also in this issue:
26
Continuous Learning 42
A History of Springs
Insights on Dollar Volatility
2001 Midwest Rd., Suite 106
Oak Brook, IL 60523-1335
Change Service Requested
50
Presort Standard
US Postage PAID
Rockford, IL
Permit No. 1
President’s Message
From Reb Banas
Emerging Markets — Making Footprints
n a recent trip I had a little extra time so I opened the
in-flight magazine. As I paged through the “ideal gifts,”
a pair of shoes caught my eye. A brown pair of dress loafers
with one difference—that’s right, they had a spring in the
heel! Actually, they had several compression springs just like
the Nike “Shox” every runner and kid is wearing.
As I read the entire ad, I thought about whether I should
actually buy a pair or just enjoy the instant amusement that
“spring-shoes” brought to mind. I didn’t buy the shoes but it
got me thinking about the wide array of spring applications
that exist in today’s market.
It’s exciting to see how far springmaking has progressed since the first simple
springs. In the Bronze Age more sophisticated applications emerged when tweezers
were used for healing or other tasks for which the hand alone was incapable.
Since my father owned a spring company, my personal experience with the
spring industry began in the Stanley Spring shipping room working from the summers of 1978-85—which was fun. Maybe that’s why the smell of oil and stress
relieving brings a smile to my face whenever I enter a plant. The springmaking process hasn’t changed a lot since I got involved, although manufacturing tolerances and
advances in equipment have significantly altered the labor force.
The biggest change has come from the outside. Rather than operating locally
or regionally, springmakers, to remain competitive, have reached outside their home
state, across the country and even across the sea. Thus, while the process itself
remains relatively unchanged, the overall industry continues to evolve.
For us to be successful during this evolution, it is important to view the marketplace as an ever-expanding platform. If we actively pursue new client types, improved
machine innovations, and fresh marketplaces in the next state or next country, we’ll
identify how to adapt and secure new clients.
As leaders for both our companies and the industry, each of us has the opportunity (and responsibility) to pursue emerging markets with a problem-solving
outside focus. Ask yourself these questions:
• How can we solve our customer’s problem?
• What can we do to broaden our appeal in a particular segment?
• What can we do to reach emerging overseas markets to develop
opportunities and partnerships?
• How can we partner with other springmakers to strengthen the industry?
This mindset should be a central part of how we operate so that it invades our
comments, permeates our actions, and is a part of everything we do.Your springs
may not be used to secure your customer’s next meal—as in the day of the bow
and arrow—but it could put food on the table by helping him or her win a new
production contract.
SMI represents 320 employers and thousands of employees across North
America. Individually we may make progress but together we can leave a large
footprint—maybe using a shoe with a spring in the heel!
O
Reb Banas, Stanley Spring
& Stamping, reb@stanleyspring.com
2 SPRINGS July 2008
SMI Board of Directors
President, Reb Banas, Stanley Spring & Stamping • Vice
President, Scott Rankin, Vulcan Spring & Manufacturing
• Secretary Treasurer, Steve Moreland, Automatic
Spring Products • Immediate Past President, Dan
Sebastian, MW Industries • Executive Committee
At-Large, Russ Bryer, Spring Team • Tom Armstrong,
Duer/Carolina Coil • Dennis Backhaus, Spiros Industries
• Mike Betts, Betts Spring • Tim Bianco, Iowa Spring •
Dan Bishop, Automatic Spring Coiling/MW Industries •
Ron Curry, Gifford Spring • Ann Davey, John Evans’ Sons
• Gary Dickerhoof, The Yost Superior Company • Linda
Froehlich, Ace Wire Spring & Form • Bert Goering,
Precision Coil Spring • Mark Habicht, The Kirk-Habicht
Co • Bob Iorio, Gibbs Wire & Steel • Steve Kempf, Lee
Spring Co • Richard Rubenstein, Plymouth Spring •
Chris Wharin, Bohne Spring • Ted White, Hardware
Products • Chris Witham, Motion Dynamics • Tim Zwit,
Michigan Spring & Stamping
Springs Magazine Staff
Lynne Carr, Advertising Sales, lynne@smihq.org
Sandie Green, Assistant Editor
Luke Zubek PE, Technical Advisor, luke@smihq.org
Gary McCoy, Managing Editor,
gmccoy@fairwaycommunications.com
Springs Magazine Committee
Chair, Richard Rubenstein, Plymouth Spring • Carol
Caldwell, Century Spring/MW Industries • Lynne Carr,
SMI • Randy Deford, Mid-West Spring & Stamping
• Pam Dix, All-Rite Spring • Ritchy Froehlich, Ace
Wire Spring & Form • Tressie Froehlich, Ace Wire
Spring & Form • LuAnn Lanke, Wisconsin Coil Spring
• John Schneider, O’Hare Spring • Europe Liaison:
Richard Schuitema, Dutch Spring Association •
Technical advisors: Loren Godfrey, Colonial Spring •
Luke Zubek, PE, SMI Technical Director • Tim Weber,
Forming Systems
Advertising sales - Japan
Ken Myohdai, Sakura International Inc.
22-11 Harimacho
1-Chome, Abeno-ku
Osaka 545-0022 Japan
Phone: +81-6-6624-3601 • Fax: +81-6-6624-3602
E-mail: info@sakurain.co.jp
Advertising sales - Europe
Jennie Franks, Franks & Co.
63 St. Andrew's Road
Cambridge
United Kingdom CB41DH
Phone/Fax: +44-1223-360472
E-mail: franksco@BTopenworld.com
Advertising sales - Taiwan
Robert Yu, Worldwide Services Co. Ltd.
11F-B, No 540, Sec. 1, Wen Hsin Rd.
Taichung, Taiwan
Phone: +886-4-2325-1784 • Fax: +886-4-2325-2967
E-mail: stuart@wwstaiwan.com
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) 4958588; 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 by Rachel Slick
Table of Contents
FEATURES
22
Do You Suffer from an Ingrown Nail or Want to Make Great Leaps
Forward? A Spring System May Help: A look at the many uses of springs
By Konrad Dengler
26
A History of Springs: A look back shows that springs are the unsung heroes
of many intricate mechanisms
Edited and compiled by Cheryl Chonajcki
31
Unusual Applications of Springs
33
Ubiquitous Springs: The spring is the source of magic, beauty, luxury, efficiency,
safety security and comfort in every corner of the earth
By Wallie Dayal and Joanne Gucwa
42
Continuous Learning
By Brian Tracy
46
Shot Peening — Proper Application and Practices
By Kumar Balan
50
Insights on Dollar Volatility
By Jeff Thredgold
53
Fighting for a Level Playing Field
By Gary McCoy
56
Health Insurance Cost Containment Trends Create
New Opportunities for SMI
By Henry Trevor
22
33
COLUMNS
42
14
Checkpoint Business Tips
Local Politics: Help Promote Business Friendly Regulations
By Phillip M. Perry
19
Spotlight on the Shop Floor: The Human Factor in Quality Assurance
By Randy DeFord, Mid-West Spring & Stamping
21
Be Aware Safety Tips: The Latest OSHA Activities
By Jim Wood
66
IST Spring Technology: The Lessons of History
By Mark Hayes
69
Technically Speaking: Spring Failures: Local Elevated Temperature Exposure
By Luke Zubek, PE
DEPARTMENTS
69
4 SPRINGS July 2008
2
President’s Message: Emerging Markets — Making Footprints
7
Global Highlights
61
Inside SMI: Staff Focus on Dina Sanchez, Lots of Information and Worn Shoes
73
New Products
75
Advertisers’ Index
75
Sprung
76
Snapshot: Steve Kempf, Lee Spring Company
From aviation to art,
ISW soars higher.
MEET YOUR MATCH FOR QUALITY.
Since 1935, Industrial Steel & Wire has helped quality-conscious businesses like yours
achieve greater heights of success. Now, as a nationwide leader in spring wire,
manufacturers of everything from art to jets count on our quality and capabilities.
t Ferrous and non-ferrous wire and specialty strip at competitive prices
t More than 400,000 sq. ft. of warehousing, nationwide, for timely delivery
t Round and shaped wire, custom plating, torsion straightening and straighten & cut
New
©2008 Industrial Steel & Wire Company
SOAR HIGHER TODAY WITH ISW.
www.industeel.com
HOUSTON
Location
800-767-0408
BRISTOL
800-767-4792
CLEVELAND
800-767-4434
CHARLOTTE
800-767-0089
LOS ANGELES
800-767-0485
CHICAGO HEADQUARTERS
800-767-0408
6 SPRINGS July 2008
Global Highlights
Overseas
The wire 2008, International Wire and Cable
Trade Fair held in conjunction with Tube 2008,
International Tube and Pipe Trade Fair, and Metav
2008, International Trade Fair for Manufacturing
Technology and Automation, attracted 2,157 exhibitors on more than one million square feet of exhibit
space. A total of 73,600 trade visitors from more
than 90 countries took part in the events.
The 40,700 visitors at wire 2008 came from 72
nations and about 58 percent of the attendees were
from outside of Germany. Tube 2008 was attended
by 32,900 visitors from 71 nations, with 52 percent
traveling from countries other than Germany. The
majority of the non-German visitors at the trade
fairs were from France, India, Great Britain, Northern Ireland, Italy, the U.S., Poland, Brazil, Belgium,
the Netherlands, the Czech Republic, Switzerland
and Spain. The U.S. was well represented with 72
companies exhibiting at wire 2008 and 39 companies at Tube 2008. Visitors gave both wire and Tube
2008 top ratings. Most wire visitors were interested
in machinery and systems for wire production and
processing, materials, specialty wire and cables,
testing technology, measuring and control technology as well as process engineering tools.
The next staging of wire, Tube and Metav will
take place in 2010 in Düsseldorf, Germany. For
information on visiting or exhibiting, contact Messe
Dusseldorf North America at (312) 781-5180 or visit:
www.mdna.com.
Shinko Machinery Co. Ltd. and its sales and
service company, Shinko Machine Tool Co. Ltd.,
both in Osaka, Japan, announced that Takashi
Takumi was appointed president and their former
president, Koichi Takumi, became chairman. Readers may contact the companies by e-mail at info@
shinko-mach.co.jp.
Ewes Stalfjader AB, Bredaryd, Sweden, has
received the prestigious Supplier of the Year award
by Kongsberg Automotive Raufoss. Ewes met KA
Raufoss’ volume increase of 25 percent and still
maintained 100 percent precision of delivery and
continuous quality level.
The European Spring Association (ESF)
elected Federico Visentin as its new president at
the International ESF Standard’s meeting held in
April. Mr.Visentin is associated with Mollificio Mevis
spa, a springmaker in Rosa, Italy. Axel Schnöring
of Germany was elected treasurer and Nick Goss,
UK, Michel Guillemet, France, and Piero Longoni,
Italy, were elected vice presidents. H.D. Dannert
was appointed general secretary. All positions are
on a two-year basis.
Numerous international visitors attended the
ESF fairs and topics such as economic issues
and ISO standardization projects were discussed.
Andrew Watkinson from the Institute of Spring Technology (IST) in Sheffield, England, made a proposal
for a “Web-based multi-language spring dictionary,”
which was well received.
Overseas Events
September 18-20, 2008: Cable & Wire 2008,
Istanbul, Turkey, CNR Expo Center, Mediaforce
Fuarcilik Ltd. Sti., 90-212-465-65-45,
info@mediaforceonline.com
September 23-26, 2008: wire China, Shanghai,
China, Messe Düsseldorf China, (312) 781-5180,
www.messe-dusseldorf.de.
November 20-22, 2008: Wire & Cable India
2008, Mumbai, India, Cheryl Fernandes,
Business Fairs, Confederation of Indian Industry,
91-22-24931790, ext. 470, www.ciionline.org.
North America
Bill Shockey, formerly of Numalliance and Numamerica, has formed BT Machinery Sales LLC in
Eldridge, Iowa. The company represents the Nimsco
distributed lines of spring manufacturing and the
Numamerica line of wire and tube forming machinery. The lines for Nimsco are Bennett Mahler, IST,
MicroStudio, Simplex-Rapid, TC-HP, and the lines
for Numalliance are Latour, Macsoft and Satime.
The company is located at 408 South Ninth Avenue,
Eldrige, IA 52748, telephone (563) 285-5515, e-mail
bill@btmachinery.com.
SPRINGS July 2008 7
Bazz Houston Co., Garden Grove, Calif., has
purchased Connor Manufacturing Services de
Mexico. The two companies are completely integrated and Bazz Houston Mexico has relocated its
facility to La Mesa Industrial Park in Tijuana. Bazz
Houston Co. with manufacturing facilities in both
Southern California and Tijuana is able to offer its
customers the benefits of lower cost manufacturing
together with in-house engineering support for new
product design and existing parts. Both facilities are
registered to ISO 9001:2000.
The IMI Sensors division of PCB
Piezotronics (PCB) has announced
the appointment of Doug Eberhart
as IMI Sensors international sales
manager. He is a 25-year veteran of
the industrial vibration monitoring
market overseeing the growth and
development of new and existing
sales channels. He brings to PCB decades of global
sales and business development experience in the
industrial machinery condition monitoring marketplace, as well as a background in both sensor and
instrumentation manufacturing and representation,
in addition to establishing and servicing large multimillion dollar OEM and factory direct accounts.
8 SPRINGS July 2008
The Aerospace Metals Engineering Committee
(AMEC) of the Aerospace Materials Division of the
Society of Automotive Engineers has sanctioned the
formation of a shot peening sub-committee. AMEC is
composed of technical specialists in aerospace metallic
materials and related processes. The first responsibility of the group will be to update current shot peening
specifications and create new specifications to meet
the needs of today’s shot peening industries. Twentytwo companies from the U.S., Europe, Asia and the
U.S. Army sent 27 representatives to the January
2008 meeting. During the two-day work session, the
group reviewed shot peening specifications including AMS-S-13165, AMS-2430, AMS-2431.2, 0.3, 0
.6, 0 .7 and SAE J-442. Also discussed was the creation of new shot peening specs for flapper peening,
needle peening, ultrasonic peening, eddy current
non-destructive testing, low sodium glass bead for
peening and the new SAE J-2597 industry standard
for use of computer-generated curves for shot peening
intensity tests.Membership in the AMEC shot peening sub-committee is open to qualified individuals
that are interested in contributing to the evaluation
and development of shot peening specifications.
For more information, contact Jack Champaigne at
(574) 256-2001 or e-mail jack.champaigne@electronics-inc.com.
Titan Spring Co., Hayden, Idaho, has achieved
AS9100 Rev “B,” ISO 9001:2000 and Boeing BQMS
D6-82479 Appendix “A” certification. The manufacturing facility in Hayden opened in October 2007.
Dan Day has been appointed
Midwest regional territory manager
of Iowa Spring Mfg. & Sales in
Adel, Iowa. Iowa Spring is a manufacturer of springs
for the residential
and commercial
overhead garage
door industry, specialty manufacturers and farm/agriculture related
equipment manufacturers. Day
is responsible for building these
markets throughout the sevenstate Midwest region. He has held
various sales positions during his
25-year career and has a strong
background in agriculture and farm
equipment.
coiled springs, including compression, extension,
torsion, double torsion and garter; flat springs, constant force springs; wire forms and small stampings.
Michigan Spring & Stamping is a producer of compression and torsion springs, stampings, wire forms,
and custom-engineered assemblies, primarily for the
automotive industry. Hines Corp. is a privately held
company specializing in helping mature businesses
to grow organically and through acquisitions.
American Coil Spring Co. and
Michigan Spring & Stamping, both
of Muskegon, Mich., announced a
merger of the two companies. The
merger allows the combined companies, operating under the name
of Michigan Spring & Stamping
LLC, to offer customers a broader
product line, a larger skilled work
force with significant experience in
springs and stampings, as well as
greater geographic coverage. Hines
Corp., a Western Michigan-based
holding company of industrial
firms, including American Coil
Spring Co., acquired Michigan
Spring & Stamping from the Precision Products Group. Gerald
Baker, president of Michigan Spring
and president/CEO of Precision
Products Group, the selling party,
leads the combined company.
Tim Zwit, president of American
Coil Spring Co., assumed the role
of executive vice president of the
combined companies. American
Coil Spring manufactures precision
cold-formed metal products and
SPRINGS July 2008 9
Exact Software North America LLC, a provider
of solutions that connect the people, processes, and
knowledge essential to an organization, announced
a partnership with quality management and compliance software provider Cebos to bring the Cebos
MQ1 quality management software system to users
of Exact’s Jobboss.
MQ1 helps companies running Jobboss improve
the processes that drive a top-notch quality program. MQ1 can help organizations implement and
maintain ISO and Six Sigma standards, and respond
to industry-specific or government requirements,
including FDA and Sarbanes-Oxley compliance mandates. For more information on the partnership, visit
the Web site at www.exactamerica.com/jobboss.
Logansport, Indiana-based MW Industries,
Inc. (MWI) has acquired RAF Electronic Hardware
(RAF), a division of R&R Manufacturing Company,
Inc. The transaction was announced on June 27,
but terms were not disclosed.
RAF, headquartered in Seymour, Conn., is a
leading manufacturer and catalog marketer of electronic hardware components, serving customers in
the computer, telecommunications, medical, defense
and aviation industries.
Dan Sebastian, president and CEO of MWI, commented, “We are very pleased to be adding RAF to
the MWI family of companies. This acquisition is a
great complement to our existing catalog operations,
adds critical mass to our presence in key segments
of the technology sector and strengthens our distribution network.”
Jim Callaghan, CFO of MWI further stated, “RAF
is a strong and well-regarded brand in its markets.
We believe there is great opportunity to leverage
RAF’s strong market position for even greater growth
in the future.”
Tom Rafferty, president of R&R Manufacturing,
also commented on the transaction. “The choice of
the right buyer was critical to us. We believe that MW
Industries is a great fit with RAF. They understand
RAF’s products and markets, and have the capital
resources to invest in the company and its people.
We want to wish MWI every success in the future.”
MW Industries, Inc. (www.mw-ind.com) is a
manufacturer of springs, stampings, and fasteners.
Started 80 years as a single company, MWI today
operates 13 facilities and employs over 900 people.
MWI serves the global transportation, construction,
agriculture, electronic, energy, medical, power tool
and industrial machinery industries with precisionengineered custom parts and off-the-shelf catalog
components.
10 SPRINGS July 2008
North American Events
Aug. 12-13, 2008: Fundamentals of Spring
Design, Naperville, IL, SMI, (630) 495-8588, fax
(630) 495-8595.
Sept. 16-18, 2008: 8th Annual SPE Automotive Composites Conference & Exhibition,
(ACCE), Troy, MI, MSU Management Education
Center, Peggy Malnati (248) 592-0765,
p.malnati@sbcglobal.net.
Sept. 21-24, 2008: Titanium 2008 Conference, Las Vegas, NV, Caesar’s Palace Hotel,
International Titanium Association (ITA),
(303) 404-2221, www.titanium.org.
Oct. 13-14, 2008: Fundamentals of Spring
Design, Naperville, IL, SMI (630) 495-8588, fax
(630) 495-8595.
Oct. 15-17, 2008: Spring World 2008,
Rosemont, IL, CASMI, (630) 369-3772,
www.springworld.org.
Oct. 20-22, 2008: ITC Mexico, Monterrey,
Mexico, Crown Plaza Monterrey, WAI
(203) 453-2777, www.wirenet.org.
Nov. 9-12, 2008: 57th IWCS Conference and
Symposium, Providence, RI, Rhode Island Convention Center, www.iwcs.org; phudak@iwcs.org.,
(732) 389-0990.
April 25-30, 2009: Interwire 2009, Cleveland,
OH, International Exposition Center, WAI,
(203) 453-2777, fax (203) 453-8384,
www.wirenet.org. ◆
Correction
In the April 2008 issue, some information about
personnel changes at Industrial Steel and Wire Company was incorrect. We apologize for this error and
include the following updated information.
Industrial Steel and Wire Co., Chicago, Ill.,
announced the promotion of Dr. Brian Furlong to
president. He joined the company in 1996 after
receiving his Ph.D. in chemical engineering from Rice
University. Ralph Furlong, who led the company
for the past 40 years, will remain active within the
company as its new chairman. Dr. Harry Furlong
founded the company in 1935. David Merrills has
been appointed director of sales and is responsible
for worldwide sales and marketing of all ISW products. He will also manage the customer service team.
