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TopFIA Quick Read Newsletter

May 19, 2011

Welcome New Members!

FIA is pleased to welcome two Forging Producer members to the Association:


ThyssenKrupp Presta Cold Forging LLC


Located in Danville, IL, ThyssenKrupp Presta is a custom producer of cold forgings for the automotive industry.  Marcel Montoya, Director of Finance, will serve as Official Representative.  (217) 709-1500


Dyson Corporation (www.dysoncorp.com)


Located in Painsville, OH, Dyson Corp. produces impression and open die forgings for a variety of markets.  Dave Heckel, President, will serve as the company's Official Representative to FIA.  (440) 946-3500.

Erie Press Systems Celebrates 50 Years of FIA Membership

Erie PicGeorge Currie, Exec. VP, was recognized by FIA President Kevin Crowley at the Annual Meeting of Members with a plaque to commemorate 50 years of continuous FIA membership for Erie Press Systems.


ERIE Press Systems was incorporated in 1895 by five local investors as Erie Foundry Company, a grey iron foundry, and capitalized with $10,000.00. In 1904, ERIE purchased the machine tool business of Pittsburgh Shear Knife and shipped its first 600 pound single frame hammer to Rome Brass and Copper Company.  A 1908 fire destroyed the machine shop, but left the foundry and office. 


One of the founder's nephews, D. Angus Currie (Doug and George's grandfather) left his father's Michigan farm to join the Company in 1906 as a timekeeper working his way up during the automotive growth and WWI years to become President in 1935. Mechanical trim presses were introduced in the teens while small custom application hydraulic presses were introduced in the twenties.  Doug and George's father, Jim Currie returned from WWII and succeeded as president when his father, Angus, died in 1955. Today, as third generation, Doug and George hope to continue the ERIE legacy for another 115 years by continuing to build their technical and manufacturing capabilities in order to serve the forge and several other key industries which the Company has supported over the years.


Congratulations, Erie Press Systems!


Welcome New Members
Erie Press Celebrates 50 Yr. FIA Membership
Forging & Die Design School
IFM Registration Opens
Industry Elects New Leadership
Safety, Health & Environmental Newsletter
Aerospace Subcommittee Update
2011/2012 FIERF Projects
Optimism Fuels Successful FIA Annual Meeting
What Members are Saying About FIA/FIERF
2011 Forging Capability Guide Released
Members Raise Funds for Scholarships
Job Shop Lean Workshop
Defense Logistics Agency Releases New Video
Meanwhile in the Real World

Theory & Applications of Forging & Die Design School - June 20-23 - Cleveland

The "Theory and Applications of Forging & Die Design" school continues to evolve, reflecting new insights into forging technology and the wide availability of metal flow simulation software.  This four-day school is taught by a team of industry experts and engineering professors who work together to carefully explain principles and practice.  We urge you to join the 1200+ forging employees who have already attended this course.


(Click here) to view/print brochure.


This will be the only offering of this program in 2011. Class size is limited, (last year's class filled up early, leaving many closed out), please don't wait to register.


For additional information, contact George Layne at: glayne@forging.org.

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International Forgemasters Meeting Registration Opens - Early Bird Expires June 30

The 18th International Forgemasters Meeting (IFM) will be held in the United States, September 12-15, 2011. This will be the first time IFM has been held in the USA since 1994. The Meeting will be held at the Omni William Penn Hotel in Downtown Pittsburgh, and will include 80 technical papers from 12 nations covering everything from steelmaking and refining to simulation and modeling. In addition, 10 country/regional market overviews will be presented from the world's leading open die producing nations. Also occurring during the meeting will be an exhibition featuring 35 forging supplier companies from all over the globe displaying the latest technology and improvements in their respective areas. Two plant tour options will be offered that will take attendees through five forging and supplier companies.


Don't miss this unique opportunity to meet and greet top level forging and supplier executives from across the globe! See www.IFM2011.com for registration information, or request a printed brochure by calling FIA at 216-781-6260.



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Industry Elects New Leadership at Annual Meeting

NewFIALogoFour new directors have been elected to Forging Industry Association's (FIA) Board of Directors for three-year terms. They are:


Cesar Garza, President, W. Pat Crow Forgings, Fort Worth, TX  

Charles J. Crout, President, AJAX-CECO, Park-Ohio Capital Equipment Group, Wickliffe, OH

Simon Ormerod, President & CEO, AJAX Rolled Ring & Machine, York, SC       

Matthias Praus, General Manager, Metform LLC, a Maclean-Fogg Company, Savanna, IL


Michael A. Kamnikar, Senior V.P., Marketing & Business Development, Ellwood Group, Inc., Ellwood City, PA was elected President. Dennis Potter, COO, Impact Forge Group of Hephaestus Holdings, Inc., Columbus, IN was elected Association Vice President for the coming year.


