager at Newcomb Spring of
Connecticut after a month-long transition period
Global Highlights
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Bensalem, PA 19020800.638.3544215.244.7789
FaxRolledMetalProducts.com
Your Edge Is Our Roll
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SPRINGS / Winter 2014 / 9
working with the facilitys previous general manager, Keith
Porter, Jr. Porter is now general manager at Newcomb Spring of
Carolina.
I m rea l ly enjoy ing my new pos i t ion , a nd t h e N e w c o
m b S p r i n g organization, said Tetreault. I think my knowledge
of machinery and past metal forming experience allows me to ef fect
ively assist customers, while also giving me the ability to control
shop
continuous service and been welcomed into the companys 25-year
club. Half of the current 32 employees are members of this
exclusive club. Q
Top: Brian Russell is pictured standing center with colleagues
at Airedale Springs.
Left: Brian Russell, right, receives a parting gift from
Airedale Springs commercial director Sean Parkinson.
Daniel Tetreault
oor activity with a hands-on approach. I look forward to
providing Newcombs customers with the very best products and
service.
A veteran of the U.S. Army, Tetreault received his Bachelor of
Science degree in manufacturing engineering from Georgia Southern
University. In addition to post-graduate business studies, he also
received training in advanced metal form manufacturing in both the
United States and Germany.
InternationalBrian Russell has retired after a 44-year career
with
Airedale Springs in Haworth, West Yorkshire.Russell, of
Oxenhope, joined the company as a
chargehand instructor in 1969, becoming chief instructor a year
later with overall responsibility for the training of the companys
apprentices. In 1978, he was promoted to training superintendent
and in 1980 his role was extended to cover to the supervision of
the heavy springmaking department.
In 1983, Brian reverted to having sole responsibility for
company training, and three years later, while still maintaining an
overview on training issues, his primary role was meeting the needs
of Airedale Springs smaller customers through his work in the
custom spring department.
Chairman Tim Parkinson said Russell was regularly praised by
customers for the personal service he provided and the way he
always went that extra mile.
Parkinson commented, Brian is a unique character. He trained the
majority of our current staff and many others who over the years
have gone on to work in other companies within the area. While he
has retired after 44 years of dedicated service, he will certainly
never stop being part of the Airedale Springs family.
The company, which last year moved into a new purpose built
factory completing a 3.5m investment, is renowned for longevity of
service among its workforce.
Since Airedale Springs was founded 68 years ago, a total of 44
employees have completed 25 years of
Global Highlights
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10 / SPRINGS / Winter 2014
WCSMA Closes Out 2013
CASMI Holds SpringWorld Dinner
T h e W e s t C o a s t S p r i n g Manufacturers Association
(WCSMA) closed out 2013 with three events. The group held its
annual outing to see the Los Angeles Angels of Anaheim on August 3.
The group held a tailgating party in the parking lot of Angel
Stadium of Anaheim prior to the start of the event.
The WCSMA bi-annual Tabletop Expo was held on Thursday, October
24 at the Holiday Inn in La Mirada, Calif.
The groups golf outing and dinner was held on November 14 at
Skylinks in Long Beach.
For more information, visit the WCSMA Facebook page or
www.wcsma.us.
Looking toward October 2014, the Chicago Association of Spring
Manufacturers (CASMI) held its SpringWorld 2014 Kickoff dinner on
Thursday, October 17, 2013 at the Donald E. Stephens Convention
Center in Rosemont, Ill.
CASMI executive director Tom Renk said SpringWorld 2014 will
feature several new innovations to enhance the experience for
attendees and exhibitors. SpringWorld 2014 will be held at Donald
E. Stephens Convention Center October 810.
The SpringWorld 2014 kickoff dinner featured a presentation by
SMI president Steve Moreland, who said international competition is
a reality in todays spring marketplace. He shared his experience of
traveling to Europe and learning more about
the composit ion of the worldwide spring market.
After Morelands presentation, special guest speaker, Nick H a l
l e y, a r e t i r e d U.S. Army Brigadier General, talked about
leadership and the war against radical Islam.
In regards to the subject of leadership, Halley said leaders
must improve their leadership quota. He advised that leaders must
be good listeners and lead by example all the time.
He concluded his remarks with information from his book,
Terrorism The Target is You! The War Against Radical Islam.
CASMI c losed out it s 2013 schedule with its member
dinner/holiday party on December 12 at The Great Escape in Schiller
Park, Ill.