John Dickman has been promoted to director of
operations. He will oversee purchasing, materials
management and the operations of the company’s
six divisions including their newly opened Houston,
Texas warehouse. Wayne Bennett, CPA, MBA, is
the new director of finance and will head the company’s administration, finance and human resources
departments. He holds a master’s degree from Northwestern University Kellogg School of Management.
SPRINGS July 2008 11
76 Meeting
TH
SMI Annual
JW Marriott Desert Ridge Resort & Spa
APRIL 5 – 7, 2009 • PHOENIX, AZ
Brian Tracy –
(motivational speaker)
Continuous Learning
Brian Tracy
Gretchen Carlson
(Fox National News
Anchor) – Company
Growth through
Opportunities for
Leadership
Gretchen Carlson
EARLY BIRD
SPECIAL
Save
$100
12 SPRINGS July 2008
Register before October 1, 2008 for the 2009 SMI
76th Annual Meeting and save $100 off registration!
2009 Annual Meeting Registration Fee: $599 Members; $899 Non Members
Annual Meeting Early Bird Registration Fee: $499 (SMI members only)
TO EARLY BIRD REGISTER: Call Lynne at 1-630-495-8588 or email her at
Lynne@smihq.org with “Early Bird” in the subject line.
NOTE: THE ANNUAL MEETING EARLY BIRD PRICING REPRESENTS SUBSTANTIAL SAVINGS, THEREFORE IT IS
NON REFUNDABLE AND PAYMENT MUST BE RECEIVED BY MIDNIGHT ON OCTOBER 1, 2008.
SMI Obituaries
It is with deep regret that Springs announces the passing of former SMI president Stanley Banas of Northbrook,
Ill., May 10, 2008 of complications from diabetes. He was
the first employee at the spring and metal stamping business his father started in the family’s garage in 1944. He
continued in the spring industry until just last year. He had
a degree in mechanical engineering from Purdue University;
however, his strength was as a salesman, and he kept in
contact with hundreds of customers for Stanley Spring and
Stamping Corp. in Chicago. Mr. Banas served as president
of the Chicago Association of Spring Manufacturers, the
Spring Manufacturers Institute and served on the boards of many other community
organizations. He is survived by his wife, Dorothy; daughters, Veronica Shedd, Andrea
Bauer and Mary (Robert) Hess; sons, Stanley J. (Susie), Michael (Mary Gaye) and Jim
(Bobi Jo). He was grandfather of eight and uncle to many nieces and nephews.
It is with deep regret that Springs announces the
passing of Dave Hillstrom, former president/CEO and
chairman of Precision Steel Warehouse (PSW) and Joe
Cole, former vice president of sales and marketing with
the company. The two passed away within a week of each
other in February.
A Northwestern University grad who served as a lieutenant in the Army Infantry during the Korean conflict,
Hillstrom, 81, began his career with PSW in 1951 as an
outside salesman. In 1956 when the company moved to
Franklin Park, he was appointed sales manager. He became
vice president of sales in 1963, and was promoted to the position of executive vice
president-general manager in 1968. In 1974, Hillstrom became president/CEO of
PSW, and in 1981 he was appointed chairman of the board, president/CEO. He
retired from the company in 1999.
A University of Illinois graduate, Cole, 77, played football for the Rose Bowl Championship team in 1952 and
was a member of Sigma Chi Fraternity. After serving two
years in the Air Force as a lieutenant, he spent his entire
career in the steel and specialty metals industry. He first
worked for House of Stainless, where he served as vice
president of sales for 26 years, and then at PSW for over
18 years. He retired in 2000 from PSW as vice president of
sales and marketing.
PSW is a premium quality cold-rolled strip stainless
steel service center.
It is with deep regret that Springs announces the passing of Craig O. Snyder,
52, Luckey, Ohio. He graduated from Toledo University in 1977 with a bachelor’s
degree in business and finance and was employed by Seneca Wire and Manufacturing
Company, Fostoria, Ohio as a salesman. He is survived by his wife, Luann; daughter,
Kendra (Ryan) Hall; sons, Brent and Brandon; parents, Otto and Margaret Snyder;
along with two brothers, a sister and several nieces and nephews.
SPRINGS July 2008 13
Checkpoint
Business Tips
Local Politics:
Help Promote BusinessFriendly Regulations
By Phillip M. Perry
©iStockphoto.com/René Mansi
ith the 2008 presidential campaign in full
swing you’re probably assessing each candidate’s support for business-friendly legislation.
Politics at the national level, of course, can have
a profound influence on profits. And federal policies can help or hinder success in the international
marketplace which continues to grow in importance.
Consider the experience of JN Machinery, Bensenville, Ill., where some 95 percent of revenues now
emanate from overseas. “Ninety-nine percent of
my dealing with ‘politics’ is on foreign soil, not in
the United States,” says company president Daniel
Pierre III.
“In fact, my company is wondering why it
remains a U.S. company, and for that matter, why
remain on U.S. soil — just to maintain a ‘Made in
USA’ label? I spend all my time jumping the hoops
that China, Europe and other regions of the world
put up so I can operate most efficiently in their
countries.”
W
Thinking local
Despite the continuing importance of national
politics and international trade, the fact remains
that for many springmakers local politics is also a
vital piece of the profit puzzle.
“We are pretty involved with politicians at the
city and state level,” says Jim Zawacki, Sr., CEO
of GR Spring and Stamping, Grand Rapids, Mich.
“I know the mayor and the city commissioners and
have met with all of them for breakfast.” Making
such contacts, he adds, really helps when you need
something done. “Because I have cultivated political
contacts over the years I have been able to resolve
Phillip M. Perry is an award-winning journalist specializing in the fields of business
management and law. Over the past 20
years, his byline has appeared more than
3,000 times in publications such as World
Trade, Business, Corporate Risk Management,
Human Resource Executive and The Legal
Times of Washington. Readers may contact
him by fax at (212) 226-5580 or e-mail at
phil@pmperry.com.
14 SPRINGS July 2008
Effective lobbying is a process, not a destination.
Don’t expect your representatives to agree with you
all the time.They won’t. But over time, if you
participate in small ways by attending meetings
and voicing your opinions, you can have an influential
voice when a really big issue arises.
problems such as untended potholes and poor
snowplow service.”
Zawacki recalls one problem in particular:
When leaving the Grand Rapids plant after work his
employees had to negotiate a busy traffic intersection with nothing but a stop sign. Because Zawacki
had made contacts with local commissioners, and
because he was an active member of a neighborhood
association, his company was able to lobby successfully to have a traffic light installed. That facilitated
traffic flow and increased safety for everyone.
One other thing: With city and state help
Zawacki was able to get into two local enterprise
zones with 15-year exemptions from city, state and
property taxes.
Cultivating contacts
As the experience of Zawacki’s company attests,
cultivating local contacts can be smart. “What government does and how they regulate is important
to your business,” says Al Arnold, director of the
Academy of Local Politics, Rice Lake, Wis. “It’s your
bread and butter. Your city officials can help you
or kill you.”
That makes sense. Think about local tax
rates, business fees and unanticipated business
regulations that throw a monkey wrench into your
plans.
And how about unmaintained streets, filled
with potholes and ruts? They can keep customers
from visiting your place of business. Then there are
slow police response times that can magnify the
financial costs of burglary and robbery. Does your
fire department lack sufficient funding? Your whole
business might go up in smoke. And then there’s
public school quality: You need excellent institutions
to attract top talent.
Starting small
If getting things to work right often depends on
the priorities and the capabilities of your city or town
politicians, it can be difficult to fit politics into a
management schedule. Those who have been there
advise starting small and building up.
“Start by learning how your local government
operates,” suggests Arnold. “Politics is a game. In
order to be successful in any game you need to know
the rules.”
Arnold advises attending one local government
meeting each year to “watch, listen and learn by
observation” how local government works. “One
meeting won’t make anyone an expert, but over the
years you will become more knowledgeable about
your local officials and how they work.”
Learn how your town develops its annual budget
— the pivotal document for taking action. “A city
budget is not just a financial document,” explains
Arnold. “It is a policy document.” Where tax money
is being spent, or not spent, gives a clear indication
about your city council’s priorities. Furthermore,
funds have to be available for the city to take any
action you may desire throughout the year. “It does
no good to complain about something that needs
to be done if the money is not in the budget,” says
Arnold.
Indeed, policy decisions can have more of a
bottom line impact than the local tax rate. “Saving a
couple of bucks in taxes can cause your business to
burn to the ground if fire protection is inadequate,”
points out Arnold.
Networking
Personal networking is a powerful tool for influencing local laws. “All politics is personal,” says
Nancy Bocskor, a political consultant in Arlington,
Va. “Even in our modern world of e-mail, getting
things done still comes down to whom you have a
relationship with.”
In developing relationships, make the telephone
your friend. Call your local politicians at the city and
state level and meet with them. These politicians
look for ways to help constituents. They don’t know
how to do that if you don’t speak up. If you remain
hidden your politicians may well vote in ways that
unintentionally harm your business.
Don’t wait until you have concerns before meeting with your local representatives. Your politicians
often have issues they are grappling with and need
to talk with business people about the effects of
certain regulations.
Learn which committees are likely to deal with
business issues. “Find out where agendas for committee meetings are posted,” suggests Arnold. “Many
times they are on the town website. Make a point of
following these agendas on a regular (monthly if not
weekly) basis. This is the only way to catch issues
before votes are taken.”
SPRINGS July 2008 15
“What government does and how they regulate is
important to your business,” says Al Arnold, director
of the Academy of Local Politics, Rice Lake,Wis.
“It’s your bread and butter. Your city officials
can help you or kill you.”
Offer your input as early as possible. Will a proposed legislation or regulation have unanticipated
consequences? Call and let your politicians know.
“Issues are like rolling snowballs,” says Arnold.
“They get bigger and bigger with time. It is easier to
destroy a hand size snowball than it is the base of
Frosty the Snowman.”
On the state level the best way to follow issues
is to join an organization which does this for you. “If
your business has a statewide association, pay the
dues and belong to it,” suggests Arnold. “If there is
no such association join an independent business
group of some kind to get your information. And
when your association asks you to respond to a ‘call
to action’ on an important issue, do so.”
Joining groups
Running a business leaves you only so much
time to communicate with your politicians. So leverage your relationships with organizations that can
help communicate your message.
“Your local chamber of commerce will often talk
with political leaders,” notes Nancy Ploeger, presi-
16 SPRINGS July 2008
dent of the Manhattan Chamber of Commerce, New
York City. “Many chambers have legislative directors
or advocacy managers. Usually the presidents of the
chamber are involved with that aspect.”
Group action can be a powerful force in getting things done, notes Ploeger. She gives a recent
example: Working together, the New York state
chambers of commerce convinced the governor to
reduce the workers compensation insurance rates
by some 10 percent. Attend, or volunteer to serve
on the chamber committee that is responsible for
developing positions on local political issues.
Staying involved
Effective lobbying is a process, not a destination. Don’t expect your representatives to agree with
you all the time. They won’t. But over time, if you
participate in small ways by attending meetings and
voicing your opinions, you can have an influential
voice when a really big issue arises.
“You have to be a citizen activist,” says Bocskor. “When you are not involved it is amazing how
fast laws are passed that have unintended consequences.”
Don’t let that happen. Reach out to your local
politicians and you will end up with a more productive business environment. “I get so angry when
people say they are too busy,” says Arnold. “You
can’t be too busy to not follow what government is
doing to regulate your business.” ◆
Spring Performance
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Recent upgrades in our rolling mills, and our finishing equipment in, slitting, edging and oscillating
gives Ulbrich an advantage in meeting spring makers most stringent strip specifications.
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Ulbrich Stainless Steels & Special Metals, Inc.
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SPRINGS
ULBRICH-CA, USA: (800) 237-2888 • ULBRICH-CT, USA: (800) 243-1676 • ULBRICH-IL, USA: (800) 323-7035 • www.ulbrich.com • E-Mail:
springJuly
stee2008
l@ulbr17
ich.com
18 SPRINGS July 2008
The Human Factor in
Quality Assurance
By Randy DeFord, Mid-West Spring & Stamping
Spotlight
on the
Shop Floor
irtually everyone in the manufacturing world
has been exposed to quality standards. ISO is a
popular worldwide standard that Wikipedia defines
this way:
©iStockphoto.com/RTimages
V
The International Organization for Standardization (Organisation internationale
de normalisation), widely known as ISO,
is an international standard-setting body
composed of representatives from various
national standards organizations. Founded
on February 23, 1947, the organization
promulgates world-wide industrial and commercial standards.
Quality system standards are really not hard to
understand. A company creates and follows a system
of instructions that define the difference between a
good product and a bad one. If things are done correctly, standards are created and communicated to
the shop floor. Employees follow the standards and
product gets shipped to customers that meet their
requirements.
Don’t we all wish the quality assurance process
was that simple! Too often communication and
implementation are issues that are glossed over and
not corrected. It involves the human factor on both
sides of the manufacturing chain.
Let’s start with communication. Poor communication means any failure of management to explain
to the shop floor exactly what quality standards are
from the start. A typical scenario is ready-go-set! It
never works.
Randy DeFord is the engineering manager
at Mid-West Spring & Stamping in
Mentone, IN.
He has 30-plus years in the spring
industry, and believes that educating both
customers and associates is the key to
great customer service.
Readers may contact him by e-mail at
rdeford@mwspring.com or by phone at
(574) 353-7611.
The very moment you tell people you will
hold them accountable for product quality,
you fire an emotional “wake-up call.”
You put them on notice that they will be
held accountable for their actions.
The ideal scenario is where all employees are
brought together to have the standards explained in
detail and how the company will implement them.
This is more than just talking about the nuts and
bolts mechanism of the quality system, it goes to
what the system is truly about – accountability.
The very moment you tell people you will hold
them accountable for product quality, you fire an
emotional “wake-up call.” You put them on notice
that they will be held accountable for their actions.
It is important to communicate that everyone makes
mistakes, but it must be done not to punish but for
the sake of accountability.
Most of us were taught as young children to “not”
do certain things and were punished accordingly
when we broke those rules. That childhood image
of punishment and the disappointment that goes
with it still lingers for many people. Especially when
someone tells them: “You made a mistake.”
SPRINGS July 2008 19
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A quality system should never be about punishment — it’s about making things right and defining
what that is. Discipline, not punishment, is the key
to any quality system. Discipline is done to make
corrections and move forward. It requires every
employee to understand what quality standards are
expected, and then commit to making it a priority
each and every day.
Quality standards are at the heart of great
manufacturing. It says we know how to do it right,
we have it in writing and have told everyone what
it’s all about. This starts from the top down.
One of the more painful errors in American
manufacturing is the tendency to divorce top management from both the product and the process.
Top managers need to understand the system and
how it’s used. They do not need to know the detail
level used by the inspector or floor worker, but they
do need to know what standard they have asked
employees to follow and what results can be expected
if everyone follows the game plan. This standard
needs to be communicated in a clear and deliberate
manner to each employee.
20 SPRINGS July 2008
The people in your “Quality Assurance” department do not assure quality, they define it. They
are the lawmakers and the police. The production
floor is where the responsibility lies for the actual
implementation of the quality standards you have
defined.
It’s everyone’s responsibility to talk openly about
problems and then solve them. Unfortunately,
humans are naturally poor communicators. A good
exchange of information from one brain to another is
a skill that takes time, patience and a goal. Since all
human experience involves emotion (joy, happiness,
pride, disappointment), no one can discount the
emotional affect of holding people accountable.
Be sure the message is all about identification and
correction…not identification and punishment. ◆
Be
Aware
The Latest OSHA Activities
By Jim Wood
Safety Tips
ach year we try to keep the springs industry
abreast of OSHA’s activities and where their
efforts have been concentrated.
OSHA’s fiscal year ending September, 2007 saw
an increase in inspections by 4.3 percent over its
stated goal for 2007 and a 6 percent increase over
2006. Serious violations increased by 9 percent.
The following table lists the 25 most frequently
violated standards for 2007 along with un-adjusted
penalties for general industry within the NAICS 331
group, which includes metal stamping, wire forms
and springs.
Whenever a safety violation does not have a
particular standard that applies, OSHA cites the
E
Standard
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
1910.1200
1910.212
1910.1200
1910.23
1910.212
1910.151
1910.147
1910.215
1910.305E
1910.147
1910.1200
1910.134
1910.134
1910.178
1910.303
1910.147
1910.219
1910.132
1910.305
1910.215
1910.132
1910.147
1910.133
1910.242
1910.132
General Duty Clause: 5 (a)(1) Each employer shall
furnish to his employees a place of employment
which are free from recognized hazards that are
causing or are likely to cause death or serious
physical harm to his employees. OSHA used this
clause 1,336 times with an average penalty of
$3,000.
Jim’s Regulatory Tip:
Enforce the use of seatbelts on your forklift
trucks. In the past year, OSHA has cited a number
of companies for not using seat belts on their forklift
trucks. They cite this using the General Duty Clause.
The average penalty is $5,000. ◆
Violation
Hazard Communication, Written Program
Machine Guarding - General
Hazard Communication – Employee Training
Guarding, Platforms and Runways
Machine Guarding – Point of Operation
Eye Wash and Emergency Shower
Lockout/Tagout – Written Program
Grinders – Guard Adjustment
Electrical – Wire Methods
Lockout/Tagout – Enforce Lockout Program
Haz/Com – Complete MSDS File
Respiratory Protection – Medical Evaluation
Respiratory Protection – Written Program
Forklift – Operator Training
Electrical – Installation and Approved Use
Lockout/Tagout – Periodic Assessment
Guarding – Pulleys and Sprockets
Protective Equipment – Hazard Assessment
Electrical – Approved Use Methods
Grinders – Lack of Work Rests
Protective Equipment – Written Program
Lockout/Tagout – Employee Training
Eye and Face Protection
Compressed Air – Blow Off, 30 psi Max
PPE – Provide, Use and Maintain
Penalty
$ 485
$2,040
$ 356
$2,680
$2,306
$1,152
$2,032
$ 459
$ 860
$1,494
$ 160
$ 555
$ 735
$1,300
$ 875
$1,339
$1,078
$ 315
$ 735
$ 709
$ 253
$1,355
$ 830
$ 900
$2,201
Jim Wood is an
independent
regulations
compliance
consultant
to the Spring
Manufacturers
Institute (SMI).
A certified instructor of the OSHA
Out-Reach Program, Wood conducts seminars, plant Safety Audits
and In-House Safety Training.These
programs help companies 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) 495-8597 or e-mail at
regs@smihq.org.
SPRINGS July 2008 21
Do You Suffer From An
Ingrown Nail Or Want
To Make Great Leaps
Forward? A Spring
System May Help
A look at the many uses of springs
to
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iap
Se
efa
t
By Konrad Dengler
Special contributor to Springs
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St
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©iStockphoto.com/P_Wei
Springs are necessary in many technical constructions.This article will
provide insights into the variety of spring applications. It will also look at
European spring manufacturers as they describe production examples
and general considerations for spring design.
/Jim
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©iS
Ensuring Mechanical Functions
In industrialized countries, nearly everyone uses
springs each day. Most people are not aware of it
because many springs seem insignificant or are
hidden to the bare eye. However, the significance of
a spring can be felt immediately, when it fails.
Think of when the pressed push-button of a PC
keyboard doesn’t jump back into its initial position
or a toaster doesn’t return a slice of bread. Consider
what could happen if the pressed-down accelerator pedal of a car remains in its position instead
of returning back. This is a potentially frightening
scenario.
©iStockphoto.com/César Gutierrez Wong
t
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Pru
22 SPRINGS July 2008
Function Principle
Regardless of the particular function of a spring,
it can be said that all springs work according to
a principle: By changing their shape, they store,
transform or set mechanical energy free. Springs are
elastic, meaning they return to their initial shape
after having been unloaded. Springs are also used
to absorb impacts or vibrations.