Arnold Visser, COO, IMT, Ingersol, Ontario and Ronald A. Wallis,Technical Director, Wyman Gordon Forgings, Inc., Houston, TX, were elected to the FIA Executive Committee to serve with Kamnikar and Potter.


NewFIERFLogoFour trustees have been elected to Forging Industry Educational and Research Foundation's (FIERF) Board of Trustees for three-year terms. They are:



Tim Gudszend, COO, Rotek Incorporated, Aurora, OH

Darryl S. Hammock, CEO, Weld Mold Company, Brighton, MI

Markus Knoerr, VP Engineering, HHI, Royal Oak, MI

Jack H. Simmons, Mgr. Marketing & Product Development, Electralloy, Oil City, PA


Brad A. Ahbe, President, Canton Drop Forge, Inc., Canton, OH was elected to a one-year term as President of the Foundation. 


James Woidke, COO, SIFCO Industries, Inc., Cleveland, OH was elected as Vice President for the coming year.


Douglas Brown, President & COO, Inductoheat, Madison Heights, MI and Jeffry D. Jones, VP, Girard Engineering, Inc., Cleveland, OH were elected to the FIERF Executive Committee to serve with Ahbe and Woidke.


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FIA Safety, Health and Environmental Newsletter

May / June 2011 Issue


In this Issue:

         Attention Environmental Affairs

         Lesson Learned

         AWARENESS ALERT - Swivel Hoist Ring

         Bills filed to Codify VPP

         Congratulations to FIA Safety Award Winners

         Remember the Safety Star Program


Click here to view/print Newsletter


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Aerospace Subcommittee Update

Special thanks to Stan Revers - Business Development Manager and Kevin Wetzel - Staff Engineer from Performance Review Institute (PRI) who attended FIA's Annual Meeting, and participated in the aerospace market roundtable.  Their presentation on the history of NADCAP and workings of PRI was very interesting.  The Q & A after was very informative, and provided FIA member companies the unique opportunity to discuss at length their questions and allowed for great give and take between the parties in attendance.


Watch Quick Read in the future for information from PRI that will describe ways for FIA members to get involved with the NADCAP process via various Task Groups and Supplier Councils.


If you want more information or want to join the aerospace subcommittee, email Roy Hardy at roy@forging.org


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2011/2012 FIERF Research Projects Approved!

The following research projects have been approved by the FIERF Board for school year 2011/12. They are scheduled for completion August, 2012

Marquette University - Heat Loss Study on Ring Rolling and Evaluation of Heat Amounts Required for Near Isothermal Rolling

University Of Michigan - Advanced Tonnage Signal Analysis for Forging Process Monitoring and Quality Improvement (Four Year Project)

Colorado School of Mines - Hot Deformation and Recrystallization Behavior of Ni-Base Superalloys

Case Western Reserve University - Development of Coatings and Procedures for Reducing Decarburization during Preheat of Forging Billets

Rensselaer Polytechnic Institute - Effect of Carbide Formers on Steel Decarburization

Wright University - Economic Ways to create UFG Bulk Materials for Forgers

University of Pittsburg (co-sponsored by Ellwood Group, Inc.) - Effects of Aluminum Nitride Precipitation on Hot Ductility of Steels

Illinois Institute of Technology (co-sponsored by A. Finkl & Sons) - Experimental and Finite Element Investigation of Defect Closure in Large Forgings

For a copy of the project plan please contact FIA Technical Director Carola Sekreter at carola@forging.org

For reviewing all on-going projects click here.

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Optimism Fuels a Successful 2011 FIA Annual Meeting

With an improving economy, diverse program, exceptional location and wonderful weather, the 2011 FIA Annual Meeting was highly rated by the 170 attendees on hand. Held April 30 - May 3 at the Hyatt Regency Scottsdale Resort at Gainey Ranch in Scottsdale, AZ, FIA members enjoyed perfect weather and a casual outdoor setting for the opening dinner party Saturday night. The highlight of the evening was a golf chipping "sink or swim" contest, where members purchased balls for a closest to the pin contest with all proceeds going to FIERF scholarship programs. (Click Here for more info). After a welcome from FIA President Kevin Crowley, Sunday's business session opened with a dissection of the economy with long time favorite Ken Mayland. He was followed by Greg Yezback, Plant Manager of American Axle's award winning Three Rivers facility, discussing why his plant is lauded as one of America's best. To close the sessions, Forbes Publisher Rich Karlgaard discussed real-world examples of: one innovation hardwired into our DNA; five innovation basics that are essential for every 21st century company; and four innovation shockers practiced by tomorrow's likely.