For more information, visit www.casmi-springworld.org.
iStockphoto.com
/Scott Hirko
Regional Spring Association Report
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SPRINGS / Winter 2014 / 11
NESMA Christmas Celebration and Recognition Dinner
By Ted White, Hardware ProductsThe New England Spring and
Metalstamping Association (NESMA) had a record turnout of 166
people for its annual Christmas Dinner on December 5, 2013. George
Fournier, the president of NESMA, greeted attendees with a few
light hearted
and jocular comments and welcomed several honored guests,
including Susan Sadecki, CEO of The Main Street Community
Foundation, and Joyce Mowrey and Steven Hanecak from Bristol
Technical School.
Thanks was g iven to Cindy Scoville from the Central
Connecticut
Chamber of Commerce who ably assists NESMA, and her associates
Mary Kuharski and Reiny Malsheske for helping organize the
dinner.
The main purpose of the event was to celebrate Christmas and
give special recognition to some NESMA members. But because this is
one of
Avoid no-bids or timely set up on short runs. CenturySpring is a
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12 / SPRINGS / Winter 2014
only two general gatherings per year, NESMA used the opportunity
to bring members up to date on recent efforts.
NESMA has been working to coordinate fragmented efforts to
improve technical education in the Bristol area. Members were
advised that this was a problem that neither the educators nor the
legislators could solve. It is a problem that the entire membership
needed to get involved with if they wanted to see workforce
improvement.
It was pointed out that it is ludicrous for parents and
educators to steer high school students only into college
preparatory programs, when the reality is that some will attend
college, graduate with $150,000 in debt, and end up unemployed. At
the same time, the manufacturing industries in the area are
screaming for educated technical employees.
Recognition was given to several individuals, including Joe
Panella and
Regional Association Report
Bobby Cox from North American Spring Tool. Both Joe and Bobby
have long been noted for their dedication to the spring industry
while conducting their business in the most gentlemanly way. Mark
DiVenere captured these many years of history in a most accurate
way during his presentation of the award.
Bill Waseleski of Century Spring made the next presentation to
Doug Johnson. Doug is a tireless individual who is involved in many
efforts to create technical education and serves on many boards to
advocate this. Doug, in a humorous acceptance speech, said that he
had the unfortunate luck of sitting at a table with his two female
superiors and his wife who were all telling him what to say and how
to say it.
Bil l Lathrop then presented Loren Godfrey with an award for his
professional accomplishments over the years. Now semi-retired,
Loren is
still available to help springmakers through SMI when
needed.
Bill Lathrop then presented the next award to yours truly for
Diligent and Tireless Efforts to Improve the Recognition of the
Spring Industry and NESMA. Consider ing the eminence of the other
honorees I was not sure that I belonged in the same group. However
it certainly meant an awful lot to me to be honored by my peers and
to be included in such a well-respected group.
To conclude the festivities George Fournier once aga in caut
ioned NESMA members that the problem of future manufacturing
employees was all ours and that it would be in our best interests
to collaborate and begin solving the problem together.
For more information on NESMA, visit www.nesma-usa.com. Q
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-
SPRINGS / Winter 2014 / 13
Jim Wood is an independent regulations compliance consultant to
the Spring Manufac-turers Institute (SMI). A certified instructor
of the OSHA Out-Reach Program, Wood conducts seminars, plant Safety
Audits and In-House Safety Trainings. These programs help
com-panies create safer work environments, limit OSHA/Canadian
Ministry of Labor violations and insurance costs, and prepare for
VPP or SHARP certification. He is also available for safety advice
and information by phone at 630-495-8588 or via e-mail at
[email protected].
OSHA Inspections: How You Were Chosen and What to ExpectBy Jim
Wood
Be Aware Safety Tips
It is a misconception that OSHA picks companies at random. It is
true, however, that they conduct inspections without advance
notice. OSHA focuses their inspection resources on the most
hazardous workplaces in the following order of priority:
1. Imminent Danger Situations hazards that could cause death or
serious physical harm receive top priority. Compliance ofcers will
ask employers to correct these hazards immediately, or remove
endangered employees.
2. Fatalities and Catastrophes incidents that involve a death or
the hospitalization of three or more employees come next. Employers
must report such catastrophes to OSHA within eight hours.
3. Complaints allegations of hazards or violations also receive
a high priority. Employees may request anonymity when they le these
complaints.
4. Referrals of hazard information from other federal, state or
local agencies, individuals, organizations or the media receive
consideration for inspection.
5. Follow-ups checks for abatement of violations cited during
previous inspections are also conducted by the agency in certain
circumstances.
6. Planned or Programmed Inspections inspections aimed at specic
high-hazard industries, or individual workplaces that have
experienced high rates of injuries and illnesses, also receive
priority.
When an OSHA inspector appears at your front door, the rst thing
you should do is ask for his/her credentials, which include both a
photograph and a serial number. If you have any doubt about their
identity, call the local OSHA area director and get conrmation that
the person is indeed an inspector.