©iStockphoto.com/David Hills
©iStockphoto.com/Thomas Pullicino
©iStockphoto.com/Barbara Quinn
Some years ago, the German commercial newspaper Handelsblatt quoted Horst Dieter Dannert,
then-secretary of the German spring manufacturers
association VDFI and current general secretary of
the European Spring Federation (ESF): “Technical
springs are everywhere, where something is moving.
Every light switch, every valve, whether in a power
station or in a kitchen, needs a spring.”
Cars, airplanes, typewriters, computers, clocks,
washing machines, mousetraps, door -handles,
coffee makers or mattresses — these are all products
most of us encounter in our daily private or business
life that contain several springs which ensure their
mechanical function.
History
Since its very beginning, mankind has used
the elastic characteristics of natural materials and
forged metals like copper and iron. Fibulas made
from copper were used to hold together clothing and
can be seen as forerunners of modern safety pins.
Since the Middle Ages in Europe the development of iron production and wire manfucturing had
a reciprocal influence on the applications of springs
and spring manufacturing technology.
Today’s armaments industry began with weapons like crossbows and rifles that were based on
spring mechanisms. At the beginning of the 14th
century watchmakers used springs to manufacture
clockworks. Craftsmen improved continuously the
quality and the shape of springs.
In the 18th century spiral springs were generally
used for clocks and fob clocks. Today, the automotive
industry is the most important customer of spring
manufacturers, but other industries which produce
investment and consumer goods need large quantities of springs too.
Manifold Variety of Shapes
As the operating conditions can vary greatly
with many parameters acting on a spring, there is
a nearly endless number of construction possibilities concerning the material, shape and design of a
spring. Springs can have a standardized shape like
the helical compression spring in a ballpoint pen,
but a simple blade or a clip can also be a spring.
Plus, there even are creations that, at first sight,
seem to be unique works of modern art.
Some years ago, at the annual VDFI convention,
Dr. Thomas Blum, then a member of the managing board of the spring machinery builder Wafios
and today a consultant for the spring industry,
showed pictures of bizarre wire forms that looked
like abstract art but were technical springs. The
curious form was the result of a phenomenon that
is well-known in the spring industry: The designer
of a complex technical system had forgotten to
consider the spring in his construction. Only at
the end of the development process had he noticed
that a spring was necessary to make the construction work. A spring manufacturer was confronted
with the task of developing a spring that could be
mounted into the space which by chance was left
free. Such springs can be manufactured on modern
electronically controlled spring coilers.
Market Requirements
The following example shows, how impor tant close contact between customers and spring
manufacturers is. For the North Italian spring
manufacturer Mollificio Valli Srl, situated at Oleggio Castello near the Lago Maggiore, the automotive
industry has always been an important customer.
“There is a great demand for all kind of springs,”
says Angelo Passarotti, technical and commercial
manager of the company. “As these springs must
respond to severe operation and safety conditions
– for example valve springs must support without
problems a life span of 100 million (1 x 108) or more
load alternations – the quality requirements are very
high. The basic condition for success is therefore a
close cooperation with our customers,” explained
Passarotti.
“It’s not unusual that two years are necessary
for the development and the specification of a new
spring before the serial production starts,” said
Passorotti.
SPRINGS July 2008 23
Tendencies
Mollificio Valli manufactures springs for many
other applications too. In the past they developed
springs for educational toys which help children
discover and train their senses. However, for cost
reasons the production of toy springs in the highly
industrialized countries of Europe is in decline and
has been replaced by countries in Southeast Europe
or China.
On the other hand, new markets are growing. For
example, there is an increasing demand for springs
which are integrated into the hinges of kitchen and
other furniture. “These springs assure a certain
kinematic for the opening or closing of doors and
lids,” explains Passarotti.
Henrik Hagens, managing director of Hagens
Fjedre AS based at Støvring, Denmark, noticed, “that
there is a general tendency towards higher forces
and load cycles, smaller tolerances and more spring
shapes. The limits of the materials characteristics are
exhausted, and there are no imagination limits.”
By following its company motto “springs while
you wait,” Hagens Fjedre AS — which manufactures
springs for many small and medium-sized companies
in practically all branches like machinery construction, agricultural machinery, energy technology,
off-shore-technology and wind power plants — is
confronted with new and sometimes original tasks.
24 SPRINGS July 2008
The concept means that technical calculations and
the production of prototypes and small series are
carried out within a matter of days or even hours. “A
time ago,” remembers Henrik Hagens, “the designer
of an arts studio came to us and asked us to make
springs which then were inserted into street lamps.
These springs don’t have a technical function but
cause an aesthetic effect which one can see now in
the pedestrian zone of a certain Danish town.”
Matthias Dietz, managing director of Federnfabrik Dietz GmbH, is also familiar with many
different spring applications. Springs made in his
company hold the pipes of organs, while other
springs help adjust the many little mirrors of operating room lamps or control the blood flux in dialysis
automats.
The company, based in Neustadt near Coburg in
Southern Germany, manufactures springs and bent
parts which are used in many sectors like automotive, electronics and electrical appliances, locks,
jewelery, decorative articles and even devices which
can help children train their motor skills.
Where do new ideas concerning the application of
springs come from? “We cultivate longstanding relations with our customers; we are of course open to
every inquiry,” says Dietz, “and have our own creative
team which stands ready to develop and produce
concepts for innovative spring manufacturing.”
©iStockphoto.com/Ryan Burke
Original and Witty
There are nearly no limits for the application
of springs. Here are three interesting, original and
witty ideas.
Years ago a German pedicurist developed a
spring system which immediately helps elminate
pain from ingrown nails and corrects the nail growing process. Furthermore, painful operations can
be avoided. Orthonyxists who have been trained to
apply the “VHO-Osthold-Method® perfect” are able
to apply correctly the “VHO-Osthold-Brace® perfect”
(www.VHO-Osthold.com).
Another interesting spring
application has also to do with the
feet: the “Pogo Stick.” The stick is
equipped with handles, footpads
and a compression spring. The
operator places his feet on the
footpads while balancing on the
pole, then jumps or presses down
on the footpads to compress the
spring. When the spring has been
fully compressed, the operator lifts
his weight, aided by the recoil of
the spring, being launched several
inches or feet into the air. This process is repeated to create a hopping action.
Finally there is the “Slinky”, a long coil with
the shape of a simple helix which can “walk”
down stairs when the coils
stretch and reform as gravity moves them down each
step. More information on
these products are available at Wikipedia (www.
wikipedia.org), the free Web
encyclopedia.
For More Information:
Federnfabrik Dietz GmbH
Am Floßgraben 10
D 96465 Neustadt
Tel. +49 9568 94 42-0
Fax +49 9568 94 42-22
E-mail: info@federn-dietz.de
Web:www.federn-dietz.de
Hagens Fjedre AS
Hagensvej 13
DK 9530 Støvring
Tel: +45 98 37 14 44
Fax +45 98 37 41 43
E-mail: home@hagens-fjedre.com
Web: www.hagens-fjedre.com
Mollificio Valli Srl
Via Ceserio, 39
I 28040 Oleggio Castello (NO)
Tel. +39 0322 54 17 11
Fax +39 0322 53 80 67
Web: www.mollificiovalli.it
E-mail: info@mollificiovalli.it
©iStockphoto.com/Craig Veltri
Conclusion
Springs are needed nearly everywhere. As
there is a huge variety of applications and a lot of
aspects to be considered, the requirements of all
spring applications can’t be satisfied with a few
standardized spring products. Spring manufacturers can be assured of their competitiveness if they
have experience, mental flexibility, an aptitude for
technical contexts, product and production knowhow, modern production equipment, and creativity
to help their customers discover further spring
applications and new markets. ◆
Konrad Dengler is a special contributor to Springs. A freelance
correspondent, Dengler writes about the wire and spring industry
in Europe for several industry publications. Previously, he was
editor of the technical journal Draht. He is an engineer in materials
sciences, and works as a technical journalist and translator. Readers
may contact him by e-mail at KDengler@t-online.de or by fax
0049 9135 3990
SPRINGS July 2008 25
A History of Springs
A look back shows that springs are the unsung
heroes of many intricate mechanisms
*Edited and compiled by Cheryl Chonajcki
©iStockphoto.com/Achim Prill
The unsung heroes of many an
intricate mechanism, springs have
been present in human innovation
since almost the very beginning.
The history of springs gained great
momentum in the Middle Ages,
when artisans and craftsmen of all
kinds forged or hammered out metal
springs for their various wares. But
forerunners showed up long before
in antiquity — first in primitive cloak
pins and later in weapons of war.
26 SPRINGS July 2008
here was a time when the only metal springs to
be found anywhere may have been the fasteners
on ornamental clasp pins in prehistoric Europe and
Asia. Fashioned of copper and brass, these decorative pins relied on simple spring tension to close skin
cloaks around the wearer’s body. Later, jewelers began
looping the pin wire, producing ancient helical torsion
springs similar to those on today’s safety pins. Many
of these clasps have been uncovered by archaeologists
over the years.
Some of the greatest spring works have been seen
in the early instruments of war. A drawn bow with an
arrow is a kind of spring that dates to biblical times.
The crossbow, which appeared a few hundred years
before the birth of Christ, and the arbalest, developed
during the Middle Ages, utilized spring tension even
more than the simple bow — not only in the release of
the arrow or bolt, but also in the trigger mechanism
that sprang the missile.
Ancient and medieval siege engines, including
the catapult and ballista, employed powerful torsion
springs to fling stones, arrows and other projectiles.
The spring action was produced by twisting two ropes,
often made of the sinews of a bull’s neck, around a
long wooden arm that forwarded missiles to the enemy
with great force.
T
The clock industry has made important contributions
to the manufacture and use of springs. Patent replica
courtesy of National-Standard Company.
But these primitive models were only kissing
cousins to metal springs that were yet to come.
Abbott Payson Usher, in his 1929 classic, History
of Mechanical Inventions, suggests it wasn’t until
almost the birth of Christ that people figured out that
bendable metals might find purpose. “A passage in
Philo (Byzantium, 2nd century B.C.) is the first clear
indication of any realization of the possible significance of the elasticity of metals,” Usher writes, “and
it must have been a new idea as he devotes a whole
paragraph to the reality of the elasticity in metals.
“He cites particularly the mode of testing Celtic
and Spanish swords by bending them, and calls
attention to the exact and immediate resumption
of their former state. Until that time there is no
record of the use of any form of metal spring except
in certain types of pins approximately the form of
the modern safety pin.”
There wasn’t a lot written in the next several
centuries, either. Little is known about springs or
any other mechanical advancements from 400 to
1400 A.D., largely because the medieval Church suppressed scientific discovery, deeming it heresy. Still,
spring usage continued to evolve, and it is assumed
that for a long time the different kinds of artisans
— blacksmith, goldsmith, silversmith and jeweler,
and makers of locks and clocks and watches and
armor—simply made their own. Craftsmen began
organizing into guilds as far back as the 11th century and on into the 16th and 17th centuries, but
there is no record of a springmaker’s guild.
Timepieces
The clock industry was one of the earliest and
most important contributors to the manufacture
and use of springs. Weight-driven, mechanical
timepieces began to replace sundials and water
clocks after 1000 A.D., and a description of the
Glastonbury clock of 1330 was one of the first to
mention springs in its construction. It was during
the 14th or 15th century that clockmakers began
using space-saving spring coils rather than falling
weights to power timepieces.
It was a tricky transition. Spring-driven clocks
were quite inaccurate in their early days, as the
weights had regulated the driving mechanism with
a constant force, while spring energy diminished
as the spring unwound. A cam device called a
stackfreed was developed to solve the problem. Its
use, however, was limited, and another innovation,
the fusee, appeared on the scene. A conical drum,
spirally grooved, the fusee compensated for declining spring force as the timepiece’s cord unwound
from the mainspring onto the cone, rotating the
SPRINGS July 2008 27
The development of guns has depended on the
development of springs, as seen in this patent from
April 19,1864. Patent replica courtesy of NationalStandard Company.
main driving gear. Fusees are gone now, too, except
in some styles of finer watches.
First appearing in the early 1500’s, the pocket
watch coincided with the dawn of the Renaissance.
Peter Henlein, a German locksmith, is usually
credited as the inventor, and the type of spring he
used is unknown; historians assume it was a flat
coil type.
In the mid-1600s, further advancements to the
clock are credited to British physicist Robert Hooke
and Dutch mathematician Christiaan Huygens, who
experimented separately to improve control of the
balance wheel. The result was a balance spring, or
hairspring, and though it wasn’t clear for centuries which man developed it first, Hooke usually
is acknowledged as the inventor. The hairspring,
emerging pendulum technology and upgrades in
clock escapements allowed timepieces to capitalize
on spring power as never before. As manufacturing
improved and parts were made more accurately,
time mechanisms ran more smoothly, and the load
on mainsprings was reduced. The quality of clocks
continued to advance as craftsmen sought better
materials for their springs.
28 SPRINGS July 2008
In England, blister steel was usable enough in
the early 1700s but was not considered dependable.
Shear steel was better, until Benjamin Huntsman,
a clockmaker near Sheffield, developed cast steel in
1740 by heating and cooling pieces of blister steel in
a crucible. Later improvements made the cast steel
non-porous, but Huntsman’s process continued to
be used for the best grades of steel springs long after
his death in 1776.
Locks, leaf springs and guns
Not only clocks, but also locks, have helped
advance the manufacture of springs. The complicated
locking mechanism of a 17th century chest employed
several types of flat springs, including a heavy flat
coil on which car door locks were later based.
Car suspension, on the other hand, has
commonly relied on the leaf spring — as did its
predecessor, the carriage. Carriage bodies in Europe
were first suspended on leather straps, but experiments with steel springs were reportedly made as
early as 1669. Leaf springs began replacing leather
sometime in the following century and continue to
undergird heavy commercial vehicles yet today.
As the spring industry
has developed over the
years, the reliance on
precise measurements
and testing equipment
has increased.
Guns have depended on the development of
springs, beginning with the invention of the matchlock gun and the first gunlock spring in the early 15th
Century. Almost 100 years later, the wheel lock gun
was designed to ignite by means of a spring-driven,
rotating steel wheel, and the sparking material was
held under spring pressure. In 1575, the springs
in the flintlock gun contributed to its success as a
popular firearms choice for more than 300 years
after, and today’s small arms industry continues to
employ precision springs of many kinds.
Da Vinci
An interesting “aside” in the history of springs
is the imagination of Leonardo da Vinci; perhaps
no other person has had a greater potential impact
than he. Although many of da Vinci’s ideas never
actually left the drawing table, they often involved
the use of springs.
The Renaissance artist/scientist reportedly
designed a wheel lock pistol well before it was
invented by the German watchmaker who got credit
for it in 1517. The Nuremburg device used a flat
spring; da Vinci’s would have operated with what he
called a spiral spring, now known as a flat coil. This
kind of spring also figured in the motor of a vehicle
he designed, and his flying machines relied on a strip
of spring steel and powerful elliptical springs.
Da Vinci sketched a punch press with a semielliptical spring for withdrawing the die from the
punch, and he sketched an automatic iron lock with
a heavy helical spring. He designed an apparatus to
extend the run of a clock through the use of multiple
springs positioned one on top of the other.
More recent advancements
While most of da Vinci’s designs were never
actually constructed, other inventors did see their
ideas come to fruition. Before World War I, helical
springs were generally made by winding wire onto
an arbor, but this was no longer sufficient when the
automobile, mechanized farm equipment and mass
production came into wide usage. The demand for
springs was greater than ever, and faster winding
tools were needed.
The history of springmaking entered a particularly rich and fertile period in the early 1900s, and
U.S. officials routinely approved patents for new
machinery. A hand tool in 1910 for winding a helical spring. A machine that same year for tapering
SPRINGS July 2008 29
coiled springs. Two years later, an adjustable spring
winder, a large-diameter coiling machine and an
automatic spring coiler that was probably the first
torsion machine invented.
Various other coiling machines followed, each
designed with a slightly different mission. In 1916,
an automatic machine was patented for making
right- or left-hand torsion springs and could be
adapted for compression or extension springs. One of
the most significant developments was the universal
coiler, patented in 1918 by Frank H. Sleeper, founder
of the renowned Sleeper & Hartley Corp. Revolutionary for its time, the Sleeper machine brought
springmaking into an era of high production and
practically eliminated the need for lathe coiling.
In 1933, the Samuel Popcorn Type produced
springs even faster and at a lower maintenance
cost. The Torin torsion attachment in 1939 made
straight-tail barrel springs on a clutch type coiler,
an important advancement for torsion springs which
previously had to be made in secondary or hand
operations.
A hand-operated spring coiler ideal for prototypes, samples and small production runs appeared
in 1949. The first machines to combine spring coiling and looping were developed in the mid-1950s.
In 1966, a double-action coiler produced a spring
on the forward movement and another on the return
stroke. Many continuing advancements, too numer-
ous to mention, have bounced the spring industry
right into the 21st century.
Among them were fourslide machines, a valuable tool credited to the Baird Co. and Blake and
Johnson, earliest producers of fourslide wire forming. U.S. Tool Co. of New Jersey introduced the
Multi-Slide® in the late 1920s, and 30 years later,
Torin brought out a vertical design of fourslide called
the Verti-Slide®.
The growing spring industry also required spring
grinding and testing machines, and over the years,
the ingenuity of engineers produced many pieces
of special equipment as well — automatic looping
devices, electronic length gauges, carbide tools that
lasted 10 times as long as their predecessors, shot
peening machines, temperature controls, constant
force springs, the slack wire feeder and, of course,
computers.
The quality of spring wire has been upgraded,
too, thanks to enhancements in wire-drawing dies,
lubricants, coatings and materials used to make the
wire itself. Cast iron and steel dies served until 1928,
when tungsten carbide dies and, later, diamond dies
came into use. Before improvements were made,
there were no micrometers to check size; diameter
and roundness were difficult to maintain. Heat generated in the operation compromised ductility until
air- and water-cooled equipment and electronic
temperature controls were developed.
Chrome silicon spring wire, first used for recoil
springs in World War II antiaircraft guns, was a
vast improvement over earlier wire materials, solving the problem of spring failure due to heat. The
development of new coatings and wires of stainless
steel, hardened steel and non-ferrous metals such
as phosphor bronze, beryllium copper and titanium,
have also been essential contributions.
The invaluable service of pioneers like Dr. A.M.
Wahl, who researched spring failure and developed
his well-known curvature correction factor, or K-factor, has been vital to the industry’s success. We’ve
come a long way from the primitive spring power of
cloak pins. But with the ongoing efforts of professionals in the Spring Manufacturers Institute, an
effective force in the growth of springmaking for 75
years, the industry will be prepared to meet the needs
and challenges of the constantly changing world. ◆
*Condensed from articles first appearing in Springs
magazine in May 1974, October 1974 and May 1975.
Much of the information was compiled by George E.
Underwood, former executive vice president of SMI.
Cheryl Chonajcki is a freelance writer and columnist in the
Chicago suburbs.
30 SPRINGS July 2008
July 2008
Quick Reference
Supplier Guide
The companies listed below are among the most prominent suppliers to the spring industry. Each of these companies, presented
here under product or service category, advertises in every issue of Springs. Though their products and services vary widely,
these companies can all be characterized by their enthusiastic willingness to serve the needs of spring manufacturers.
Coilers / Wire Formers
Ank, Inc.
Enrico Yang
++886-2-22042140
Fax ++886-2-22057801
Forming Systems, Inc.
Tim Weber
(269) 679-3557
Fax: (269) 679-3567
HTC
TBE
Whitelegg
JayKase
www.formingsystemsinc.com
Maguire Machinery
Jim Maguire
(609) 266-0200
Fax: (609) 266-9079
www.maguiremachinery.com
Nichols International Machinery
Systems Co.
Jerry Jacques
(563) 391-0400
Fax: (563) 445-0710
Simplex Rapid/SECEM
www.nimsco.com
RK Trading
Rob Meyers
(847) 640-9771
Fax: (847) 640-9793
Herdon, Bobbio
Shinko Machinery Co., Ltd.
++81-6-6794-6610
Fax: ++81-6-6794-1025
www.shinko-mach.co.jp
SIMCO/Gibraltar Corp.
Michael Shapiro
(847) 769-2099
www.simcotw.com
Furnaces / Ovens
HSI/Forming Systems, Inc.
