Plant Engineering September 2016 Magazine

34 Meet the 2015 Engineering Leaders Under 40
Sister act
Building on their fathers legacy, a new generation

moves Bales Metal Surface Solutions forward 27
Its time you get more than

you paid for in a PLC.
Affordable Innovation
Introducing the
NEW
Its not just the low price, but the incredible built-in features
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Why pay thousands elsewhere for features that are
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programming functionality and a super low cost of
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* See our Web site for details and restrictions. Copyright 2015 AutomationDirect, Cumming, GA USA. All rights reserved.
AutomationDirect
CPU and I/O

Comparison
Allen-Bradley
Productivity2000
CompactLogix
Base (if required)
$69.00
N/A
Power Supply
$69.00
P2-01AC
$414.50
1769-PA4
CPU
$255.00
P2-550
$3,160.00
1769-L33ER
16 AC Inputs
$105.00
P2-16NA
$286.00
1769-IA16
16 24VDC Inputs
$69.00
P2-16NE3
$244.00
1769-IQ16
8 Relay Outputs
$51.00
$301.50
8 Analog Input
Channels (mA)
P2-08AD-1
$199.00
$713.50
ASCII Comm Module
$0.00
$737.00
Modbus RTU
Comm Module
$0.00
Built in to CPU
$701.00
1769-SM2
Total System Price with

USB, Ethernet and Serial
$817.00
$6557.50
P2-04B
P2-08TRS
Built in to CPU
N/A
1769-OW8I
1769-IF8
1769-ASCII
All prices are U.S. published prices. AutomationDirect prices as of 6/5/2015.

Allen-Bradley retail prices taken from www.plccenter.com 5/12/2015.
Get more than you paid for . . .
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input #1 at www.plantengineering.com/information
the #1 value in automation
kaeser.com
KAESER SUCCESS STORY
COMPRESSORS
Keep It Under Control!
Kaeser puts automotive supplier in the

drivers seat of compressed air efficiency
PROBLEM:
A Tier 1 automotive seating and electrical supplier was interested in
taking advantage of local utility rebate incentives. For their compressed
air needs, they had been relying on four compressors manufactured
in the 1980s, inherited from a sister plant. Each unit operated in
modulation control and was manually switched on and off, leaving
the units continually fighting each other, resulting in wasted energy,
fluctuating pressure, and increased maintenance costs.
SOLUTION:
Kaeser performed a complete Air Demand Analysis (ADA) to identify
the plants current compressed air needs and to develop a plan for
implementing the most energy efficient solution possible. Additionally,
Kaeser recommended a Sigma Air Manager (SAM) master controller
to properly control the system and ensure the most energy efficient
combination of units would be selected to meet current plant demand.
RESULT:
Thanks to better controls and adding an energy efficient variable
frequency drive compressor, the customer was able to reduce their
annual maximum power consumption by 865,440 kWhthe equivalent
of removing 100 homes from the power grid for one yearall without
compromising stable system pressure. With the older compressors
relegated to back-up, annual maintenance costs have been reduced
from $37,000 to $18,000. Less maintenance also means less downtime,
for increased productivity.
Specific Power of Previous System:
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Specific Power of New System:
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2015 Kaeser Compressors, Inc.
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Get to the problem before

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no added cost. You cant afford a factory shutdown, but you can afford the Keysight TrueIR Thermal Imager.
Keysight U5850A
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Company A
Company B
Detector resolution
160 x 120 (19,200 pixels) 160 x 120 (19,200 pixels) 160 x 120 (19,200 pixels)
In-camera ne/super resolution
320 x 240 (76,800 pixels) N/A
(Image enhancement)
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3.1 mrad
3.39 mrad
2.72 mrad
Sensitivity
0.07 C at 30 C
< 0.1 C at 30 C
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September 2015
Volume 69, No.7
Cover image courtesy: CFE Media
27 Sister act
Stacey Bales is president of Bales Metal
Surfacing Solutions, tackling the strategic
vision. Her sister, Sara Mortensen, is vice president and heads up the sales and marketing effort.
They are leading their company, and their fathers legacy, into the future.
30 Better training leads to a stronger workforce

In a world of robotic articulation, machine-to-machine communications, transfer-line technology
for blank to finished workpiece flow, and even the elimination of the zone controllers, its obvious that controls suppliers must make a commitment to follow every development in the market.