Opening Conference The compliance ofcer will explain why OSHA
selected your workplace for inspection and describe the scope of
the inspection, walk around procedures, employee representation and
employee interviews. The employer then selects a representative to
accompany the compliance ofcer during the inspection. An authorized
representative of the employees, if any, also has the right to go
along. In any case, the compliance
ofcer will consult privately with a reasonable number of
employees during the inspection.
Walk around Following the opening conference, the compliance
ofcer and the representatives will walk through the portions of the
workplace covered by the inspection, inspecting for hazards that
could lead to employee injury or illness. The compliance ofcer will
also review worksite injury and illness records and posting of the
ofcial OSHA poster.
During the walk around, compliance ofcers may point out some
apparent violations that can be corrected
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/oytun karadayi
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14 / SPRINGS / Winter 2014
immediately. While the law requires that these hazards must be
cited, prompt correction is a sign of good faith on the part of the
employer. Compliance ofcers try to minimize work interruptions
during the inspection and will keep condential any trade secrets
they observe.
Closing Conference After the walk around, the compliance ofcer
holds a closing conference with the employer and the employees
representative to discuss the ndings. The compliance ofcer
discusses possible courses of action an employer may take following
an inspection, which could include an informal conference with OSHA
or contesting citations and proposed penalties. The compliance
ofcer also discusses consultation and employee rights.
Results OSHA must issue a citation and proposed penalty within
six months of the violations occurrence.
Citations describe OSHA requirements allegedly violated, list
any proposed penalties and give a deadline for correcting the
alleged hazards. Violations are categorized as other than serious,
serious, willful, repeat and failure to abate. Penalties may range
up to $7,000 for each serious violation and up to $70,000 for each
willful or repeat violation. Penalties may be reduced based on the
employers good faith, inspection history, and the size of the
business. For serious violations, OSHA may also reduce the proposed
penalty based on the gravity of the alleged violation. No good
faith adjustment will be made for alleged willful violations.
Appeals When OSHA issues a citation to an employer, it also
offers the employer an opportunity for an informal conference with
the OSHA area director to discuss citations, penalties, abatement
methods, abatement dates or any other information pertinent to the
inspection. The agency and the employer may work out a settlement
agreement to resolve the matter and to eliminate the hazard.
Alternatively, employers have 15 working days after receipt of
the citation and proposed penalties to formally contest the alleged
violations and/or penalties by sending a written notice to the area
director. OSHA forwards the contest to the Occupational Safety and
Health Review Commission for independent review. Alternatively,
citations, penalties and abatement dates that are not challenged by
the employer or settled, become a nal order of the Occupational
Safety and Health Review Commission.
Jims Regulatory Tip:Designate a key management employee that is
well
versed in OSHA inspection procedures to accompany the compliance
ofcer during every step of the inspection. This employee should ask
the compliance ofcer to explain every alleged violation found and
record all information about the alleged violation. At the end of
the day your representative should have a duplicate list of
everything cited by the compliance ofcer. The best rule when
accompanying the compliance ofcer is ask questions, give truthful
answers to questions asked, but volunteer nothing. Q
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and Cable Trade Fair
www.wire.de
Wire, Cable,Fibre Optic,Wire Productsand Machinery
FastenerTechnology
Mesh Welding Machinery
Spring Making
For show information: Messe Dsseldorf North America 150 North
Michigan Avenue
Suite 2920 _ Chicago, IL 60601Tel. (312) 781-5180 _ Fax (312)
781-5188
[email protected] _ www.mdna.comFor hotel and travel arrangements:
TTI Travel, Inc.
Tel. (866) 674-3476 _ Fax (212) 674-3477
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SPRINGS / Winter 2014 / 15
IST Spring Technology
Mark Hayes is technical advisor to the Insti-tute of Spring
Technology (IST) in Sheffield, England. He is also the principal
trainer for the spring training courses that the Institute offers
globally. Readers are encouraged to contact IST with comments about
this cautionary tale, and with subjects that they would like to be
addressed in future tales - e-mail [email protected]
Cautionary Tale:Stainless Steel Turns 100 Years OldBy Mark
Hayes
Did you know stainless steel was invented 100 years ago in
Shefeld, which is the headquarters town for IST? For those
interested in more information on this important spring material,
there is an excellent new book written by Shefeld metallurgist Dr.
David Dulieu entitled Stay Bright. The book describes the history
of stainless steel from it invention by Harry Brearley to its
current use today.
The last cautionary tale discussed the oxide which forms
naturally on stainless steel and how that oxide confers corrosion
resistance. This prompted the idea that the various types of
stainless steel should be described. They all have a layer of
chromium oxide providing corrosion resistance. There are four
distinct types of stainless steel. Two are excellent for spring
production, but the other two are not.