Tim Weber
(269) 679-3557
Fax: (269) 679-3567
www.formingsystemsinc.com
JN Machinery Corp.
Daniel Pierre III
(630) 860-2646
Fax: (630) 860-2720
www.jnmachinery.com
Pyromaître
Mario Grenier
(800) 231-PYRO
Fax: (418) 831-3206
www.pyromaitre.com
Grinders
Bennett Mahler/NIMSCO
Jerry Jacques
(563) 391-0400
Fax: (563) 445-0710
www.nimsco.com
OMD/Emanon/Forming Systems Inc.
Tim Weber
(269) 679-3557
Fax: (269) 679-3567
www.formingsystemsinc.com
SIMCO/Gibraltar Corp.
Michael Shapiro
(847) 769-2099
www.simcotw.com
Spring De-Tangler
Dispense Works Inc.
Michelle Morin
(815) 363-3524 Fax: (815) 363-8089
www.dispenseworks.com
Spring Manufacturers
Diamond Wire Spring Co.
Frank Fazio
(800) 424-0500
www.diamondwire.com
Vulcan Spring & Manufacturing Co.
Bob Gustafson
(215) 721-1721
www.vulcanspring.com
Testers / Measurement
IST/NIMSCO
Jerry Jacques
(563) 391-0400
Fax: (563) 445-0710
www.nimsco.com
Proto Manufacturing Ltd.
Robert Drake
(800) 965-8378
Fax: (519) 737-6330
www.protoxrd.com
Spring Analysis Systems Inc./Forming
Systems Inc.
Tim Weber
(269) 679-3557
Fax: (269) 679-3567
www.formingsystemsinc.com
Trade Associations
Chicago Association of Spring
Manufacturers Inc.
Tom Renk
(630) 369-7786
Fax: (630) 369-3773
www.springworld.org
www.casmi.org
Spring Manufacturers Institute
Lynne Carr
(630) 495-8588
Fax: (630) 495-8595
www.smihq.org
Uncoiling Systems
Durant Tool Co.
Heidi Rice
(401) 781-7800
Fax: (401) 738-2586
www.durantco.com
Wire Straighteners
Durant Tool Co.
Heidi Rice
Fax: (401) 738-2586
(401) 781-7800
www.durantco.com
Nichols International Machinery
Systems Co.
Jerry Jacques
(563) 391-0400
Fax: (563) 445-0710
SECEM
www.nimsco.com
Wire/Strip Materials
Admiral Steel
(800) 323-7055
Fax: (708) 388-9317
www.admiralsteel.com
Alloy Wire International
Donald Dinuccio
(866) 482-5569
Fax: (401) 737-8395
www.alloywire.com
Blue Blade Steel
Jeff King
(908) 272-2620 Fax: (908) 272-8252
www.BlueBladeSteel.com
Elgiloy Specialty Metals
Gene Kunos
(847) 695-1900
Fax: (847) 695-0169
www.elgiloy.com
Gibbs Wire and Steel
Bill Torres
(800) 800-4422
Fax: (860) 628-7780
Suzuki Steel Wire
www.gibbswire.com
Haldex Garphyttan Wire
Kirk Manning
(888) 947-3778
Fax: (574) 232-2565
www.haldex.com
Industrial Steel & Wire
Dave Ritter
(773) 804-0404
Fax: (773) 804-0408
www.industeel.com
InterWire
Frank Cardile Jr.
(914) 273-6633
Fax: (914) 273-6848
www.interwiregroup.com
Kiswire Trading Inc
(201) 461 8895
Fax: (201) 461-8021
www.kiswire.com
Mapes Piano String Company
Robert Schaff
(423) 543-3195
Fax: (423) 543-7738
www.mapeswire.com
Mount Joy Wire Corp.
George Belforti
(717) 653-1461
Fax: (717) 653-6144
www.mjwire.com
Precision Steel Warehouse Inc.
Steve Kraft
(847) 455-7000
Fax: (847) 455-1341
www.precisionsteel.com
Raajratna (India)
(847) 485-8210
Fax: (847) 485-8254
www.raajratna.com
Radcliff Wire Inc.
Scott Kirkpatrick
(860) 583-1305
Fax: (860) 583-6553
www.radcliffwire.com
Tool King Inc.
Peter Hestad
(800) 338-1318
Fax: (847) 537-6937
www.toolkinginc.com
Ulbrich Stainless Steels & Special
Metals Inc.
Rich Papeika
(800) 243-1676
Fax (203) 239-7479
www.ulbrich.com
Zapp Precision Strip
Byron Ress
(203) 386-0038
Fax: (203) 502-6681
www.zapp.com
July 2008
Quick Reference
Supplier Guide
The companies listed below are among the most prominent suppliers to the spring industry. Each of these companies, presented
here under product or service category, advertises in every issue of Springs. Though their products and services vary widely,
these companies can all be characterized by their enthusiastic willingness to serve the needs of spring manufacturers.
Coilers / Wire Formers
Ank, Inc.
Enrico Yang
++886-2-22042140
Fax ++886-2-22057801
Forming Systems, Inc.
Tim Weber
(269) 679-3557
Fax: (269) 679-3567
HTC
TBE
Whitelegg
JayKase
www.formingsystemsinc.com
Maguire Machinery
Jim Maguire
(609) 266-0200
Fax: (609) 266-9079
www.maguiremachinery.com
Nichols International Machinery
Systems Co.
Jerry Jacques
(563) 391-0400
Fax: (563) 445-0710
Simplex Rapid/SECEM
www.nimsco.com
RK Trading
Rob Meyers
(847) 640-9771
Fax: (847) 640-9793
Herdon, Bobbio
Shinko Machinery Co., Ltd.
++81-6-6794-6610
Fax: ++81-6-6794-1025
www.shinko-mach.co.jp
SIMCO/Gibraltar Corp.
Michael Shapiro
(847) 769-2099
www.simcotw.com
Furnaces / Ovens
HSI/Forming Systems, Inc.
Tim Weber
(269) 679-3557
Fax: (269) 679-3567
www.formingsystemsinc.com
JN Machinery Corp.
Daniel Pierre III
(630) 860-2646
Fax: (630) 860-2720
www.jnmachinery.com
Pyromaître
Mario Grenier
(800) 231-PYRO
Fax: (418) 831-3206
www.pyromaitre.com
Grinders
Bennett Mahler/NIMSCO
Jerry Jacques
(563) 391-0400
Fax: (563) 445-0710
www.nimsco.com
OMD/Emanon/Forming Systems Inc.
Tim Weber
(269) 679-3557
Fax: (269) 679-3567
www.formingsystemsinc.com
SIMCO/Gibraltar Corp.
Michael Shapiro
(847) 769-2099
www.simcotw.com
Spring De-Tangler
Dispense Works Inc.
Michelle Morin
(815) 363-3524 Fax: (815) 363-8089
www.dispenseworks.com
Spring Manufacturers
Diamond Wire Spring Co.
Frank Fazio
(800) 424-0500
www.diamondwire.com
Vulcan Spring & Manufacturing Co.
Bob Gustafson
(215) 721-1721
www.vulcanspring.com
Testers / Measurement
IST/NIMSCO
Jerry Jacques
(563) 391-0400
Fax: (563) 445-0710
www.nimsco.com
Proto Manufacturing Ltd.
Robert Drake
(800) 965-8378
Fax: (519) 737-6330
www.protoxrd.com
Spring Analysis Systems Inc./Forming
Systems Inc.
Tim Weber
(269) 679-3557
Fax: (269) 679-3567
www.formingsystemsinc.com
Trade Associations
Chicago Association of Spring
Manufacturers Inc.
Tom Renk
(630) 369-7786
Fax: (630) 369-3773
www.springworld.org
www.casmi.org
Spring Manufacturers Institute
Lynne Carr
(630) 495-8588
Fax: (630) 495-8595
www.smihq.org
Uncoiling Systems
Durant Tool Co.
Heidi Rice
(401) 781-7800
Fax: (401) 738-2586
www.durantco.com
Wire Straighteners
Durant Tool Co.
Heidi Rice
Fax: (401) 738-2586
(401) 781-7800
www.durantco.com
Nichols International Machinery
Systems Co.
Jerry Jacques
(563) 391-0400
Fax: (563) 445-0710
SECEM
www.nimsco.com
Wire/Strip Materials
Admiral Steel
(800) 323-7055
Fax: (708) 388-9317
www.admiralsteel.com
Alloy Wire International
Donald Dinuccio
(866) 482-5569
Fax: (401) 737-8395
www.alloywire.com
Blue Blade Steel
Jeff King
(908) 272-2620 Fax: (908) 272-8252
www.BlueBladeSteel.com
Elgiloy Specialty Metals
Gene Kunos
(847) 695-1900
Fax: (847) 695-0169
www.elgiloy.com
Gibbs Wire and Steel
Bill Torres
(800) 800-4422
Fax: (860) 628-7780
Suzuki Steel Wire
www.gibbswire.com
Haldex Garphyttan Wire
Kirk Manning
(888) 947-3778
Fax: (574) 232-2565
www.haldex.com
Industrial Steel & Wire
Dave Ritter
(773) 804-0404
Fax: (773) 804-0408
www.industeel.com
InterWire
Frank Cardile Jr.
(914) 273-6633
Fax: (914) 273-6848
www.interwiregroup.com
Kiswire Trading Inc
(201) 461 8895
Fax: (201) 461-8021
www.kiswire.com
Mapes Piano String Company
Robert Schaff
(423) 543-3195
Fax: (423) 543-7738
www.mapeswire.com
Mount Joy Wire Corp.
George Belforti
(717) 653-1461
Fax: (717) 653-6144
www.mjwire.com
Precision Steel Warehouse Inc.
Steve Kraft
(847) 455-7000
Fax: (847) 455-1341
www.precisionsteel.com
Raajratna (India)
(847) 485-8210
Fax: (847) 485-8254
www.raajratna.com
Radcliff Wire Inc.
Scott Kirkpatrick
(860) 583-1305
Fax: (860) 583-6553
www.radcliffwire.com
Tool King Inc.
Peter Hestad
(800) 338-1318
Fax: (847) 537-6937
www.toolkinginc.com
Ulbrich Stainless Steels & Special
Metals Inc.
Rich Papeika
(800) 243-1676
Fax (203) 239-7479
www.ulbrich.com
Zapp Precision Strip
Byron Ress
(203) 386-0038
Fax: (203) 502-6681
www.zapp.com
Unusual
Applications of
Springs
Perhaps you cannot fly a plane,
Or even sail a schooner,
But there’s something you can surely do
To bring Johnny home the sooner.
The folks here on the home front
Let out the biggest wail
Because the merchant does not have
What he should have for sale.
Chandelier and jazz
Band figures created by
Debbie Dickerhoof,
The Yost Superior Co.
We’re sure there are some war plants
Right near your town or city.
If you don’t have the springs they need,
It really is a pity.
The farmer working in his fields –
This year he’s raising more.
A spring breaks on his tractor –
And does that make him sore!
Now Ma, she does the washing,
’Cause the laundries are too busy.
But when the old machine won’t work,
It surely makes her dizzy.
And lots of gals in factories,
At work for victory,
Are also doing housework,
And that’s no cinch, you see.
For springs in all their gadgets
On you they will depend.
We know that you won’t let them down –
You want this war to end.
So mail your order in right now,
The springs we’ll try to send you,
And help the boys who are out there
A’fighting to defend you.
– W.B. Jones Co., June 22, 1944
SPRINGS July 2008 31
Don’t Let OSHA Play
Games with Your Company!
Hidden Hazards can be Dangerous and Expensive.
SMI’s Safety Audit of your facility will identify
safety hazards and recommend abatements.
The program includes a preliminary interview, a review of
the company’s written programs, a plant floor inspection and
a detailed, written, post-audit report.
Cost: $1,000 for Members, $1,250 for Nonmembers
For more information, contact:
Spring Manufacturers Institute
2001 Midwest Rd, Suite 106
Oak Brook, IL 60523
Phone: 630-495-8597 Fax: 630-495-8595
E-Mail: regs@smihq.org
32 SPRINGS July 2008
IIIIIIISMIII
Spring
Manufacturers
Institute
Ubiquitous Springs
The spring is the source of magic,
beauty, luxury, efficiency, safety,
security and comfort in every
corner of the earth.
by Wallie Dayal and Joanne Gucwa
ey
rk
im
Sta
T
m/
o
o.c
ot
ph
k
oc
St
©i
oday, life without the wheel is unimaginable. Off
and on we are reminded that there is “no need
to reinvent the wheel,” and its basic shape is selfexplanatory to the smallest child. Wheels of all kinds
are an integral part of our existence. Indisputably,
our lives depend on wheels.
T
Springs come close. Compared to the obvious
shape and function of a wheel, their shape is concealed, their function less intuitive. At the same time,
life without springs, the storage devices for mechanical energy that date back to the bow and arrow, is
just as inconceivable as life without wheels.
SPRINGS July 2008 33
It is not surprising that each country has been
trying to optimize the use of springs since the beginning of time. But just as basic human needs are
fairly consistent across cultures, it could be argued
successfully that applications of springs demonstrate universal needs.
Unusual Applications From The UK
Tim Parkinson, chairman, Airedale Springs Ltd.
in the UK provided the following list of unusual applications of springs as compiled by his employees:
• Spring legs for a giant pig. Contestants sat on this pig
during a popular Saturday night TV show in 2007.
• Mounting springs for the head of a horse used in
the London West End musical production of Lord
of the Rings.
• Springs attached to the ends of garden stakes to which
garden twine can be easily tied to make any size or
shape of plant support. They also prevent gardeners
from poking out their eyes when bending down.
• Springs as Christmas tree decorations.
• Springs as tracking aids for sharks (see photographs). The spring is part of a clamping device
that bites into and holds onto the dorsal fins of
sharks (see pictures).
Pictures courtesy of Airedale Springs
The novel idea of making a list of unusual uses
of springs continues to generate lively discussions
at Airedale’s coffee machines. One person may
have a bright new idea for an unusual application
of springs, but colleagues often point out that such
a “new” application has long been conventional in
one way or another.
Complete unawareness of that unusual person
who has figured out a way to improve living standards with the aid of a humble spring tends to be
the norm. A marvelous spring tends to be the handmaiden that makes something work better, faster,
smoother. And yet, this contribution to human
comfort lacks public acclaim. The spring fulfills its
function in seclusion, often noiselessly.
No Quality Of Life Without Springs
It would be exceedingly difficult to exist for a
single day, even an hour without benefiting from
the force of a spring concealed in a gadget, chair, or
appliance. In spite of each person’s daily intimacy
with spring-operated products, the hidden spring is
taken for granted. No one is aware of a spring until
it is broken or worn out.
This attitude is common to people worldwide.
Likewise, technically inclined inventors like to tinker
with springs. This is illustrated by a patent application filed by Margaret Weiser of Tarzana, Calif. It
was published as United States Patent 6 773 768
34 SPRINGS July 2008
entitled, Novelty with spring attached appendages,
in 2004.
Abstract: A spring novelty item which has a head
and appendages attached to a body by means of a
spring connecting means so as to add dynamic and
aesthetic beauty to any garden, kitchen or other
setting.
This patent alone references various other
related patents.
Some Patent References
Novelty with spring attached appendages
1652775
Funk, et al.
1710478
1837662
2663970
2729022
2760303
2816384
3435550
D294843
D301992
D324353
D337358
D382029
Hoppin
Jacobs
Brodrib
Polk
Del Mas
Rexius
Carlson
Lund
Zumwalt
Urso
Orak
Hong Cheng
446/317
D21/204
D11/158
D11/162
D21/160
D21/161
Mechanical radiator
ornament for vehicles
Hat support
Bird form
Ambulatory animal toy
Movable toy bird
Articulated figure toy
Decoy
Animated duck decoy
Baseball novelty
Stork ornament
Flamingo figurine
Blinking bird
Articulated toy figure
Mass vs. Custom Production
At the other extreme, standardized mass production of springs tends to attract the lion’s share of
commercial attention in all parts of the world.
For most manufacturers of springs, “one-off”
applications generate limited interest.
“Fewer and fewer springmakers are willing to
work with these inventors,” says Parkinson. “We are
one of the few companies left who will consider low
volume production.”
But Parkinson’s views may not be as isolated
as they appear. A number of veteran European
springmakers believe that the most interesting and
lucrative springs market can be found in sparsely
publicized “one-off” applications and springmaking
operations.
The View From Japan
Similar logic applies to Japan, where the automotive industry accounts for approximately 70 percent
of springs. There, the springs industry is dominated
by Nippon Hatsujyou (NHK) of Yokohama and Chuo
Spring of Nagoya. These companies invest heavily
in R&D, which has yielded design and performance
improvements. But many of the over 2,000 other
Japanese springmakers also actively contribute to
spring research by sponsoring the metallurgical
research activities and advanced materials science
departments of Japanese universities.
SPRINGS July 2008 35
IF YOU’RE IN THE SPRING INDUSTRY
YOU SHOULD ATTEND
SPRING WORLD 2008
®
October 15-17, 2008 • Donald E. Stephens Convention Center • Rosemont, Illinois
WHAT SPRING WORLD IS ABOUT
We all recognize the fiercely
competitive environment facing the spring manufacturing and wire forming industry.
Attending SPRING WORLD 2008 offers an opportunity to see the newest technology
available in machinery, materials, quality control, grinding, heating and other
processes and services you depend on.
CASMI makes it easy to attend with the most convenient location – the Donald E.
Stephens Convention Center in Rosemont, Illinois – just five-minutes from O’Hare
International Airport. Not to be ignored is the FREE REGISTRATION (prior to
September 20), and the option of registering online, by mail or fax.
THIS IS THE ONE SHOW SPONSORED BY SPRING
MANUFACTURERS FOR SPRING MANUFACTURERS
Starting in 1959, CASMI (Chicago Association of Spring Manufacturer, Inc.) the
show has become renowned for bringing more people together than any other
industry event. It has been called the World’s Best Spring Show!
We understand that it’s difficult to “get away” from your day-to-day responsibilities,
but if you are forward looking, you will not want to miss any opportunity to learn how
to make your business grow.
ATTEND SPRING WORLD!
Attending SPRING WORLD provides a
unique opportunity to network with other spring manufacturers and wire formers in
an informal situation. One on one with others who share your problems and
concerns can be invaluable in gaining new insight to your business. That may be a
bonus on top of seeing the newest technology available to improve your
productivity, quality, and service. You have the further opportunity to speak directly
with exhibitors who can answer questions.
SIGN-UP TODAY!
Mail or fax the registration form provided, or register
online at www.springworld.org. Note the convenient hotel list all within walking
distance of the convention center. Get a FREE shuttle to any of the hotels and you
won’t need a rental car while you are here. If you are driving, we have included a
hotel with free parking and a shuttle to the convention center. Parking is available at
all the hotels. Check with them for current rates. Convention center parking is
available on a daily basis for $13 per day, no overnight privileges.
CASMI MEMBERS LOOK FORWARD TO SEEING YOU IN
ROSEMONT AT SPRING WORLD 2008 • OCTOBER 15-17!
WEDNESDAY, OCTOBER 15 Exhibits Open – 10:00a.m. until 6:00p.m.
THURSDAY, OCTOBER 16 Exhibits Open – 9:00a.m. until 6:00p.m.
36 SPRINGS July 2008
FRIDAY, OCTOBER 17 Exhibits Open – 10:00a.m. until 4:00p.m.
REGISTRATION FORM FOR SPRING WORLD 2008
Attendance Limited to Jobshop Spring, Four-slide, Multi-slide, Stamping, and Wire Form Manufacturers.
Children under 14 years of age will not be admitted. Those under 16 must be accompanied by a responsible adult.
__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I___I__I___I___I___
___I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I___I___I___I___I___I___I___I
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NAME (PLEASE PRINT)
TITLE
__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I___I__I__I___I__I___I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I___I___I___I___I___I___I___I___I___I___I___I
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COMPANY
__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I___I___I___I___I___I___I
I
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___I___I__I__I__I__I__I__I__I__I__I__I__I__I___I___I___I___I___I I___I__I
ADDRESS
CITY
__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I___I___I___I___I___I___I
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STATE
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COUNTRY
PHONE
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__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I___I__I___I___I___I
I
E-MAIL
WEBSITE
Please Check One Category:
(A-1)
■ Spring Manufacturer
(A-2)
■ Exhibitor
(A-3)
___I__I__I__I___I
I
ZIP
___I___I___I__I__I__I__I__I__I__I__I__I___I
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FAX
___I___I___I___I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I__I___I___I___I___I
■ CASMI Member
(A-4)
■ Other (explain) __________________________
Answer the Following Questions:
Is the company a “Job Shop” Spring Manufacturer? Yes ______ No ______ If the answer is “No” what does the company do?