They are among the young people
who have made a commitment to
manufacturing and are displaying
uncommon skills in moving
manufacturing forward.
43 A return to apprenticeships delivers

skilled workers to Pratt & Whitney
Partnering with local community colleges to develop skills of future manufacturing workers is
critical to the companys success, and it has created programs near its facilities to train current
and future employees.
PLANT ENGINEERING (ISSN 0032-082X, Vol. 69, No. 7, GST #123397457) is published 10x per year, monthly except in January and July, by CFE Media, LLC, 1111 W. 22nd Street, Suite #250, Oak Brook, IL 60523.
Jim Langhenry, Group Publisher /Co-Founder; Steve Rourke CEO/COO/Co-Founder. PLANT ENGINEERING copyright 2015 by CFE Media, LLC. All rights reserved. PLANT ENGINEERING is a registered trademark of CFE Media, LLC used
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PLANT ENGINEERING
September 2015 3
LASER & PLASMA CUTTING
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CONTENT SPECIALISTS/EDITORIAL
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PUBLICATION SERVICES
9 Manufacturing Day a way to

reach out into the future
The fourth annual Manufacturing Day on Friday, Oct. 2, is
designed to show a whole new generation of young people how todays
manufacturing is all about advanced
technologies, state of the art facilities
and fast paced work environments.
JIM LANGHENRY, Co-Founder & Publisher

630-571-4070 x2203, JLanghenry@CFEMedia.com
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PAUL BROUCH, Director of Operations
630-571-4070 x2208, PBrouch@CFEMedia.com
14 OEE vs. MTBF:

Which is the right metric?
OEE (overall equipment effectiveness) and MTBF (mean time
between failure) can be very informative and drive some specific
behaviors when applied correctly. However, when applied incorrectly, they will likely lead to confusion and frustration. Here are
some insights on how and where we might best apply these metrics to get the greatest impact.
MICHAEL ROTZ, Print Production Manager

717-766-0211, Fax: 717-506-7238
mike.rotz@frycomm.com
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LETTERS TO THE EDITOR
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INFORMATION
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REPRINTS
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Brett Petillo, Wrights Media
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Tel. +44 208 464 5577
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Mechanical Solutions
47 Take a total system approach

to compressed air reliability
Understanding the total impact of running a compressed air
system and identifying the necessary actions based on unique
compressed air needs can reduce
energy costs by as much as 20%.
52 Selecting a filler
metal: Seven factors
to consider
Using a filler metal that provides the appropriate mechanical
and chemical properties for the joband is able to withstand the
service conditions the weld encountersis critical. It helps minimize the risk of cracking, corrosion, and/or weld defects that
could lead to time-consuming and costly rework.
PLANT ENGINEERING
September 2015 5
SEPTEMBER
Trending
New Products
Maintenance
Electrical
Mechanical
Energy Management
VIDEO:: A bicycle built for IIoT
Plant Automation
Safety
People and Training
Engineering eNewsletters
Stay in touch with
changes in the
industry, including
news, articles, and
product updates.
eNewsletters include:
Hotwire, Maintenance
Connection, PlantMail,
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Showcase, and Whitepaper Connection.
Subscribe to one or more eNewsletters at:
In an Industrial Internet of Things (IIoT) demonstration using a mountain bike tricked out with
sensors and instrumentation, ThingWorx, a PTC business, revealed how an operator might see
an industrial machines metrics in real time by looking through a wearable human-machine
interface (HMI). The presentation at the August NIWeek showed how hardware and software
can widen IIoT capabilities. For more videos visit www.plantengineering.com/videos.
Your most-read stories at www.plantengineering.com
Here are the 10 most often referenced articles at www.plantengineering.com in August. Use our
extensive search engine to find articles on manufacturing solutions whenever you need help with
plant floor issues ranging from maintenance to personnel.
1. Five strategies to achieve world-class preventive maintenance
2. The truth about five common VFD myths
3. Understanding variable frequency drives
4. Big data drilldown part 2: Sensor and data collection technologies advance
5. How to choose the best lighting for a food facility
6. 12 tips to sustain improvement in Lean equipment maintenance programs
7. A hands-on approach for manufacturing
8. Electric motor power measurement and analysis
9. Study identifies 10 ways to improve supply chain efficiency
10. Absorption cooling makes sense
Webcasts: 1 hour to knowledge
Plant Engineerings Webcast series offers a wide selection of on-demand knowledge

everything from the latest innovations concerning the Industrial Internet of Things (IIoT) to
reports on motors, air quality and safety. All Webcasts can be completed in just an hour, and
many of them offer continuing education credits.
Among the current topics at www.plantengineering.com/webcasts:
Motor and Drive System Considerations to Ensure Maximum Performance, Increase Reliability
and Extend Product Life
Considerations for Buying or Upgrading Dust Collection Equipment
5 Ways to Improve Your Plants Training Strategy
Portable Spot Air Conditioners in Industrial Applications: Increase Revenue and Create a Safe
Working Environment
3D Laser Scanning: Revolutionizing Facility Management
6 September 2015
PLANT ENGINEERING
www.plantengineering.com/newsletters
Read this on your tablet

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editions of this
publication are greatly
enhanced and have
unique content for digital
subscribers. They also
include interactive tools
Sister act
such as videos, Web
links, and other items.
Update your subscription,
and receive the digital
edition in your e-mail in-box:
Building on their fathers legacy, a new generation

moves Bales Metal Surface Solutions forward 27
www.plantengineering.com/subscribe
Upcoming webcasts
Register for educational webcasts at
www.plantengineering.com/webcasts:
November 3: IIoT Webcast Series
Part 3: Integration considerations
Join the discussion