The type of stainless steel invented by Harry Brearley contained
13 percent Cr (chromium) and 0.25 percent C (carbon), and becomes
corrosion resistant after it has been hardened and tempered to a
martensitic microstructure. At rst sight this might seem ideal for
springs because it is corrosion resistant and has high
strength.
Martensitic stainless steel is used for manufacturing knives and
surgical instruments, industries for which Shefeld remains famous
today. However, martensitic stainless steel has a fatal aw that
makes it a very unlikely choice for making springs. It is not very
corrosion resistant, so even a slight trace of corrosion which will
cause this type of stainless steel to fail by stress corrosion
cracking. That is the rst moral of this cautionary tale do not be
tempted to use martensitic stainless unless you are certain that
its corrosion resistance is good enough.
For springs, a stainless steel is needed that will repair its
oxide lm in the event of slight corrosion before it fails.
Stainless steel with 18 percent Cr and 8 percent Ni (nickel) has
better corrosion resistance than the martensitic type. It has a
microstructure of austenite, which needs to be cold worked to
acquire spring strength. The microstructure is austenite prior to
the start of the wire drawing process, but during wire drawing some
of the austenite transforms to martensite, and this is what makes
this grade slightly magnetic. The predominant microstructure
remains austenite though, and this type of stainless steel is the
most frequently used for springs everywhere in the world today.
The 18/8 stainless steel is usually called 302 or 304 type.
There are two variants in common use. One is 316 type, which has 2
to 3 percent Mo (molybdenum) added for improved corrosion
resistance, especially in salt environments. The other variant is
17/7PH (type 631), which has 1 percent Al (aluminium) added for
precipitation hardening, and hence a strength level higher than 302
type.
Today, there are two other types of stainless steel, again both
named for their microstructure. There is ferritic stainless steel,
which has very good corrosion resistance, but not the high strength
needed for springs. This is the type of stainless used for car
exhausts.
Finally, there is duplex stainless steel, which has a duplex
microstructure of ferrite and austenite, which is very corrosion
resistant especially when molybdenum
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16 / SPRINGS / Winter 2014
(Mo) is an alloying element, and it may be drawn to high
strength levels, hence conferring excellent spring properties. IST
predicts that duplex stainless steel will gradually replace 316 as
a spring material because it outperforms the latter with respect to
corrosion resistance and strength levels.
All of these stainless steels contain at least 12 percent
chromium. It is often said that their corrosion resistance is due
to the formation of chromium oxide on their surface, something that
happens naturally in air at room temperature. That is certainly
true. However, the very
photoelectron spectrographic studies have shown that there is
almost no Mo present in the oxide there is concentration of Mo
below the oxide, but how does that help? This leads to the second
moral of this cautionary tale the precise explanation for the
corrosion resistance of stainless steels is, as yet, incomplete.
This fact should keep metallurgists employed for some years to
come. Q
Finally, there is duplex stainless steel, which has a duplex
microstructure of ferrite and austenite, which is very corrosion
resistant especially when molybdenum (Mo) is an alloying element,
and it may be drawn to high strength levels, hence conferring
excellent spring properties. IST predicts that duplex stainless
steel will gradually replace 316 as a spring material because it
outperforms the latter with respect to corrosion resistance and
strength levels.
thin oxide on each type of stainless steel differs slightly,
and, despite being only nanometers thick, is always made up of
several oxide layers. Hence, there are differences in the corrosion
resistance of the four types of stainless steel.
One thing that has always puzzled the industry is the fact that
molybdenum (Mo) additions will invariably improve the corrosion
resistance of stainless steels. So one might ask how the Mo affects
the oxide, and X-ray
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SPRINGS / Winter 2014 / 17
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18 / SPRINGS / Winter 2014
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SPRINGS / Winter 2014 / 19
ROBOTSand the Spring Industry
he term robot conjures up a lot of images and ideas. Baby
boomers might remember back to the days of Rosie, the household
robot in the animated television show The Jetsons or HAL
(Heuristically programmed ALgorithmic computer) 9000 in 2001: A
Space Odyssey. While those types of robots are the lore of science
ction, they bear little resemblance to the ones being used in
industrial manufacturing settings such as the spring industry,
where wire is coiled to make springs or bent to form wire parts.
This article will attempt to take robots from the realm of TV,
books and movies into practical applications for manufacturing.
T
A Fanuc M16 robot using dual Schunk PZN style grippers and ATI
Robotic Tool Changer loads a part into the spindle of a Haas
SL-20
lathe. The air blow nozzle is used to clear jaws of dirt and
swarf prior to load.
Article photos provided courtesy of Productivity, Inc. and are
used by permission.
By Gary McCoy
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20 / SPRINGS / Winter 2014
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