_____________________________________________________________________________________________________________________________________
Check all product categories your company makes:
(B-1)
(B-6)
(B-11)
(B-2) ■ Four Slide
(B-3) ■ Power Springs
(B-4) ■ Compression Springs
(B-5) ■ Flat Springs
■ Extension Springs
(B-7) ■ Torsion Springs (B-8) ■ Wire Forms
(B-9) ■ Spring Washers
(B-10) ■ Hot Wound Springs
■ Stampings
■ Other Products (describe) __________________________________________________________________________________________________
Indicate if you are a member of any of the following spring/metalforming organizations (Check all that apply)
(D-1)
■ CASMI
(D-2) ■
NESMA
(D-3)
■ PMA
(D-4)
■ SMI
(D-5)
■ TMA
(D-6) ■
WAI
(D-7)
■ WFA
Advance registration (received prior to September 20, 2008) is FREE! Registration received at CASMI office after September 20, 2008 will be assessed the onsite
registration fee, and must be picked up and paid for at the show registration desk. Onsite registration fees are: CASMI members & exhibitors $20, non-members $35.
MAIL TO: CASMI, 1601 Bond Street, Naperville, IL 60563, Phone (630)369-3466, Fax (630)369-3773 or Register Online: www.springworld.org
HOTEL ROOMS FOR SPRING WORLD 2008 AND WIRE FORMING
CASMI has arranged for special show rates at the following hotels; single or double occupancy (unless otherwise noted). All provide FREE
shuttle from O’Hare Airport. Subject to the current Rosemont room tax of 13%. Call for reservations. Ask for SPRING WORLD rates.
CROWNE PLAZA CHICAGO O’HARE RATE: $169
Phone: (888) 233-9527 • (847) 671-6350
Book by 9/21/08
TO
AIR
PO
RT
DOUBLETREE HOTEL O’HARE-ROSEMONT RATE: $179
Phone: (800) 222-TREE • (847) 292-9100
Book by 9/22/08
UNITED AIRLINES IS THE OFFICIAL
AIRLINE FOR SPRING WORLD 2008
N
H
SOFOTEL
ITE
L
SKYBRIDGE
DONALD E.
STEPHENS
CONVENTION
CENTER
GENCY
HYATT RERE
O’HA
TO
TA
A/R O
CT ICAG
CH
INTERCONTINENTAL CHICAGO O’HARE
RATE: $199 Standard King • Phone: (800) ICHOTELS
Book by 9/20/08
INTERCONTINENTAL
CHICAGO O’HARE
ASSY
EMBITES
SU
HOTEL SOFITEL RATE: $189 Run of the House
Phone: (800) SOFITEL • (847) 678-4488
Book by 9/20/08
G
PARKIN E
GARAG
REE
BLET
DOU
HYATT REGENCY O’HARE RATES: $169 Single or Double
• $189 Triple • Phone: (800) 233-1234 • (847) 696-1234
Book by 9/20/08
SKYBRIDGE
NE
CROWZA
PLA
EMBASSY SUITES HOTEL O’HARE
RATES: $179 Standard King, $189 Standard Double/Double
Phone: (800) EMBASSY • (847) 678-4000
Book by 9/23/08
United is offering a 10% discount off the unrestricted, fully-refundable coach fare or 2% discount off the lowest applicable fares, to all attendees of SPRING
WORLD 2008. An additional 5% discount will apply when tickets are purchased at least 30 days in advance of the attendees travel. Domestic airfare rates
quotes will be good for three days prior to the Show to three days after the Show (From October 12th to October 20th). International airfare rates quoted
will be good for 7 days before the show and for 7 days after the show (From October 8th to October 24th).
This special offer applies to travel on domestic segments of all United Airlines and United Express flights (UAL/UAX/UA). Convenient schedule and
discounted fares are available through United’s Meeting Desk or your travel agent. Call 1-800-521-4041 and referenceSPRINGS
Meeting July
ID 2008
Number
37 539TP.
Dedicated reservationists are on duty Monday thru Friday 8:00am–10:00pm and Saturday & Sunday 8:00am – 8:00pm EST.
One area of emphasis of this research is weight
reduction in product design. Putting “springs on a
diet” includes springs ranging from the large size
used in the Shinkansen high-speed bullet trains to
micro springs (0.1mm OD) used in medical and precision equipment. Another is memory shape, which
is a mechanical attribute that is critical to a broad
range of applications.
Furukawa Co. states on its website that it was
“the first company in the world to manufacture and
commercialize the super-elastic NT alloy product.”
Applications are as varied as rice cookers, coffee
makers, air conditioners, solar cell positioning for
satellites and water temperature mixing valves.
Japan’s second-largest spring company, Chuo
Spring Co. is adding a splash of color and competitive
advantage to springmaking by offering coil racing
springs in multiple colors. Sawane Spring Co. sells
springs in every color of the rainbow: green, orange,
red and even pink.
NHK claims to have more than 30 percent of the
world market for automotive suspension springs.
Like other springmakers, it anticipates continually
rising raw material costs. To offset them it employs
creative cost-reduction efforts going far beyond the
leading edge Japanese streamlining of the ‘90s. Entire
production structures are now subject to reorganiza-
tion. New production lines are being introduced in
some facilities and production centers are being set
up in China. NHK produces a wide range of springs,
such as suspension, seating, precision applications
and disk drive suspensions. Some of NHK’s springs
are among the smallest produced anywhere in the
world. These take advantage of advanced precision
processing technologies for microcontactor product
development in nanotechnology.
NHK has nine plants in Japan, 23 domestic affiliates and 22 affiliates outside Japan, including five in
the United States. Chuo Spring has four proprietary
plants, a technical center, multiple sales branches,
10 affiliated companies in Japan and another 11
affiliated companies outside of Japan, including
three in the United States.
These multiple locations of both large springmakers utilize Just-in-Time and Lean Manufacturing
production practices that were systematized by
Toyota in the 1950s. Plants, service and R&D centers, sales branches and company affiliates are
located strategically and are quickly accessible to
the major customers they serve.
Like NHK, Chuo Spring also serves non-automotive industries. It makes wheelchair fixtures for
safe attachment to vehicles, rooftop and window
operating systems for sunlight and ventilation,
and fingerprint identification devices; it supplies
the automotive industry with suspension springs,
precision springs and control cables. Customized
springs include low-height coil springs and colored,
printable springs that are flat-ground on both ends
for the racing industry. Chuo Spring is also developing symmetric coiling. Here, the springs on one
side of a vehicle are coiled clockwise, and those on
the other side are coiled counterclockwise. This
reduces friction and improves comfort and steering
performance.
Japanese springmakers are taking other important steps into the future by paying more than lip
service to environmentally conscious manufacturing.
Chuo Spring, for example, is in the process of introducing “clean manufacturing” techniques through a
cold forming process to produce SASC (Side Action
Spring by Chou KK).
Doing Business Japanese-Style
Because most Japanese spring research dollars
appear to be dedicated to automotive development, opportunities may exist in Japan. European
and American springmakers could leverage their
presence in Japan regardless of size. Companies
affiliated with NHK or Chuo provide opportunities
for doing business Japanese-style.
It starts with a “proper” introduction. Businessto-business cold calling is simply not done in Japan.
38 SPRINGS July 2008
(It has, however, become quite an annoyance for
consumers.) A banker, an accountant or an attorney
with whom a springmaker has a relationship — and
who in turn has a business relationship with the
prospective customer — could be a proper conduit.
A businessman (women have made strong inroads
in the public sector, less in the private sector) or
family member who knows both parties could also
make an introduction. Golf outings frequented by the
prospect where the host or coordinator introduces
the newcomer hold promise. A direct approach would
be highly improper and counterproductive in Japan.
Only the patient will ultimately
meet with success.
Japanese business relationships are known for their longevity:
decades, if not centuries. Modern
times and new technologies have
loosened some historically strong
ties providing points of entry. Still,
business relationships are not
established overnight. They are
built on a solid foundation of trust
and “face time.”
Green tea is ubiquitous in
Japanese society and the ritual
of drinking tea is the daytime
refreshment that allows prospective
partners to get to know one another.
It would be a fatal error to proclaim
a lack of time. Alcoholic beverages
join the green tea at evening meals
and unhurried participation is an
important social ritual. But teetotalers need not fear. The Japanese are
not offended by those who decline
alcohol for health reasons.
Alternatively, vendors may want
to host an event. That is appreciated, but it requires deep pockets,
as expenses easily escalate beyond
all expectations.
Dropping a respected brand
name can be helpful, as it engenders respect and builds loyalty. A
Japanese businessman needs to
be convinced beyond doubt before
he is willing to even consider trying
out an upstart product, much less
replace his trusted brand. A new
supplier has a better chance of
convincing a Japanese prospect if
he already supplies a globally recognized company such as Daimler
Benz, General Motors, Siemens,
General Electric or Hewlett-Packard. This will help
legitimize his status.
In addition to a proper introduction, patience,
time, the right credentials and a thorough understanding of the competitive environment is absolutely
essential. This involves more than knowing the
names of competitors and their basic product
offerings. It extends to a thorough knowledge of
competitors’ entire product range, product features
and marketing structure. And the Japanese business environment is not transaction-based, as is
most often the case in the United States.
SPRINGS July 2008 39
In Japan, a transaction must fit within the existing relationship structure and business context, lest
it harm another link in the longstanding Japanese
business configuration. But when a relationship
is established, it tends to be lucrative and longlasting.
Japanese companies also take great care to
protect their good name and go to extremes to avoid
unfavorable publicity. Some have even implemented
a “no quotes” policy except by authorized personnel
because information casually provided had once put
the company in an unfavorable light.
At the other end of the spectrum, some companies claim to have received their best leads into
China on Asian websites. Portals, such as the New
Industrial Springs Directory, launched by Worldwide Industrial Marketplace, which can be accessed
at this URL: http://www.pr9.net/business/
trade/7041january.html, have been established for
connecting springmakers with spring users.
“These technical Internet portals have become
essential today for connecting the progressive
manufacturer with the cutting edge technology of
component suppliers with competitive pricing,” says
Steve Demster, CEO of ROSS Controls, a worldwide
manufacturer of electro-pneumatic control systems.
ROSS Controls consists of a U.S. company and
seven overseas subsidiaries in Europe, Asia and the
Americas.
“In turn, we list ROSS Controls and its products
on such portals as GlobalSpec.com which brings
us sales leads from all parts of the world,” explains
Demster. “Those who ignore Internet sourcing do so
at their own peril.”
In all likelihood, the business of springmaking
around the world is as varied and surprising as are
the applications of springs.
Just like in the days of bows and arrows, springs
continue to be the source of peril and opportunity.
They stimulate the inventor and the springmaker
and pamper or aid the user. They are enablers in
nanotechnology, provide the contact for most batteries and grace garden stakes.
Springs thrive everywhere. Hats off to the ubiquitous spring! ◆
Wallie Dayal is president of Dayal Resources Inc., a Chicagobased firm that helps initiate and support American-European
business. She is a business consultant, translator and writer. Readers may contact Dayal by Web site at www.dayalresources.com.
Joanne F. Gucwa is president of Technology Management
Associates, Inc. in Chicago. She is a Certified Management
Consultant, and has been consulting to Japanese industrial firms
since 1983. Readers may contact Gucwa by Web site at
www.techmanage.com.
40 SPRINGS July 2008
SPRINGS July 2008 41
Photodisc/Punchstock
Continuous Learning
By Brian Tracy
(Editor’s note: Brian Tracy will be one of the
featured speakers for SMI’s 2009 Convention in
Phoenix at the JW Marriott Desert Ridge Resort &
Spa from April 5-7, 2009.)
42 SPRINGS July 2008
hroughout the developed world, we have moved
from an era of manpower to an era of mind power.
We have moved from the use of physical muscles to
the use of mental muscles. Today the chief sources
of value in our society are knowledge and the ability
to apply that knowledge in a timely fashion. In the
information age, knowledge is king, and those people
who develop the ability to continuously acquire new
and better forms of knowledge that they can apply to
their work and to their lives will be the movers and
shakers in our society for the indefinite future.
When you learn and practice the techniques for
rapid learning, when you join the learning revolution, you will learn how to unlock the incredible
powers of your mind. You will learn how to become
smarter, faster than ever before. You will learn how
to become a master of your fate rather than a victim
of circumstances. You will learn how to take com-
T
plete control of your present and future destiny so
that you can accomplish and achieve anything you
want in life.
Knowledge is doubling every two to three years
in almost every occupation and profession, including
yours. This means that your knowledge must double
every two to three years for you to just stay even.
People who are not aggressively and continuously
upgrading their knowledge and skills are not staying
in the same place. They are falling behind. You see
this demonstrated all over the place with massive
lay-offs, declining wages, and growing insecurity in
the workforce. You see it in the increasing bewilderment and despair on the part of people who are
being displaced from low-skill jobs which have either
moved overseas or disappeared altogether. We are
in the midst of a societal revolution where unionized industrial workers are becoming a smaller and
smaller percentage of our workforce each year.
As recently as the ‘50s and ‘60s it was common
to believe that you finished your schooling, got a job
with a large company and stayed with that company
for the rest of your life. This was based on the old
paradigm of learning. In this old paradigm, life was
divided into three parts. First were your “learning”
years, during which you got your education, however
extensive or limited. Then came your “earning” years.
This was the period of time during which you worked
for a living. After that came your “yearning” years.
This was the period of retirement which would be
paid for by Social Security, savings, and pensions.
Today, with workforce requirements changing
so rapidly, you must continually be asking yourself,
“What is my next job going to be?” You must also
be asking yourself, on a regular basis, “What is my
next career going to be?”
Imagine for a moment that your entire company
or industry vanished overnight and you had to start
all over again in an entirely new business doing an
entirely different job. What would it be? And don’t
think this question is speculative or that it applies
to someone else. It is a question that you will probably have to deal with, perhaps far sooner than you
expect. In thinking about your new job and your new
career, here is the most important question of all:
“What do I have to be absolutely, positively excellent
at doing, in order to earn an excellent living in my
new job and my new career?”
The answer to almost every question and the
solution to almost every problem in the world of work
is to learn and practice something new and different.
When you learn how to use the incredible power of
your brain to absorb and apply new ideas and information, you will be able to lead the field and rise to
the top of any profession or occupation.
Here’s another question for you: “What is your
most valuable asset? In terms of cash flow, what is
the most valuable thing you have?” Well, unless you
are very rich, or have a family trust account, your
most valuable asset is your “earning ability.” It is
your ability to earn money. It is your ability to apply
your knowledge and skill in a timely fashion to get
results for which others will pay.
All your education, knowledge, experience,
reading, training, and work has contributed toward
building up your earning ability. According to the
research, the so-called “rich” in America, and in
other countries, are almost invariably people who
started from common beginnings, often with great
disadvantages, and then overcame those circumstances by investing an enormous amount of time
and effort on developing their earning ability. And
you can do the same thing, starting today, or at
any time.
Management consultant Peter Drucker says that
the truly educated person today is a person who
has learned how to learn continuously throughout
life. Tom Peters says that continuous learning may
be the only real source of sustainable competitive
advantage for individuals and corporations. And
Peter Senge, who wrote The Fifth Dimension, says
that only learning organizations, those organizations that are capable of taking in new information,
SPRINGS July 2008 43
adapting it, and using it faster than their competitors, will survive in the fast-changing, competitive
world of tomorrow.
The more you know, the better you will be at
solving problems and getting results for which people
will pay you. The more you know, the more freedom
and opportunity you have. And the more you learn
and the faster you learn it, the more rapidly you
move upward and onward in your career and in
every other area of your life.
Between where you are and where you want to
go, there is almost always a gap, and in almost every
case you will find that you can bridge this gap with
knowledge and skills. In order to get from where you
are to your goals, you have to learn and practice
something new and different. You have to learn new
skills and abilities. You have to learn new attitudes
and methods. You have to learn new techniques
and practices. If you want to be a better parent,
you must learn and practice better parenting skills.
If you want to be a better spouse, you must study
and practice relationship skills. If you want to earn
more money, you have to determine what it is that
people will pay more money for, and then get busy
learning and practicing those behaviors.
44 SPRINGS July 2008
Specific knowledge and specific skills will become
obsolete with the passing of time, but learning how
to learn is a permanent skill that you can use all the
days of your life. The people who join the learning
revolution, and who learn how to learn faster, like
those people who first learned how to operate computers, or learned how to become excellent in their
fields, will be able to earn more in one or two years
of work than the average person earns in perhaps
five or ten years.
By joining the learning revolution, you will
enhance every area of your life. You will be able to
help your spouse and your children unlock and realize more of their individual potentials. You will be a
better friend in helping your friends use more of their
abilities. And you will be a better manager, developing
the skills that will enable you to get far more out of
yourself and other people than ever before. ◆
Brian Tracy is chairman and CEO of Brian Tracy International,
a company specializing in the training and development of individuals and organizations.Tracy has consulted for more than 1,000
companies and addressed more than 4,000,000 people in 4,000
talks and seminars throughout the U.S., Canada and 40 other
countries worldwide. As a keynote speaker and seminar leader,
he addresses more than 250,000 people each year. For more information, phone (858) 481-2977 or visit www.briantracy.com.
SPRINGS July 2008 45
Shot Peening –
Proper Application and Practices
by Kumar Balan
Product Engineer, Wheelabrator Group
he significance and benefits of peening have long
been established in advanced manufacturing
economies. Whether it is peening leaf springs, coil
springs or transmission parts for automotive, or
landing gear and engine components for aircrafts,
the importance of proper peening techniques cannot
be diminished by habit-forming, conventional blast
cleaning practices. As a knowledgeable colleague
of mine explains the difference rather eloquently,
“cleaning is an art, peening is a science!”
Though there are other methods to evaluate
cleaning quality, most commonly cleaning results
are purely visual. A component is either clean or it
isn’t. The degree of cleaning could be subjective to
some extent, but this debate can be quantified using
visual comparators provided by international standards, as is common for plate, pipe and structural
steel. If a particular anchor profile or etch is desired
on a part, the roughness becomes a parameter to be
checked using a profilometer. In comparison, peening is more tangible and defined.
The shot peener is required to achieve a particular Almen intensity, saturate the part and
demonstrate 100 percent or greater coverage. This
intensity directly translates to a particular value of
compressive stress that the component designer has
designated as a requirement. Additionally, deterministic parameters such as size of blast media i.e. steel
shot, conditioned cut wire, glass bead, etc. are also
stipulated by the designer.
Science has taught us more than one path to
arrive at the solution. Sure, there is an optimum
way and that’s what users strive to identify when
assessing their shot peening application.
Peening practices continue to remain underdeveloped in developing economies. The fallacy that
cleaning machines can be used for peening applications is quite widespread. This is driven by three
main causes:
• lack of educational resources pertaining to
shot peening
• inability to dedicate adequate investment for
proper peening equipment
T
46 SPRINGS July 2008
• existing blast cleaning machines and
established ‘cleaning’ habits
In emerging economies such as India and
China, the industry is noticing a major shift in
thought process. As global conglomerates set up a
manufacturing presence and try to implement their
time-tested techniques in these countries, processes
such as peening come under scrutiny. Licensees and
joint ventures of such conglomerates therefore see
the need to clarify and correct their peening processes in order to conform to laid-down guidelines.
In addition to the above, when developing economies
attempt to export products to mature markets such
as North America and the EU, their manufacturing
techniques have to be updated to incorporate proper
peening practices and adherence/compliance to
specifications.
As with blast cleaning, shot peening was also
originally carried out using compressed air nozzles that
propelled steel shot on to the area requiring peening.