Monday opened with the Safety Awards, presented to companies showing excellent and/or much improved plant safety records in 2010. (Click Here for more info). Updates on current FIA activities were then presented... Hud Smith from  SIFCO discussed Lobby Day, Mike Kamnikar of the Ellwood Group reviewed the forthcoming International Forgemasters Meeting, Doug Brown, Inductoheat presented two Anvil Awards, (Click Here for more info), and Roy Hardy, FIA Executive VP updated progress on Strategic Plan & Tech Roadmap projects. The FIA Official Business session followed, with members approving a $1.8 million budget and a slate of four new Board members (Click Here for more info). Executive Roundtables closed the business portion of the meeting Monday. Thanks to Joe Cipriani, Keystone; Dick Johnston, Trinity Forge; Ron Wallis, Wyman Gordon; and Rob MacEachern, NOVA Forge Corp., for serving as Chairmen.


At Monday evening's Annual Dinner/Dance outgoing FIA President Kevin Crowley and First Lady Annemarie, Forged Products, introduced incoming President Mike Kamnikar, EGI, to the membership.

Tuesday's  business session opened with a look at FIA's  trade mission as an add-on program to the FIA led delegation to the 20th International Forging Congress, November 13-17, 2011 in Hyderabad, India. The meeting concluded with acclaimed demographer and author Ken Gronbach examining worldwide demographic change that will reshape the United States manufacturing landscape.

Executive photos, award winners and many of the slides from speakers mentioned above may be viewed under the Members Only portion of the FIA website. FIA Members please Click Here to view. 


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What Members are Saying About FIA & FIERF

Hear your colleagues talk about how they and their organizations have benefited from participating in FIA and FIERF activities in this video shot at the Forging Industry Technical Conference.  FIA Members, research partners, professors and students provide insights into technology development and encouraging students to work in the forging industry. 

Thank you to all who were interviewed at the Conference.  Watch for more interviews to be included in more videos!


Click here to view the video on U-Tube. 



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2011 Forging Capability Guide Released

FIA is pleased to announce availability of the new 2011 Forging Capability Guide (FCG). The fully searchable CD contains location and facilities listings of all FIA Member custom forge shops, forging market and process descriptions and graphics, and a "Special Capabilities" column that further defines forging company capabilities, making it easier for customers to select prospective sources.


The primary purpose of this Guide is to promote the capabilities of FIA members and the forging process to forging customers and prospects. It will be distributed to thousands of customers and prospects worldwide. Copies of the 2011 Forging Capability Guide are available to FIA members for $25.00 each and to FIA non-member forging and supplier companies at $100.00 each (postage and handling included). Click Here to order or contact FIA at info@forging.org.


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Members Raise Funds for Scholarships - and Have a Good Time!

GolfAnnual Meeting attendees contributed over $1500 to the Charles W. Finkl Scholarship Fund during the "Sink or Swim" chipping contest that took place during the meeting's opening reception.  Members competed to be closest to the pin of the 9th hole that lies just across the water from the Palm Grove Court where the evening's event was held.


Hackers and serious players came forward to support the scholarship fund while trying their luck and for the most part managing to avoid exploding golf balls.


Thanks to all who participated and congratulations to Paul Dimitry, Gerdau MACSTEEL who won a $500 gift certificate for being closest to the pin!


Each year the Foundation supports up to 30 undergraduate engineering students (at a cost of $60,000), a large percentage of whom end up in the forging industry supply chain.  If you would like to contribute to the Finkl Scholarship Fund or other activities of FIERF, please contact Karen at karen@forging.org or 216.781.5040.


Click here to see more photos from the event.


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Job Shop Lean Workshop Offered to the Public on June 9 and 10, 2011 in Columbus OH. 

Forgers seeking to reduce costs while improving throughput are encouraged to attend this Job Shop Lean Workshop at The Ohio State University.  This workshop will teach how to design Lean and Flexible facility layouts for jobshops using a methodology - Production Flow Analysis (PFA).  PFA supports the implementation of Cellular Manufacturing and Group Technology. At OSU, we use a proprietary software package - PFAST (Production Flow Analysis and Simplification Toolkit) - to implement PFA in any HMLV facility that struggles with the challenges of implementing Lean for their large and diverse product mix.  Several FIA forges have already benefited from this experience.   For more information and registration details click on.  http://fdmc.ati.org/documents/Layout%20Design%20for%20High.pdf


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Defense Logistics Agency Releases New Video on its R&D Investments in the Forging Supply Chain

The Defense Logistics Agency released a really cool video on its investments in the forging industry especially PRO-FORGE.  This fast paced video features two FIA member companies and an aerospace OEM which depends on forgings.  Click on this link and share it with your team.  http://fdmc.ati.org/videos/media-video.html 



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Meanwhile, in the Real World

Professor Shahrukh Irani of The Ohio State University summarizes his efforts and observations of Lean Manufacturing.  This article illustrates the value OSU's Industrial Engineering Program while providing salient recommendations for implementing lean initiatives - real world recommendations as opposed to ivory tower theories.  For this quick read click onhttp://fdmc.ati.org/documents/IE-MAGAZINE_April-2011%20(2).pdf


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