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WAI Operations Summit & Wire Expo 2014 Conference Sessions

TUESDAY, MAY 6, 2014

9:00 a.m. - 10:30 a.m.
Machinery Roundtable: Drives & Control
Panelists: David Hawker, Nexans Energy Cables Div. NA, USA; Michael Kaczynski, OEM Design Services, USA; Bill Riley, Parker Hannifin Corp., SSD Drives Div., USA; and Tim Tanner, President, Teknikor, USA
Join this panel of equipment suppliers and wiredrawers as they discuss upgrading drives and control. They will address how to decide between a mechanical overhaul and an electrical upgrade, with attention to who owns responsibility for the process. They will examine the ins and outs of replacing equipment electronics, including the pitfalls, timeframes, and downtime involved. Each panelist will have an opportunity to present his own take on the topic, followed by a general discussion among the entire panel, with questions from the audience.

10:30 a.m. - 11:15 a.m.

Blocks & Coatings
“Gaining a Competitive Advantage in Your Wiredrawing Process”
Gene Klein, Sr., Parkway-Kew Corporation (PKC), USA
This session focuses on improving quality, and speed of wire production. This is done by managing wiredrawing machinery, as well as other components that have direct contact to the wire. Taper, radius, and water cooling in ferrous production, along with nonferrous components are discussed. Issues related to alloy type and specific wire such as flux core are touched on, along with the problems of overlapping and climbing.
Gene Klein, Sr., has served as president of Parkway-Kew Corporation (PKC), North Brunswick, New Jersey, USA, since 1987. He has also been involved in sales and engineering roles as a member of PKC, and has serviced the wiredrawing industry with hard surfacing, and block maintenance issues with PKC for 43 years. He holds a B.A. degree in economics from the University of Pittsburgh.

11:15 a.m. - 12:00 p.m.
Single-Line Galvanizing
“Eco-Friendly ‘Green’ Galvanizing: The SunWyre MHD Galvanizing Process”
Patrick Weister, SunWyre Inc., USA
This presentation explains in detail the Magneto-Hydro-Dynamic (MHD) galvanizing process and shows the many green features that are not available in a classical hot dip galvanizing system.  These include: no acid, no acid rinse, and no flux; no hazardous waste or byproducts; blast cleaning and surface profiling to prepare the steel; energy-efficient induction heating of the wire and rod; and low power consumption for heating one tonne of molten zinc. The proprietary process that incorporates MHD offers an innovative approach to the production of galvanized and Galfanized long products including steel wire, rod, rebar, and tubing.

10:30 a.m. - 11:15 p.m.

Closed-Loop Controls
“Dimensional Measurement and Control Advancements for All Segments of the Nonferrous Wire and Cable Industry”

Keith Donahue, Zumbach Electronics Corp., USA
This presentation reviews the latest advancements in dimensional measurement technology, including ultrasonic, X-Ray, and Camera/Laser systems to enable improved dimensional control, increased product stability (i.e., higher statistical CPK), and dramatic material savings opportunities. Each major market sector, from fiber, communication, building, power, and others is specifically reviewed, with their unique product constructions and measurements requirements, to provide an overview of the best available technology for each application.
“Gravimetric Blending”
Dana Darley, Process Control Corporation, USA
Gravimetric blending and gravimetric extrusion control are critical to the production of wire and cable. This presentation provides an unbiased, technical overview of all available blending and control technologies, details each process with examples from multiple equipment suppliers, discuss the pros and cons of each, and draws some basic application guidelines. It reviews in detail batch and continuous blending, additive dosing, and loss-in-weight gravimetric extrusion control. It concludes with the economics of the systems and payback.

11:15 a.m. - 12:00 p.m.
Data Acquisition and Virtualization for Process Control Systems
Doug Hoffer, Rockwell Automation, USA
Variation is inherent in all processes and it is the responsibility of the process owner to monitor and manage the process and make real-time decisions for continuous improvement. The cost of data storage is inexpensive, enabling us to collect volumes of data, both automatically and manually. New software technology enables us to analyze and contextualize multiple data sets and make intelligent actionable decisions. Virtualization can dramatically increase the life span of IT data centers and related sub-systems used for data acquisition to more closely match the typical life of an industrial manufacturing process control system, while also reducing total cost of ownership. This presentation explores system sizing, network topology, throughput, fault tolerance, uptime/availability, security, services, and TCO considerations.

1:30 p.m. - 2:00 p.m.

"Are Robots in Your Near Future"
Rodrigo Madariaga, Mining Industry Robotic Solutions (MIRS) SA, Chile
Have suppliers been unable to communicate the advantages of robotic systems in your company? Maybe robotics is not currently in the short-term plans of the wire and cable industry. But the main advantage of robotics is to allow dynamically modifying trajectories as required. This definition immediately brings to mind applications like mobile devices for materials handling, material preparation and palletizing stations, and the like. Today, the technical challenges of robotics are largely solved and the focus now is on how much business value they contribute.

2:00 p.m. - 2:30 p.m.
Continuous Improvement Case Study
“Process Improvement Case Study: Tensile Consistency in High-Carbon Steel Wire”
Steven D. Foust and Steven M. Montague, Leggett & Platt Inc., USA
In an effort to improve the consistency of physical properties and forming characteristics in high-carbon, hard-drawn steel wire, a cross-functional Six Sigma team was formed. The members of the team included personnel with knowledge and responsibility in steelmaking, rod rolling, and wiredrawing. The team achieved its goal by independently identifying key process parameters at each stage in the process, then leveraging the combined knowledge for further improvement in the final product.

2:30 p.m. - 3:00 p.m.
The Paramount Die Story
Richard Sarver, Paramount Die Co.
Paramount Die was founded in a 6'x10' converted shipping container by two brothers with $850 in working capital. More than 45 years later, Paramount Die has evolved in to one of the world's largest manufacturers of wire dies and pressure drawing systems. Paramount Die's new 45,000 square foot facility, located on the outskirts of Baltimore, Maryland, is highly regarded for integrating the latest robotic automation and "light's out" production technologies. Richard Sarver will share Paramount Die's story and offer his perspective on maintaining a competitive advantage in the wire drawing industry.


9:00 a.m. - 9:30 a.m.

“Trends in drawing technology for bars and wires”
Motoo Asakawa, Waseda University, Japan
In this study, the author’s research group focuses on the processing related to plastic forming for high dimensional accuracy and superior mechanical and metallurgical properties in bars and wires. It discusses the axial residual stress of drawing; protrusion die drawing; the effect of the additional shear strain layer; and diameter thickening of wire during drawing. It concludes with an introduction of a novel non-slip-type continuous drawing method for fine wires.

9:30 a.m. - 11:30 a.m.
“Achieving “Zero Harm” Through SafeOperations”
Will Kraft, W & M Kraft Inc.; and Jason Adams, Ingram Barge Company, USA
This presentation details the Zero Harm / SafeOperations initiative, offering a perspective on safety from outside the wire industry that chronicles successes under the most dangerous conditions. Injuries and incidents don’t just happen—they happen because we fail to manage risk to the lowest possible level. How people approach and do work does make a significant difference. Organizations achieve safety excellence through creating distinctive behaviors through use of systems. The four distinctive behaviors are: Plan Work with Risk Management, Accept Accountability, Take Care of Each Other, and Walk the Talk. Organizations in a wide variety of industries have significantly improved their safety performance along with other operation success factors following this strategic direction.

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