While the intended purpose would have been a peened
component, the ultimate result would likely have been
different. This process was carried out manually for the
most part and didn’t involve a great degree of capital
investment. The results were subjective and dependent on operator effectiveness. As production volumes
started ramping up, this process evolved to utilizing
machines fitted with centrifugal type blast wheels.
Centrifugal blast wheels are generally more productive than a compressed air powered blast nozzle
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Blast wheels are ideal, and sometimes the only
solution, when peening parts within a prescribed
time constraint. Such instances occur in highproduction environments such as automotive
when peening leaf and coil springs.
or multiple nozzles. A single nozzle could propel
about 20 to 30 lbs per minute of blast media depending on the nozzle diameter. Whereas a single blast
wheel could easily flow more than ten times that
amount. That said, both types of media propulsion
have their place in spring peening applications.
Blast nozzles are ideal when specific targets/
areas on the part are required to be processed. They
are also utilized when the requirement is to peen
with non-ferrous media such as glass bead and
ceramic. Blast nozzles are more adaptable to automation (nozzle manipulation) than centrifugal blast
wheels. However, blast nozzles require compressed
air, availability of which may not be easy in an existing production environment (A 3/8” diameter at 90
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PSI consumes about 175 CFM of compressed air,
this changes with air pressure fluctuations).
Blast wheels are ideal, and sometimes the only
solution, when peening parts within a prescribed
time constraint. Such instances occur in highproduction environments such as automotive when
peening leaf and coil springs. Intensity ranges could
be anywhere from 0.010” to 0.015” on the ‘A’ scale,
depending on the application. Coverage requirements
could range from 100 percent to 200 percent. The
above results are achieved by processing the parts
through a centrifugal wheel style blast machine.
Process Variables
Some of the process variables affecting peening results such as repeatability and consistency
include:
Blast wheel size/Nozzle size
Wheel Horse Power
Wheel speed
Blast angle
Wheel positioning
Control Cage movement
Nozzle manipulation (stand-off distance)
Location of blast wheels in a centrifugal wheel
type machine (for leaf and coil springs) is quite
important in determining coverage on the entire leaf
or coil surface. Wheel locations are always the result
of extensive testing by peening multiple sample parts
SPRINGS July 2008 47
with different wheel locations and studying the blast
pattern and flow from such locations.
Maintenance Aspects Of Peening Equipment
Blast cleaning and shot peening machines, by
their very nature, are self-consuming and need
routine maintenance. As much
as this seems like
a daunting task,
equipment design
can play a major
role in alleviating
any major downtime and reducing
time for maintenance. Such design aspects include:
• Use of wear-resistant material for centrifugal
wheel housings
• Direct driven blast wheels as compared to belt
drives used in older style wheels
• Machined parts in blast wheel mating surfaces
to ensure leak-free fit
• Ease of assembly (typical blast wheels take
upwards of an hour to disassemble and an
equal amount of time to re-assemble)
• Proper wheel and/or nozzle positioning inside the
blast cabinet to ensure that misdirected media
doesn’t hit cabinet walls causing undue wear
• Use of advanced controls to assist in troubleshooting and isolating trouble spots
User-friendly and intuitive controls
Among manufacturers of quality peening
equipment, it is now common to see touchscreen
style graphic user interfaces. Most machines are
equipped with a PLC (CNC in more sophisticated
machines) to control the programmable features of
the machine.
Machine controls can also be provided with
reporting capabilities which until now was privy
only to high-end manufacturing equipment. Given
such advancement in technology and the economics
of providing such components, there is very little
reason why any peening application cannot be monitored for repeatability and consistency of results.
Summary
Given the knowledge available among suppliers of
peening equipment, historical data about advantages
of peening and advancements in controls technology,
it is clear that this manufacturing process is well
defined. It is now left to the advocates of this process
to derive the benefits and establish sound peening
practices as part of their manufacturing. ◆
Kumar Balan is a product engineer with Wheelabrator Group in
Burlington, Ontario (Canada). His functions include applications
and sales of wheel and air peening equipment. He has more than
17 years experience in the surface preparation industry (Wheelabrator, Pangborn and Blastworks), including contributions to shot
peening education through workshops and articles in technical journals. He has also been acknowledged in assisting with
productivity enhancements through appropriate surface finishing
solutions in various manufacturing plants. He was selected Shot
Peener of the Year in 2006. He can be reached at (905) 320-3824
or email: kumar.balan@wheelabratorgroup.com.
48 SPRINGS July 2008
SPRINGS July 2008 49
Insights on Dollar Volatility
general downward move in the U.S. dollar versus other major global currencies has occurred
over the past few years.These measurable shifts in
currency values, like so many other developments in
“the dismal science of economics,” have a positive or
negative impact upon financial market participants,
manufacturers, exporters, importers, hoteliers, travel
agents, etc.
A
Imagezoo/Punchstock
By Jeff Thredgold, CSP,
Thredgold Economic Associates
50 SPRINGS July 2008
A simple view would suggest that U.S.-based
manufacturers, incurring costs and selling products
based in dollars, would tend to benefit from a weaker
dollar as their ability to compete with foreign producers of similar products is enhanced. Conversely,
periods when the U.S. dollar is stronger lead to U.S.
manufacturers selling products around the world
that are less competitive versus alternative products
produced outside the U.S.
Recent years have found the U.S. dollar particularly weak versus the euro currency. After being
valued by foreign exchange markets at roughly
$1.17 when first introduced in 1999, the euro fell
30 percent in value within two years. A subsequent
rebound and retreat in euro value occurred during
the following two years. A sustained rise in the
euro’s value versus the U.S. dollar has been in place
during the past 3-4 years, with the euro reaching
$1.60 before weakening somewhat.
Winners and Losers
Life has been particularly good for Europeans
traveling to the U.S. as tourists and shoppers over
the past two years as the value of the euro led to
great bargains of all shapes and sizes. Significant
purchases of U.S. real estate by European and English investors have also helped clear excess housing
inventories on the East Coast.
European exporters, however, are sweating bullets as their products have become more and more
expensive in the U.S. European hotels, restaurants,
museums, etc. seeking large numbers of visitors
from the U.S. this summer are keeping their fingers
collectively crossed.
While the national media would have one believe
the U.S. dollar has been getting widely trashed
in recent years, such is not necessarily the case.
According to the Federal Reserve Bank of Atlanta, the
U.S. dollar on a trade-weighted basis has returned
to a level commensurate with the mid-1990s. Currencies simply have periods of significant strength
and weakness, similar to any other “commodity.”
Recent Dollar Weakness
What has led to the more pronounced decline in
the U.S. currency’s value versus the euro, the Japanese yen, the British pound, the Canadian dollar,
etc. in recent years?
Initial dollar weakness was tied to the enormous
trade imbalance the U.S. runs with major trading partners around the world. A trade imbalance
near $750 billion annually, more than $2 billion
daily, simply led to an excess of dollars around the
globe.
U.S. consumers bought goods, oil, autos, minerals, etc. from producers around the globe and paid
for them with more and more dollars. Supply and
demand, the basic premise of economics, actually
does work sometimes. An excess supply of dollars
led their value lower.
More recently, aggressive cuts by the Federal
Reserve to its key short-term interest rates between
September 2007 and April 2008 led dollar-denominated investments to lower yields (or investment
returns) versus comparable investments in euro- or
pound-based investments. The sharp decline in
U.S. interest rates stood in stark contrast to any
lack of interest rate cuts by the European Central
Bank (ECB), even as European economic growth
began to stall.
Why no ECB rate cuts? Because the policy mandate of Europe’s central bank is much more focused
on inflation containment than the Federal Reserve,
America’s central bank. A European history of two
German periods of hyperinflation following World
War I and World War II led to the inflation containment focus.
The result? A weaker dollar.
While the national media would have one
believe the U.S. dollar has been getting widely
trashed in recent years, such is not necessarily
the case. According to the Federal Reserve Bank
of Atlanta, the U.S. dollar on a trade-weighted
basis has returned to a level commensurate
with the mid-1990s. Currencies simply have
periods of significant strength and weakness,
similar to any other “commodity.”
declined slightly over the past 18 months, is still out
of kilter enough to lead to further dollar weakness.
Dollar “bulls” would argue that U.S. currency
weakness of the past few years has been excessive.
Such bulls would argue that some strengthening of
the dollar is likely. These dollar strength advocates
would suggest that the dollar realignment of the past
few years greatly enhances the competitive position
of U.S. manufacturers, suggesting stronger merchandise export growth, which is occurring.
Where Do We Go From Here?
Financial market participants are split as to
where the dollar’s value will move during 2008’s
second half and during 2009.
Dollar “bears” would argue that the recent period
of dollar stabilization will eventually give way to further dollar weakness. These bears would argue that
the U.S. trade imbalance with the world, even as it
SPRINGS July 2008 51
Over time, I look at the relative value of a country’s currency as similar to the value of a company’s
stock. An investor wants to hold stock in a company
that has solid growth potential and higher earnings
prospects. In a similar way, one can view the value
of a currency.
An investor prefers to own a nation’s currency
that has solid economic fundamentals, a competitive
economy, and liquid investment markets. Such a
view favors the United States and its currency.
My View
My outlook for the U.S.
dollar suggests some strengthening, with an expectation that
a modest rebound, especially
versus the euro, will occur
during the next year. What
drives this view?
First of all, prospects for
more impressive U.S. economic growth are enhanced
as the economic weakness of
2008’s first half is likely to give
way to more impressive performance during the
year’s second half, as well as during 2009.
Second, the Federal Reserve has (presumably)
concluded its aggressive monetary ease, with seven
interest rate cuts between September 18, 2007 and
April 30, 2008 trimming the critical federal funds
rate from 5.25 percent to 2.00 percent. At the same
time, pressures upon the European Central Bank to
trim its key interest rate could be intense during the
latter part of 2008, potentially reducing the interest rate differential between euro-denominated and
dollar-denominated investments.
Third, the national media’s constant negativity
toward the U.S. housing sector could move toward a
more neutral stance, potentially leading numerous
global investors to see greater value in American
housing, thus stimulating demand for dollars.
Finally, further reduction in the U.S. trade
imbalance with the world is likely, especially if oil
prices decline during latter 2008 and during 2009
from recent levels above $120 per barrel. ◆
Jeff Thredgold is president of Thredgold Economic Associates,
a professional speaking and economic consulting company based
in Clearfield, Utah. He spent 23 years with KeyCorp, one of
the nation’s largest financial services companies as senior vice
president and chief economist. He currently serves as economic
consultant to the $50 billion Zions Bancorporation, with banks
in ten states. He can be reach at (888) 847-3346, or email: jeff@
thredgold.com.
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52 SPRINGS July 2008
Fighting For a
Level Playing Field
One man’s mission is to see
international trade that is fair to all
©iStockphoto.com/Drew Hadley
By Gary McCoy
“M
y belief is international trade should be fair
to all,” explains Bill Hickey, president of
Lapham-Hickey Steel Corporation. Unfortunately,
Hickey believes all the economic theory he learned
about free and fair trade has been thrown out the
window in recent years.
In addition, to running Lapham-Hickey Steel,
a metal service center headquartered in Chicago,
Hickey has become a passionate spokesman for the
effect of currency manipulation on manufacturing
companies and their employees. In a nutshell, his
fight is to get the U.S. government to level the playing
field for U.S. products with Asian competitors.
Lapham-Hickey Steel started in 1926 and currently employs 500 employees and has customers of
all sizes, including many SMI member companies.
A Wake-Up Call
“My wake-up call on this subject (currency
manipulation) occurred in the summer of 2001 when
one of our long-term customers in Wisconsin asked
for a meeting to talk about their business,” explained
Hickey. “He told me they were no longer going to
purchase steel products from our company, but
would purchase the parts that they had produced
from China and assemble these parts in their plant.
The finished machined parts delivered from China
would cost less than the raw steel product that we
sold to the customer.”
Hickey says this customer reduced their staff of
higher skilled and income employees and retained a
few lower skilled and income employees to assemble
and ship their product.
It has been seven years since Hickey lost his first
customer. “Since then, there has been no effective
action taken by the government,” said a frustrated
Hickey.
He says this visit started his research into how
this economic event could take place. And it begged
Hickey to answer the question: “How can China
deliver finished, machined products to the United
States at less than the cost of the raw steel?”
A Coalition Forms
The past chairman of the Metals Service Center
Institute (MSCI), Hickey has been able to answer that
question through his involvement with the China
Currency Coalition. The Coalition is an alliance
of industry, agriculture, and worker organizations
whose mission is to support U.S. manufacturing by
seeking an end to Chinese currency manipulation.
The MSCI is a member of the Coalition, which mostly
consists of supply-chain industries such as primary
metals, fabricated metals, plastics, electronics, textiles, small- and medium-sized manufacturers and
labor organizations.
“During this time the industrial economy in the
United States was in recession. Tens of thousands
SPRINGS July 2008 53
of manufacturing jobs were disappearing each
month. As these jobs vanished, our trade deficit
with China exploded, but the value of the Chinese
currency did not move,” commented Hickey. “This
is when I realized that what China had done in the
mid 1990’s was to devalue their currency by about
70 percent against the U.S. dollar, and freeze the
value at that exchange rate by intervening in the
exchange markets.”
Hickey believes this guaranteed that the Chinese manufacturers could ship massive amounts of
products to the United States at “The China Price.”
Japan, which engaged in similar tactics, was not
far behind.
“As I realized that the domestic manufacturing
companies could not compete with Asian governments,” said Hickey, “I began to witness a structural
decline of the U.S. manufacturing sector, and I was
not alone.”
An Uphill Battle in Washington
It was a little over a year ago, in May of 2007 that
Hickey testified before the subcommittee on Trade of
the House Committee on Ways and Means. He says
the frustration is “that it’s a year later and nothing’s
happened” in regards to the currency manipulation
struggle.
54 SPRINGS July 2008
Sadly, he says that as of 2007 the Chinese trade
deficit with the United States ballooned to an all-time
annual high of $256 billion, up from $233 billion in
2006. In the meantime, as Hickey point outs, millions more manufacturing jobs have been lost.
“When the Chinese devalued their currency in
the early 1990’s, there was a trade surplus of about
$10 billion — now that trade surplus is over $250
billion,” explained Hickey. “This trade deficit should
lead to appreciation of their currency, but China
does not want that to happen because if their currency appreciates, they would not be able to export
manufactured goods to the United States.
“That’s kind of the mess we’re in and the Chinese
have ignored us as we’ve tried to get them to address
the issue,” said Hickey. “Certainly this Administration has been horrible in addressing the issue and no
one knows what the next Administration will do.”
Hickey said that every time the Administration
has been pressed for action on the currency, those
pushing for action were either “insulted or ignored.”
Fortunately, he says Congress has been marginally
more responsive though no legislation has yet to
be passed.
The two strongest advocates that the Coalition has
in Congress are Representatives Tim Ryan (D-OH),
and Duncan Hunter (R-CA). They co-sponsored H.R.
In his 2007 congressional testimony, Hickey said
“We, as a country, need laws that ensure our companies and employees are not going to be destroyed
by a policy of neglect by any Administration at any
time.”
The battle continues and while Hickey and the
Coalition have focused primarily on China, he says
it’s a much bigger problem. “Japan, South Korea,
India and others are using mercantilist currency policies to engineer an artificial advantage in both their
own markets and the U.S. market,” says Hickey.
“As I realized that the domestic
manufacturing companies could not
compete with Asian governments,” said
Hickey, “I began to witness a structural
decline of the U.S. manufacturing
sector, and I was not alone.”
1498 in the last Congress to address the currency
manipulation situation but the bill never made it to
a vote on the floor of the House.
Currently, the Ryan-Hunter bill, H.R. 2942,
would provide trade remedies that Hickey believes
are consistent with international law and that
would enable injured U.S. companies and workers
to defend themselves against the damaging effects
of currency undervaluation.
A similar bill in the Senate is sponsored by
Debbie Stabenow (D-MI), Jim Bunning (R-KY), and
Evan Bayh (D-IN).
Hickey is still hopeful that a legislative remedy
can be achieved, but he is not currently optimistic.
Not a Protectionist
Unfortunately, through his battle Hickey has
been labeled by some as a “protectionist,” which he
says isn’t true. “I’m not a protectionist,” exhorted
Hickey. “I’m for the concept that trade is good, as long
as it’s good for both parties and as long as it’s fair.
“If you’re not efficient in the United States, on a
level playing field, then I say: ‘Fine we’re going to lose
those jobs if we are inefficient,’” explained Hickey.
“If we are efficient and the other country is allowing
subsidies, be it through currency manipulation or
direct subsidies, then the government has to say
‘this is not a level playing field and we are not going
to transfer our wealth creation to other countries.’
That’s all we’re saying.”
Get Involved
Hickey exhorts SMI members to get involved in
the issue.
“Contact your Congressman and Senator and
tell them to get behind this legislation,” he pleads.
“We need to encourage leadership on this issue...
someone in the House and Senate who will stand
up and get something done to help correct the loss
of jobs and the trade imbalance with China.”
He goes on to say, “The frustration I have is that
this is an issue about the lifestyle of the American
public; this is an issue about the wealth generation
of this country,” said Hickey. “Making products and
making goods are what give us wealth. You either
mine it, you grow it or you manufacture it, because
the problem is if just printing money gave us national
wealth then Zimbabwe would be the richest country
in the world. The problem is the people in Washington just don’t understand this.”
As Hickey continues his crusade for a level
playing field, he encourages springmakers to get
educated and get involved.
As a start, Hickey suggests going to the China
Currency Coalition website, www.chinacurrencycoalition.org, to learn more about the issue. ◆
Gary McCoy is managing editor of Springs magazine. He is
the president of Fairway Communications, a public relations
and marketing communications firm located in Elgin, Ill. He is
a former syndicated columnist for Motor Matters, a prominent
automotive syndicate serving small and major daily and weekly
newspapers across the U.S. He is a regular contributor to
Aftermarket Business, Aftermarket Insider, and APRA Global
Connection magazines. He can be reached at (847) 622-7228,
or email: gmccoy@fairwaycommunications.com.
SPRINGS July 2008 55
Raymond Medici/Stock Illustration RF/Getty Images
Health Insurance Cost Containment
Trends Create New Opportunities for SMI
By Henry Trevor
n today’s health insurance market there are several
time-tested methods for reducing health insurance
premiums. They include, changing carriers, using
preferred provider organizations (PPO) or health
maintenance organizations (HMO), changing the
plan design to a less-expensive plan, implementing
consumer-driven plan designs or joining an association health plan.
Let’s take a look at the benefits and challenges
that go along with each of these premium reducing
approaches and a unique program available to SMI
members.
I
Changing Carriers
Changing carriers may be just what an employer
needs to reduce premiums. Some carriers use a
similar evaluation process, which means the premiums will essentially be the same until you find a
new carrier that takes a fresh approach.
Benefits: Thanks to some legislative changes it
is now easier for groups of 50 employees or less to
change carriers. With small group reform, insurance
carriers actively writing business must issue quotes
to employer groups of 50 or less employees, and
guarantee coverage issue if the group accepts.
Challenges: It is important to find a carrier who
understands your business and has high ratings
for financial strength through independent rating
organizations. Look for opportunities through new
arrangements with time-tested carriers who have
excellent reputations and are recommended by
professional insurance brokers.
56 SPRINGS July 2008
PPOs and HMOs
Using preferred provider organization (PPO)
networks and health maintenance organizations
(HMOs) enable employers to obtain discounts on
retail charges for healthcare products and services,
which may mean a lower premium.
Benefits: With PPOs and HMOs, employers
should focus on the level of discounts and the level
of access to providers: doctors, hospitals and clinics. Different carriers have different success rates at
obtaining better discounts. Take a look at how each
carrier quotes for the same benefit levels to locate
the carrier with the best discounts.
Challenges: Pressure from providers to raise fees
is one issue facing HMOs, which were traditionally
low-premium cost alternatives. This trend means
HMO costs are rising faster than PPO prices. Adding
copays to services not traditionally seen in the HMO
environment is one way to combat this trend. Examples would be emergency room copays or inpatient
hospital stay copays. More than ever, however, PPO
options are looking more and more attractive for
maintaining level premium increases.
