WAI Operations Summit & Wire Expo | May 22-23, 2012

Omni Dallas Hotel | Dallas, Texas, USA

Fundamentals of Wire Manufacturing

Monday, May 21

Wire Breaks & Surface Damage | Dr. Horace Pops, Horace Pops Consulting Inc.
9:00 a.m. to 10:20 a.m.

Dr. Horace Pops presents a classification of wire breaks from a perspective that compares material defects to process-related problems. Rod defects will include both casting and rolling issues such as internal voids, foreign contaminants, rolled-in scale, hot cracks, and surface porosity. A detailed analysis of central bursting (cuppy wire) will include both causes, prevention, and correction. The effects of wiredrawing speed and lubrication will be discussed with respect to generation of fines, shaving, galling, and other surface defects.

Testing and Properties | C. Richard Gordon, Gerdau Long Steel North America
10:30 a.m. to 11:50 a.m.

C. Richard Gordon tensile, coiling, wrap, reverse bend, torsion, fatigue, and hardness testing procedures. It illustrates interpretation of test results in terms of sample properties. It also presents practical exercises of data analysis.

Taming the Compliance Beast: Five Ways to Make ISO 9001 Worthwhile | Doug Anton, AEM Consulting Group Inc.
1:00 p.m. to 2:20 p.m.

Doug Anton describes a blueprint for implementing an ISO 9001 quality management system. Related standards: AS9100, ISO 14001, TS 16949, and ISO 13485 are included. Real-life examples are used to illustrate a variety of applications throughout these five proven action:

1. Include only value-added processes;

2. Aim for simple and concise documentation (more is not better);
3. Integrate all ISO 9001 activities into the company’s day-to-day business;
4. Make sure senior executives are committed and involved; and
5. Engage a registrar with excellent credentials and auditors.

Wire Mill Problem Solving | C. Richard Gordon, Gerdau Long Steel North America
2:30 p.m. to 3:50 p.m.

Wire and cable manufacturing involves many processes that must function reliably within given operating specifications. Deviation from these specifications results in products that are not suited for subsequent operations or delivery to customers. Problems result from many causes including operators, equipment, materials, work methods, measurements, and environment. This presentation C. Richard Gordon examines many problems commonly found in a wire mill and outlines problem solving methodologies for identifying the root causes and implementing appropriate solutions. Specific problems from attendees will be discussed.