Changing Plan Design
Changes in plan design are the most commonly
used attempt to reduce costs. However, in an environment where it’s tough to recruit and hold on
to qualified employees, an employer must be sure
they’re not too far on the leading edge of benefit
reductions. There are more creative ways to save
money on benefit changes and not reduce employee
benefits, such as health reimabout the actual cost of the TV?
There is an old adage that
bursement arrangements (HRAs).
80 percent of an employer’s Since TVs are not purchased that
Benefits: With an HRA, an
way, consumers shop for the best
insurance claims are
employer may purchase less-exTV they can buy for their money.
pensive, higher-deductible plans
Likewise, it’s not unheard of for
generated by 20 percent
from an insurance carrier to
individuals in a QHDP to walk into
of the employer’s plan
deliver the same benefit level, or
a doctor’s office and negotiate a
members.That rings true
a slightly modified benefit level,
price for the visit.
to employees and dependents.
The QHDP under health savwhen it’s said that 90
Because HRAs are owned by the
ings account (HSA) guidelines
percent of the U.S.
employer, he or she decides how
allows for either the group or the
population incurs less
to fund the HRA: how much to
individual to establish an HSA
contribute, including whether to
bank account, which is owned by
than $500 in medical
share a portion of the difference in
the member — not the employer.
expenses in a year.
premium with employees to cover
Money can be deposited into the
the gap in coverage from the prior
account on a pretax basis and grow
plan to the new one.
tax-free. Funds can be withdrawn to pay for qualiThere is an old adage that 80 percent of an fied healthcare expenses tax-free. But like a 401k
employer’s insurance claims are generated by 20 retirement plan, funds withdrawn for expenses other
percent of the employer’s plan members. That rings than qualified healthcare are taxed and subject to
true when it’s said that 90 percent of the U.S. popu- a penalty.
lation incurs less than $500 in medical expenses
Challenges: A plan that is well thought out and
in a year.
well communicated can be a welcome change and
With an HRA, an employer could move from a enable employers and employees to save money on
$500 deductible to either a $1,000 or $1,500 deduct- insurance. Employees need information on the cost
ible, save 10 to15 percent on insurance premiums of healthcare and alternatives, making it important
and help fund the difference in exposure with the to bring in the tools (helpful websites), or be sure
20 percent of his employees/dependents who use that your carrier provides tools to inform employees
more than $500 in medical expenses through the about the cost of healthcare and prescription drugs.
TPA’s administration of the plan.
However, when a consumer-driven health plan is not
Challenges: As with any change, ensuring implemented and communicated well, employees
employees embrace this new plan and new way of can view it as a big “take-away” from their previous
thinking about their healthcare is the challenge.
plan. This is especially true when there are hourly
workers who now find they have lost their drug card
Consumer-Driven Health Plans
copays and office visit copays, and have a larger
Implementing a consumer-driven health plan deductible.
can bring about premium savings. The most
common approach is to move from what is referred Joining an Association Health Plan
to as a “first-dollar” plan, a PPO plan with copays
Become a member of an association health
and a prescription drug card, to a plan that meets plan to benefit from a larger risk pool that can help
the government’s definition of a qualified high- lower overall costs. This option is now available to
deductible plan (QHDP).
SMI members, as well as to members of four other
Benefits: The QHDP has minimum and maxi- participating metalworking associations.
mum deductible and out-of-pocket ceilings, no doctor
Benefits: Association members may be able
office copays and no prescription drug card copays. to enjoy savings by participating in an association
In a way, it’s like moving to the plans that were popu- health plan formed by the members of the associalar before managed care, but with higher deductibles. tion for the sole benefit of the membership. When an
The term “consumer-driven” comes from the belief association health plan is well planned and carefully
that if the low deductible and other low benefits managed, the membership may benefit from lower
are stripped away, the insured individual becomes costs, while still maintaining robust benefits.
more aware of the cost of healthcare consumption,
This savings potential comes from volume purultimately becoming a better consumer.
chasing where the cost of administration is reduced
One way to look at this is to consider buying a due to the large number of plan members sharing
television. If we had to pay only a copay of $20 to the cost. Another important factor is the financial
receive a nice High-Definition TV, why would we care arrangement used by the association’s health plan,
SPRINGS July 2008 57
which may have a huge impact on
the cost of buying insurance when
it’s set up in a progressive fashion
that allows the plan to keep any surplus and help drive down the overall
insurance risk.
Challenges: Be wary of endorsed
plans that offer only a discount
off of the “book rate” and no other
comprehensive benefits. Having the
association health plan fully insured
by a carrier with proven experience in
these types of arrangements is a key
factor in achieving savings potential.
The plan, available from Trustmark Affinity Markets, has the best
possible financial arrangement and
is fully insured by Trustmark Life
Insurance Company or Trustmark
Insurance Company, depending
on the location. Trustmark is an
affinity market leader with a nearly
100-year track record and more
than 50 years of association health
plan experience.
The arrangement between the
insurance company and the MMC’s
life health trust, established by the
five associations, allows the trust to
own the surplus, which can help reduce risk charges
and can earn interest. These three elements —
surplus, reduced risk charges and interest earned —
are additional factors that can make an association
health plan an attractive alternative in a world
where competition between carriers is shrinking
and answers for help in reducing costs are scarcer
than in the past. No other insurance program, except
for self-funding, has these cost-saving benefits.
It is analogous to paying yourself to be your own
customer.
Plus, it’s easy to obtain a quote for the MMC
plan. All you need is a member company’s census
containing the employee’s date of birth, gender and
dependent status (employee only, employee and
spouse, employee and child(ren), or employee and
family).
A proposal is then generated in a few days for
the member group to review. Underwriting is the
next step. For firms without experience, enrollment
is completed over the phone, with no paper forms to
fill out or chase down. Employees simply call into
a call center and spend about 10 minutes providing an application over the phone. Final rates are
produced about three days after the final phone call
is completed. This translates to an easy, paper-free
way to save money.
If this sounds like something you’ve been looking for,
please contact me at (708) 223-3338 to learn more or
obtain a quote. Or email: henryt@pro-source.com. ◆
Changes in plan design are
the most commonly used
attempt to reduce costs.
However, in an environment
where it’s tough to recruit
and hold on to qualified
employees, an employer
must be sure they’re not too
far on the leading edge of
benefit reductions.
Solution for SMI
The Spring Manufacturers Institute and four
other metalworking associations, Non-Ferrous
Founders’ Society, Precision Metalforming Association, Industrial Fasteners Institute and the Forging
Industry Association, have banded together to create
a true association health plan for the benefit of their
members under the Metalworking Manufacturing
Coalition (MMC) Trust Insurance Program.
Henry Trevor, a senior sales executive at ProSource Financial,
LLC, has nearly 25 years experience in the health insurance
industry. He has expertise in working with employer groups of all
sizes, including affinity organizations that bring health plans to
their member groups. He is a licensed insurance agent in many
states, holds an MBA from DePaul University, and can be reached
at (708) 223-3338 or henryt@pro-source.com.
58 SPRINGS July 2008
WHAT ARE YOU WAITING FOR?
Ask for a quote today!
AS A MEMBER OF THE SPRING MANUFACTURERS INSTITUTE (SMI),
you have access to the Metalworking Manufacturing Coalition (MMC)
Trust program, an exclusive group health insurance program with
health, prescription drug, dental and life insurance in one
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Plus, joining together with other participating MMC member groups
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The MMC Trust plan is administered and underwritten by Trustmark
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SPRINGS July 2008 59
A COMPREHENSIVE PREMIUM RESOURCE
Our goal is to support your spring manufacturing business with the highest quality,
best performing strip in the industry. We have engineered our facility to far exceed
industry standards and to provide the best product and service possible. With our
mill facility in Dartmouth, Massachusetts, we offer a supply chain that sets us apart
and insures continuity of supply and quality to you. Our commitment to excellence
begins with our employees, our processing equipment and the materials we produce.
Our focus and customer service is what sets us apart.
Zapp Precision Strip, Inc.
East Coast Service Center, 100 Benton Street
Stratford, CT 06615, Phone 203 386-0038, Fax 203 502-6681
ecsc@zapp.com, www.zapp.com
60 SPRINGS July 2008
zp194_193x263_rz.indd 1
21.08.2007 13:30:20 Uhr
Inside SMI
SMI Staff Focus: Dina Sanchez
Administrative Coordinator
Family: Husband, Scott, twin daughters, Veronica and
Vanessa, 11 years old, two dogs and a cat.
Started at SMI: May 2008
Before that, I was: Organizing events for Community
Support Services, a non-profit that serves people with
developmental disabilities in the western suburbs.
My most outstanding qualities: Optimism and loyalty.
Favorite pastimes/hobbies: Reading, family events,
walking the dogs.
If I weren’t working at SMI, I would: Be reading when I
probably should be doing laundry.
If I were stranded on a desert island, I would want
these three things with me: My family, a library full of
books, and enough food until the rescue party finds us.
Pictured l-to-r: Vanessa, Dina, Veronica and Scott Sanchez
Best times of my life: Watching my girls grow, change
and learn new things every day.
I knew I was an adult when: We bought our first house
and had to sign about 27 forms.
The one thing I can’t stand is: Liars.
A really great evening to me is: A dinner I don’t have to
cook, a movie my whole family can enjoy, and a full night of
sleep!
Favorite book/author: Anything by Jeffrey Archer, J.K.
Rowling or John Irving.
Favorite song/artist: Anything by Journey, Sting/The
Police or Chris Isaak.
Favorite food: Sushi, cheese, chocolate.
I’d like to be remembered at SMI for: Being friendly,
helpful and knowledgeable.
But people will probably remember me for: That’s a
hard one. I just want everyone to meet me first! ◆
Lots of Information and Worn Shoes
A Report on wire/Tube/Metav 2008
Düsseldorf, Germany, March 31 – April 4, 2008
by Scott Rankin, Vulcan Spring & Mfg. Co.
Another trip to Germany for a trade show and as
usual it’s raining in Düsseldorf. I get in at 7 am and
head for the hotel. The cab driver tells me there’s
no train strike today so I can use the rails to get to
the Messe. I used most of the flight to prepare my
game plan for the wire/Tube/Metav shows. Planning ahead is the only way to see all the people and
products I need to see. I’m glad that the hotel room
is ready, so I head upstairs for a shower and a 10
minute nap.
As I walk to the train, which is by far the easiest
way to get to the Messe in Düsseldorf, the rain slows
a bit. The train is full of people all quietly going to
the show. The quiet is partly from the early hour
and not knowing what language to speak. After the
train stops at the Messe station, everyone heads for
the escalator which brings you up to the entrance
of wire/Tube/Metav 2008. I notice that in addition
to the 17 regular exhibition halls there are two new
ones this year, Hall 8a and 8b, to accommodate more
show exhibitors.
SPRINGS July 2008 61
There’s an excitement and buzz about the hall
with high expectations from exhibitors, as well as
visitors. This show is held every other year. So if you
miss this opportunity you have to wait another two
years to see what’s new in the wire forming and tube
industries. I am more interested in the wire side of
the show but the new Metav area, which has assembly and production equipment, is also of interest for
me. My plan is to start in hall 9 and head right to
the North American Pavilion to see who’s here from
North America.
As I enter the first hall it’s clear that this is going
to be a long week. I’m wearing my most comfortable
shoes because I plan to see all 2.85 million square
feet of this place. There are 2,200 exhibitors here
from 50 countries with 629 on the Tube side and 805
on the wire side. That leaves over 800 on the Metav
side. With over 73,000 attendees, the show will take
some time and I have to stick to my plan.
In the past I’ve wandered the show to find what
I need. After burning up a pair of shoes, I never
found what I wanted. This time I have appointments
and prints, and I know when and
where I need to be. Lunch each
day includes the local alt beer and
the chance to sit and go over my
exact needs for a new spring coiling
machine, material or process.
This is not like American shows
with shorter time frames and
booths not as grand or expansive.
In America we tend to walk, look
and keep walking. In Germany you
walk, see something interesting,
then you sit and talk and study
your needs compared to what they
have to offer. You might go back to
the same booth three days in a row
to continue the conversation and
gather all the product information
you can.
Wire Products:
My first stop at the North
• Chrome Silicon
American Pavilion was Fenn Tech• Tempered
nologies. A brief “hello” and then off
• Music
to the other 23 booths in the group.
• Shaped
I talked with steel suppliers and
• Hard Drawn
machinery builders as well as com• Plated
ponent part makers and outside
• Rocket
Mount Joy Wire Corporation is a
service people. This could get con• Low Carbon
manufacturer of high quality spring wire
fusing. After each visit I took a few
used in a variety of applications. Our proven
minutes to write notes so I could
Capabilities:
track record coupled with expert technical
keep the information organized.
• 100% Chemical Cleaning
support and manufacturing versatility
There were 37 North American
• Lead Patenting
continues to make us invaluable to our
companies represented in wire and
• Spheroidize Annealing
customers. Mount Joy Wire’s capabilities
25 in tube, and I planned to see
• Oil Tempering
are unmatched in the industry, so contact us
them all.
• Electro Galvanizing
and see how we can help with your next
After visiting the North Ameri• Tinning
spring wire application.
• Sizes down to .002”
can companies I headed to unknown
territory called “the rest of the fair.”
Each conversation started with
“Sprechen Sie Englisch?” I would
hope for a “Yes” but in many cases
I got a “No” answer and they began
You are never far from our wire.
to walk away. I would then turn
to my broken German and ask for
Mount Joy, PA 17552 • Tel. 717-653-1461 • Toll Free 800-321-2305 • Fax 717-653-6144
help. Most of the time, I got the
www.mjwire.com
ISO 9000 registered company
62 SPRINGS July 2008
see the machines perform. They also had
plenty of room at their counter for a coffee
or a beer, so I got a break from the action. I
spent quite a bit of time at one machine that
intrigued me and got all the information my
brain could hold from a very knowledgeable
machine operator. I wanted to come back
when the crowds were smaller to spend more
time on this machine.
Today’s focus is on materials, so I went
back to my plan to find the perfect ones.
This was an interesting time to get more of
an education and to meet new people from
the European markets. I enjoyed all of the
variety of machines and products.
Night is not the time to relax in
Düsseldorf. After the show I jumped on
the train and went to the Altstadt for a
little German food and drink. I always go
to Schwiene Janes on the first night and
indulge in a schwienehax with sauerkraut
and a beer. This is not a low calorie meal
but I believe the beer acts as an equalizer
and counteracts the calories from the meal.
(That’s my story and I am sticking with it!)
So after dinner and a walk along the Rhine,
I was back on the train to the hotel. What a
day. Tomorrow will be here soon.
The second day is cold with light rain, so
I put on my hat and head for the train. There
are no seats, so I stand and travel silently to
the show. I think about what else I need to
see and enthused to find my next needle in
this haystack. Today is spent finding more
new products and looking back at familiar
ones to see if they now fit my needs. I set off
During his trip to wire, Tube and Metav in Düsseldorf, Scott Rankin
on my planned path and this time walk 20
(left) met with Federico Visentin, newly elected president of the
minutes to the far end of the show to work
European Spring Federation (ESF).
my way back to the front. This is another
information I needed. But as I spoke more they wonderful day of finding new ideas.
got more comfortable, forgot my first question, and
The following days are similar, with one day at
began to speak much faster. This was where my Metav and one day at Tube. I return to visit some
“Konnten Sie bitte langsamer sprechen?”(could you booths to make sure I have all my facts straight. I
speak slower please?), would come to my rescue. In find time to sit and think and enjoy reunions with
most cases a successful meeting was accomplished, old friends from SMI or past shows.
so I could move on and keep my notes.
The week ends with a few miles worn off of my
As the day progressed it seemed like a great shoes and lots of information to review on the plane
time to stop at the Wafios booth. This is kind of like ride home. I’ve succeeded and conquered another
saying an aircraft carrier is a boat, since Wafios had Messe Düsseldorf show. Exhausted for the efforts,
one of the largest booths at the show. With all dif- I’m sure there’s nothing I’ve missed and no stone
ferent machine types, this was a wonderful exhibit unturned. Except maybe that one booth …I’ll be
of Wafios technology. Plus, they had many operators back in two years. ◆
and salespeople available to help. Of course this
also meant there were plenty of customers present
to look at the machines, talk about their needs, and
SPRINGS July 2008 63
Inventory — Good vs. Evil
Practical actions to reduce inventory and increase profits.
By John Mackay, Mackay Research Group
Inventory accuracy can impact profits. Suppose
your records show that you have the parts or raw materials on hand that production needs, but when shop
employees go to get them, the materials aren’t there.
Inventory is an asset account on the balance sheet. In
this case, however, inventory has a major impact on
production. If materials are not there when you need
them, production stops. That affects the income statement and, of course, profits. If you improve inventory
accuracy, production can run more smoothly with less
down time, manufacturing labor costs are reduced, and
profits will rise.
Bad housekeeping may be a sign of troubles in
a factory. Too much stock on the shop floor can be
a sign of production problems. Excess stock creates
uncertainty; people never know what to work on next.
It also hurts employee morale by making the work
environment messy, cluttered, and cramped. There
are, however, actions you can take to reduce inventory
and increase profits.
1. Figure out how much work you have to do each
day to get to the point where you have just one day’s
stock out on the floor.
2. Put up a chart to track inventory and current
production. That reduces indecisiveness out of the shop
floor while improving the work space, and housekeeping. It also improves worker morale and motivation.
People will work with what’s there. They won’t allow
problems to accumulate. They will know how to schedule their labor. As a result, there will be a continuous
flow to the production line because now there is a limited
amount of stock. They have to make every piece count.
Volume will pick up.
According to the SMI Annual Market Report, the
typical spring manufacturer has approximately 24
percent of assets invested in inventory. Ten percent of
the asset investment is in raw material, and 14 percent
is in work-in-progress (WIP) or finished goods. Inventory turnover for the typical spring manufacturer is 6.5
times per year.
High profit spring manufacturers, however, turn
their inventory over 11 times per year. In addition,
they have only 20 percent of their asset investment
tied up in inventory. Perhaps more importantly, only
7.7 percent of the asset investment is in WIP and/or
finished goods.
If production flows perfectly then there is no finished goods inventory, if customer valued products
are the only ones produced then product design is
simplified and effort is only expended on products that
customers want. ◆
John Mackay is president of Mackay Research Group, a survey
research organization that specializes in profitability and
compensation research for manufacturing trade associations.
Mackay Research Group conducts the SMI Annual Market
Summary survey of spring manufacturer profitability each year.
He can be reached at john@mackayresearchgroup.com or by
calling (720) 890-4255.
Loren Godfrey Named
Honorary Member
The SMI Board of Directors has announced
the election of Loren Godfrey as a new Honorary
Member of SMI. Godfrey was an active volunteer with
SMI, serving as chair of the Technology Committee
for many years. During his career in the springs
industry, he worked as the lead technology person
at Associated Spring and several other spring companies. Godfrey is retired and living in Farmington,
Conn. with his wife, Cynthia. ◆
64 SPRINGS July 2008
SPRINGS July 2008 65
Cautionary Tale XXXVIII
The Lessons of History
Spring
Technology
By Mark Hayes
nusual for this column, the moral of the tale
comes first. The lesson is this: we can learn from
the important developments in the spring industry
of the past because they are likely to point the way
forward in the 21st century.
When I attended the Japan Society of Spring
Engineers (JSSE) conference in Nagoya last year,
I was asked to write a few words about the most
important stepping stones in the evolution of the
spring industry worldwide. The Japanese who were
at JSSE urged me to prepare a cautionary tale on
this subject. They reminded me of this when I saw
them again at wire 2008 in Düsseldorf. So I will
not delay any longer. It is the Japanese view that
a disproportionately large number of the historical
developments originated from the UK, and that is
my view too.
I guess the history of springs began with horse
drawn cart suspensions and bows for firing arrows.
Such springs were made from wood and/or gut
strings. The first mechanical contrivances that
required a better spring than could be made from
wood were locks and guns. The availability of brass
and steel, to use as springs materials for locks and
guns, was very limited. This made these items expensive, but it wasn’t everyone who needed them.
The first mechanical device that required springs
in larger quantities was clocks. After the invention
of the pendulum clock by Christian Huygens in the
Netherlands in 1656, the invention of the hairspring
U
Mark Hayes is the senior metallurgist at
the Institute of Spring Technology (IST) in
Sheffield, England. He manages IST’s spring
failure analysis service, and all metallurgical
aspects of advice given by the Institute. He
also gives the spring training courses that
the Institute offers globally.
Readers are encouraged to contact him
with comments about this cautionary tale,
and with subjects that they would like to
be addressed in future tales. Contact Hayes, by phone at (011) 44
114 252 7984, fax (011) 44 114 2527997, e-mail m.hayes@ist.org.
uk, or in person at Springworld, October 15–17, 2008.
66 SPRINGS July 2008
for table clocks appears to have occurred contemporaneously and coincidentally by Huygens and Robert
Hooke. Hooke, an English physicist, discovered
his law that is fundamental to all springs in about
1660 and wrote it down in terms that scholars could
understand in 1680. His first obscure definition
was motivated by the need to keep the commercial
implications of his invention for his own benefit. It
said that the load applied to a piece of wire caused
it to deflect and that load and deflection were proportional to each other. He also recognized that the
area under the linear portion of the stress strain
graph, was a measure of the energy stored and a
spring is “a device for storing mechanical energy in
the form of elastic strain.”
The next significant development was a process
for making high quality steel. Benjamin Huntsman,
a clockmaker in Doncaster, England, found that the
availability of steel for springs was the major obstacle
to making a good living. He set his mind to develop a
process for making steel which lead to the invention
of the crucible process in Sheffield. In this process
steel became molten, slag floated out and really high
quality spring steel resulted. Unfortunately, Huntsman soon realized he could make more money by
producing steel for knives and arms than he could
out of spring steel. Was this the start of the spring
industry becoming the poor relation compared with
other steel products?
The next development was high quality spring
wire. That became available following the granting of
the patent taken out by James Horsfall in 1854. The
Webster Company had already been making steel
wire for over 90 years out of crucible steel. It became
Webster and Horsfall in about 1850 when Horsfall’s
heat treatment processes enabled higher strength
wires. Patented wire has a pearlitic microstructure
that becomes strong enough for springs during the
wire drawing process. Today hard drawn wire of
this type is called music wire in some countries and
piano wire in others. However, the term piano wire
pre-dates the patent as it was used in the making
of a piano that the Broadwood Company in London
gave to Beethoven in 1818, and doubtless for many
years before that.
The development of automatic machines for
making springs started in the late 19th century and
that would require a whole book to describe. The
next material development of significance was the
invention of stainless steel. Charged with the task of
trying to find an alloy addition to steel to improve the
wear resistance of gun barrels, a Sheffield metallurgist named Harry Brearley noticed that some pieces
of discarded steel (with high chromium content) in
the yard didn’t corrode like all the others. This is the
story, often told in Sheffield, and reported in the New
York Times and was the basis of the development
of 400 series martensitic stainless steel, but history
now tells us that one year earlier, Krupp metallurgists in Germany were independently investigating
the effects of adding nickel and chromium to steel.
These inventions laid the foundation for the devel-
opment of the “300” series of austenitic stainless
steels.
In summary, it can be said that spring manufacturing in all countries today was enabled by
these inventions, which all arose out of the need for
developing better products. Watch this column for
details of the invention that will make my fortune
and be important in the spring industry in the 21st
century! ◆
SPRINGS July 2008 67
68 SPRINGS July 2008
Spring Failures:
Local Elevated
Temperature Exposure
Technically
Speaking
by Luke Zubek PE
ith regard to high temperature exposure, a
little heat is good but a lot can be disastrous.
Springs can benefit from relatively low temperature exposure (i.e. a stress relief). The stress relief
increases the yield point of the cold worked steel by
a process called dynamic strain aging.
Steel is fundamentally an alloy of iron (Fe) and
carbon (C). Most spring steel contains between 0.50
and 0.90 percent C by weight. Although this appears
to be a small addition, the properties and performance of steel is primarily dictated by the amount
of carbon present. One of the more interesting
properties of steel occurs at about 1400°F. As steel
is heated to this temperature the atomic structure
is realigned resulting in a dramatic reduction in
magnetic properties. Subsequent rapid cooling initiates another transformation to a very hard structure
(~60 HRC) known as martensite. Martensite needs to
be tempered in short order, as it is meta-stable and
may crack if not tempered. This heating, cooling and
tempering cycle is what gives strength, toughness,
and ductility to oil tempered spring steel like ASTM
A229 and A401.
So what does all this have to do with spring failures? To answer this question, try to imagine what
would happen if the steel wire did not get tempered.
The wire would be excessively hard and you would
not be able to bend the wire without it fracturing.
Actually, the wire would have so little ductility that
the wire would not be able to be wound on a spool.
Obviously, neglecting a critical processing operation
W
Luke Zubek PE is the technical director
of the Spring Manufacturers Institute,
providing failure analysis services,
technical assistance and educational
seminars to the spring industry.
Prior to that, he was a metallurgical
engineer for a major steel producer
for 10 years. He holds a masters of
materials and metallurgical engineering degree from the Illinois Institute
of Technology and a bachelors in
metallurgical engineering from the
University of Illinois at Chicago. Readers may contact Zubek by phone at (630) 495-8588 or e-mail at
Luke@smihq.org
Figure 1: Melted appearance on the wire surface.
Figure 2: Intergranular appearance on the fracture surface surrounding the
point of high temperature contact.
like tempering would never happen in reality — or
would it?
During my review of spring failures (reported
on in my previous article), I mentioned that many
springs failed as a result of local exposure of the
wire surface to intense heat. After further review, I
realized there are several sources of high temperature exposure that can detrimentally affect (break) a
spring. I’ve divided these sources as non-directional
local and directional local with length.
Non-directional Local: The most common type
of non-directional high temperature exposure is
arcing. Arcing can occur wherever there is a high
electrical potential present, like during plating and
SPRINGS July 2008 69
Figure 3: Lighter colored areas are untempered martensite; note the
crack running through the affected area on the left. The elongated
grains are characteristic of a hard drawn microstructure viewed in the
longitudinal direction. (~80X, 3% nital etch)
Figure 4: Transverse cracks on the surface near the corner of
rectangular wire.
Figure 5: Intergranular fracture surface features commonly have the
appearance of rock candy.
70 SPRINGS July 2008
electrostatic coating. Arcing can cause the affected
area to reach temperatures well above 1400°F. This
high temperature exposure can locally transform the
area of contact to brittle untempered martensite.
Another less common source of this exposure that
I have seen is from errant weld spatter or sparking.
Most springs affected in this manner tend to break
shortly after the detrimental contact. The characteristic features of this damage include:
• A melted appearance to the wire surface,
as revealed in Figure 1.
• Intergranular fracture surface appearance adjacent to the affected area, as shown in Figure 2.
• An etched cross section taken through the arced
wire will commonly show the affected area as being
a lighter colored disc-shaped area that is harder
than the surrounding metal, as shown in Figure 3.
Directional Local with Length: The most
common source of directional exposure to heat
evident on failed springs and spring wire originate
from excessive frictional forces. These frictional
forces can generate enough heat to locally raise
the surface temperature of the wire above the
critical transformation temperature of ~1400°F
and form longitudinal streaks of brittle untempered
martensite.
This phenomenon can occur during wire drawing
when high temperature exposure could be the result
of a local lack of lubrication. Further processing of
the wire can cause transverse cracks to open, as
seen in Figure 4, which occurred during the conversion of round wire to rectangular. When examined
with a scanning electron microscope (SEM) these
transverse cracks are intergranular in appearance
as seen in Figure 5. A metallographic mount taken
through the affected area will show the presence of
light colored untempered martensite if, and only if,
the wire was not subjected to heat treatment after
the damage occurred.
In some severe cases the wire breaks during
transport. I have heard this condition referred to
as “porcupine” when there are numerous breaks in
an unused spool of wire (the spool has the appearance of sharp quills like the back of a porcupine).
One good safeguard against this defect is that most
spring wire will break at the coiler and never be
made into springs.
Another source of high temperature directional
exposure can occur during the coiling of the spring.
The heat generated from coiling a spring too fast and
with too much force can also cause hard untempered
martensite streaks to form. A transverse cross section of this effect is shown in Figure 6. Once again,
the lighter area is the untempered martensite and
Figure 6: Similar to Figure 3, but the lighter colored area was coincident
with a tooling mark. (~80X, 3% nital etch)
is always coincident with the pressure mark used
during cold forming.
There are many different types of high temperature exposure that can seriously impair the
performance of springs yet most springs don’t
encounter these conditions. These hard martensite
areas on the finished product are not reversible
unless the formed spring is subsequently heat
treated (quenched and tempered). Yet heat treating
won’t get rid of transverse cracks that may have
formed at these embrittled areas. I have found that
there is very little good documentation on this exposure and hopefully this article has provided some
needed information on the subject. ◆
SPRINGS July 2008 71
72 SPRINGS July 2008
New Products
design on Auto Cad 3D. The system can cut up to
four-inch thick tools plus taper tools for compound
bending. Complicated profiles of plate cams can be
produced allowing the fine-tuning of the multi-slide
forming process. OMCG supplies machines that can
handle strips up to four inches wide and wire to over
5/8 inch with blank length assembly, cold heading, threading, wire grooving, coining and welding;
progressive die applications are a natural fit. OMCG
NA supplies systems manufactured by OMCG Spa of
Italy. For information, contact OMCG, North America
at (630) 860-1016 or visit www.OMCG.com.
Bending and Coiling Machine
Wafios AG has introduced the BM 30, a CNC
single-head bending and coiling machine. The design
encompasses the concept already familiar from the
existing BM series of turning the wire rather than
the bending head. The bending head is comprised
of four axes, including the lateral traversing axis
as a standard feature. Coiling processes are made
possible by the continuously rotatable bending and
mandrel axis, which also permits the production of
closed loops without the need for any other optional
attachments. The bending and cutting devices are
neither pneumatically nor hydraulically controlled,
reducing setup times and making the system less
susceptible to faults. All the tool types used on
Wafios CNC single-head bending machines from
six to eight mm can also be used on the BM 30. For
information, contact Wafios AG at +49 7121 14 63
09 or e-mail a.hoster@wafios.de.
Absorbent Mat
New Pig Corp.
has designed the
Fat Mat Super Absorbent mat for
special applications
that require mats
to last longer and
absorb more. Sixteen
layers of thermally
bonded polypropylene enable the Fat
Mat to absorb up to
56 ounces of oils,
coolants, solvents and water per 20-inch by 16-inch
pad. The exclusive dimple pattern speeds wicking
action across the mat and transfers liquids into the
absorbent inner layers to keep moisture away from
the surface. The fine fibers grip the floor to prevent
slips and falls. The mat will not rip, tear or fray and
is safe for use with most liquids. For information,
contact New Pig Corp. at (800) 468-4647 or e-mail
hothogs@newpig.com.
Electrical Discharge Machinery
OMCG, North America has installed an Agie
Wire EDM for cutting tools thus improving quality
and time to sample submission. This allows the
SPRINGS July 2008 73
Roll Alignment Kit
Pinpoint Laser Systems has introduced a roll
alignment kit to facilitate the alignment of rollers,
shafts and web-handling systems. This kit is compact and easy to use in all industrial environments.
Typical applications include paper and textile mills,
converting lines, printing presses, plastic bag lines,
coating lines, and other roller and web-related applications. The kit is able to make quick, precise and
quantitative measurements over large machines with
many rollers. The laser is placed on a swiveling base
and a plane of laser light is directed across the top of
the rollers. The digital receiver and display provide
readings of the roller position relative to the place of
laser light and allow the operator to determine the
Ergonomic Rolling Carts
IAC Industries announced a new color lineup
for its Dimension 4 Rolling Carts family that keeps
raw materials, manufacturing supplies and finished
products moving. They are suitable for any environment with the need for mobile product or equipment.
New colors for work surface laminates, powder coat
paint and accent trim may be seen in the company’s
catalog or online at www.IACindustries.com.
The carts are constructed of D4 aluminum
extrusion uprights, a welded tubular frame, support
beams, a laminated work surface with “T” mold edges
and radiused corners. For information, contact IAC
Industries by phone at (714) 990-8997 or e-mail at
benchsales@iacindustries.com.
Bifocal Safety Eyewear
To meet the needs of an aging work force, Gateway Safety offers two styles of bifocal safety eyewear,
each in four diopter
strengths: 1.0, 1.5, 2.0
and 2.5. By providing
workers with bifocal eye
protection, the hazard
of switching back and
forth between their
regular safety glasses
and reading glasses to
read instrumentation,
work with small parts,
or perform other tasks
is eliminated. StarLite
Mag is cost effective and
super light. Lenses are available in clear or grey and
meet or exceed ANSI Z87.2+ standard. Also available is Scorpion Mag protective bifocal with greater
flexibility in the types of tasks older workers can
perform. For information, contact Gateway Safety
Inc. at (800) 822-5347 or e-mail info@gatewaysafety.
com.
74 SPRINGS July 2008
roller orientation to within 0.001 inch. The digital
information on the position of the laser beam is
easily used for calculating surface flatness, run out
straightness, parallelism and many other geometric alignment parameters. For information, contact
Pinpoint Laser Systems at (800) 757-5383 or visit
www.pinlaser.com.
Advertiser’s Index
A
Admiral Steel
(800) 323-7055
/ 47
Alloy Wire International
(866) 482-5569
/ 20
Anchor Abrasives
(708) 444-4300
/ 39
Ank Inc.
++886-2-29076581
/ 16
B
Blue Blade Steel
(908) 272-2620
/ 48
C
Chicago Association of
Spring Manufacturers Inc.
(630) 369-3772
/ 36-37
D
Diamond Wire Spring Co.
(800) 424-0500
/ 30
Dispense Works
(815) 363-3524
/ 40
Durant Tool
(800) 338-7268
/ 11
E
Elgiloy Specialty Metals
(847) 695-1900
/ 71
F
Forming Systems Inc.
(877) 727-3676
/ inside front cover,
3, 18, 68, 72
G
Gibbs Wire & Steel Co. Inc.
(800) 800-4422
/ inside back cover
G
Gibraltar Corp.
(847) 769-2099
/ 8, 67
H
Haldex Garphyttan
(888) 947-3778
/ 41
I
Industrial Steel & Wire Co.
(800) 767-0408
/5
InterWire Products Inc.
(914) 273-6633
/1
J
JN Machinery
(630) 860-2646
/ 64
K
Kiswire Trading Inc.
(201) 461-8895
/ 49
L
Link
(734) 453-0800
/ 52
M
Maguire Machinery
(609) 266-0200
/6
The Mapes Piano String Co.
(423) 543-3195
/ outside back cover
Mount Joy Wire Corp.
(800) 321-2305
/ 62
N
NIMSCO
(563) 391-0400
/ 38, 44
Norwalk Innovation
(800) 688-2645
/ 54
P
Precision Steel Warehouse
(800) 323-0740
/9
P
Proto Manufacturing Ltd.
(800) 965-8378
/ 25
Pyromaître Inc.
(800) 231-7976
/ 10
R
Raajratna Stainless
(847) 485-8210
/ 24
Radcliff Wire
(860) 583-1305
/ 51
RK Trading
(847) 640-9771
/ 45
S
Simplex Rapid
(563) 391-0400
/ 65
Spring Manufacturers Institute
(630) 495-8588
/ 12, 32
T
TAK Enterprises
(860) 583-0517
/ 43
Tool King
(800) 338-1318
/ 15
Trustmark/ Metalworking
Manufacturing Coalition
(708) 223-3338
/ 59
U
Ulbrich Stainless Steels &
Special Metals, Inc.
(800) 243-1676
/ 17
V
Vulcan Spring &
Manufacturing Co.
(215) 721-1721
/ 58
Z
Zapp Precision Strip
(203) 386-0038
/ 60
Sprung
SPRINGS July 2008 75
Snapshot
Steve Kempf
Lee Spring Company
Occupation: CEO, Lee Spring Company (Brooklyn, NY)
Industry Affiliations: SMI Board of Directors
Birthplace: Chicago, IL
Current Home: New York, NY
Family: It is just me and my wife, Mary Dixie Carter…
for now.
What I like most about being a springmaker:
Manufacturing something that, behind the scenes, helps so
many things in this world function.
Favorite Food: Too many to name! I particularly enjoy
trying foods that I have never before tasted.
Favorite Author: Probably Mark Twain. I am currently
enjoying Jon Krakauer’s Into the Wild.
Favorite song/musician: My favorite music changes from
time to time, but Bob Dylan is always at or near the top of
the list.
Hobbies: Among many hobbies, I enjoy being outdoors,
traveling, playing ice hockey and skiing.
Steve Kempf and his wife Mary Dixie Carter
Favorite places: Aspen, Colorado
I knew I was an adult when: That moment has yet to come.
Best time of my life: Life is good — always.
If I wasn’t working at Lee Spring I’d like to be:
Making films.
A really great evening for me is: Relaxing at home with
my wife while enjoying good food and a great movie.
The one thing I can’t stand is: Traffic and other
unnecessary delays.
Those that know me say my outstanding qualities/gifts
include: Understanding the perspective of others.
When I look back on my life the accomplishment of
which I’m most proud: I am still looking forward, but I am
proud of the foundations I have established thus far.
People who knew me in school thought I was:
Deceptively quiet and calm.
The most difficult business decision I’ve ever had to
make was: Terminating anything (a person, a division or an
entire business) is always a very difficult decision.
I wonder what would have happened if:
Springs had never been invented
(see: www.archive.org/details/CaseofSp1940).
Role models: My parents.
I would like to be remembered in the spring industry
for: Carrying on the Lee Spring tradition while contributing
to the growth of the industry as a whole.
But people will probably remember me for: Carrying on.
76 SPRINGS July 2008
Why Partner With Gibbs?
Precision Medical Wire and Strip.
Now you can order your medical wire and strip from the
same company that’s been supplying your other wire and
strip needs for more than 50 years. Why split your order
when you can get the finest wire and strip for every
application all under the same roof.
No matter what you’re looking for, Gibbs can draw or slit
exactly the premium quality product you need.
lowest total cost and now a complete inventory of the
finest quality medical grade wire and strip.
That’s why so many leading companies have chosen
to partner with us.
For information contact Jim Ashwell, 1.800.800.4422 Ext. 117,
jima@gibbswire.com
Since 1956 Gibbs Wire and Steel has represented a
combination of responsiveness, knowledgeable and reliable
people, innovation and leading edge technology, the
The People You Can Rely On For Wire And Strip
1.800.800.4422
www.gibbswire.com
Connecticut
•
Indiana
•
Texas
•
California
•
North Carolina
New Sales Office in Mexico: ++52 (442) 341-8436
•
Ontario
Pinpoint Accuracy
Pin-Key Manufacturing Co. requires
exacting size wire tolerances to
manufacture their precision parts.
Their products require the most
uniform wire available. Mapes
wire meets that standard. “I wish
I could buy all my wire from Mapes,”
states Pin-Key president Bob Dyer.
MAPES quality wire
Type
Size Range
Aluminum Zinc Galfan® Coated Music Spring Wire
.177"–.062"
4.50mm–1.575mm
Galvanized Coated Music Spring Wire
.177"–.062"
4.50mm–1.575mm
Special Aluminum Zinc Galfan® Hard Drawn Wire
.177"–.062"
4.50mm–1.575mm
Special Galvanized Hard Drawn Wire
.177"–.062"
4.50mm–1.575mm
Tin Zinc Coated Music Spring Wire
.063"–.008"
1.6mm –.20mm
Tin Coated Music Spring Wire
.063"–.008"
1.6mm –.20mm
Phosphate Coated Music Spring Wire
Missile Wire (High Tensile)
Do you want to increase your production
efficiency? Mapes’ consistent quality and
careful attention to your production needs
will keep the cash flowing for your process.
Warehousing and on-demand ordering
agreements are available. Call now.
.282"–.006"
7.2mm – .152mm
.120"–.015"
3.05mm –.381mm
Galfan is a registered trademark of Galfan Information Center, Inc.
THE MAPES PIANO STRING COMPANY P.O. BOX 700, ELIZABETHTON, TENNESSEE 37644
423-543-3195 • FAX 423-543-7738 website: www.mapeswire.com e-mail: info@mapeswire.com
ISO 9001: 2000 certified