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Machining
without
Coolant!
Watch The
Video!
www.exair.com/79/49979.htm
Replace messy mist systems & improve

dry machining with clean, cold air!
Extend CNC
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The Model 5315 Cold

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Milling & Drilling
Fly cutters up to 460mm

in diameter have been
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tool life, increases
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improves finishes.
Chill Roll
Cooling a roll with 20F

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Tool Grinding
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Increase tool life and

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Low cost, portable, quiet
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High Power Cold Gun
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IN FOCUS
Manufacturing Day a way
to reach out into the future
By Ed Youdell
Fabricators & Manufacturers Association, Intl.
In October, thousands of manufacturers, colleges and trade schools

across the country will celebrate
Manufacturing Day by opening their
doors and inviting young people to
experience modern manufacturing.
The annual national event, executed at the local level, is designed to
dispel the prevalent misconceptions
about our industry and also address
the serious skilled labor gap that now
exists.
It is estimated that nearly 2 million
manufacturing jobs will go unfilled
over the next decade due to manufacturers inability to find talent with the
required skills. Numerous manufacturing jobs will be available for those
with the desired talents.
The fourth annual Manufacturing
Day on Friday, Oct. 2, is designed
to show a whole new generation of
young people how todays manufacturing is all about advanced technologies, state of the art facilities and
fast paced work environments. Its
also an opportunity to show parents
the kind of work that takes place in
manufacturing plants.
Students, teachers, parents, and job
seekers can see for themselves that
Female students learned how metal is bent to build duct work in an HVAC program
at Westmoreland County (Virginia) Community Colleges Manufacturing Day event
in 2014. Image courtesy: Manufacturing Day
manufacturing provides clean, safe,

high-tech environments in which to
pursue challenging, creative, wellpaid careers. By participating, we
anticipate more young people will
want to follow a manufacturing
career path.
Take Chris Monzyk, for example.
He was a student at Ozarks Technical
College in 2013 when he was part of
Since it was first launched 4 years ago, Manufacturing Day has gained attention from leaders in the manufacturing and political sectors. It also has shown
remarkable growth.
a Manufacturing Day tour at Detroit

Tool & Engineering(DTE) in Lebanon, Mo. Intrigued by what he saw
and identified by the company as a
possible potential recruit, Monzyk
was offered an opportunity to join the
firm. Today, he proudly works as a
machinist in the 109-person company
that builds tools, dies, and custom
automation systems.
I like to work with my hands,
said Monzyk. It sounds clich, but
working at DTE is fun, exciting and
new every day. I get to make something from virtually nothing.
2012 240 events, just under 10,000 attendees

2013 825 events, more than 35,000 attendees
2014 1,679 events, almost 400,000 attendees
2015 (Projected) 2,200 events and more than 500,000 attendees
Source: Manufacturing Day
PLANT ENGINEERING
September 2015 9
IN FOCUS
Send us your Manufacturing Day photos
Manufacturing Day 2015 will feature more than 2,200 events across the country.
The event has grown rapidly as manufacturing professionals are joined by educators, business and civic leaders, parents and students in celebrating modern
manufacturing.
Plant Engineering would like to see what Manufacturing Day events look like in
your plant. Please send photos and information about how your plant celebrated
Manufacturing Day, and well publish them online and in the November issue of
Plant Engineering.
Send your photos (300 dpi, jpeg) and information to content manager Bob Vavra at
bvavra@cfemedia.com. All photos submitted may be used by Plant Engineering in
its print and online publications.
It is estimated that nearly 2 million manufacturing

jobs will go unfilled over the next decade due
to manufacturers inability to find talent with the
required skills.
Your One-Stop
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Offering over 52 courses including:
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And then there is Micah Rider

who, as a high school student
in 2013, took a Manufacturing Day tour arranged through
Wichita Area Technical College
(WATC). By 2014, he had graduated
and was enrolled at
WATC and was leading one of its facility
tours on Manufacturing Day.
Rider is excited
about his pursuit
of a manufacturing
career and getting
other kids to follow
in his path. I ask kids, What do you
like to do? Do you like to play with
Legos? Have you ever thought about
building stuff? he said.
Manufacturers who open their doors

for Manufacturing Day 2015 are not
only educating their communities
about career opportunities, they also
may discover a new employee or two.
By reengaging local communities
to showcase their
manufacturing sector and demonstrate
the contribution
t h a t m a n u f a c t u ring makes to the
local economy, we
can ensure a better future and way
of life for our children and grandchildren. Our future
depends on our ability to strengthen
and advance this vital sector of our
nations economy. PE
To learn more about Manufacturing Day, including locations that will

be offering tours, and tools and advice to plan a celebration, visit
www.mfgday.com.
877-594-3156
WWW.AVOTRAINING.COM
10 September 2015
PLANT ENGINEERING
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14
Waiting Is Costly. Call Now!

info@oeo.com
EIG-020 Powerinput
& Consult
7/22/15 12:51 PM Page 1
#9 at www.plantengineering.com/information
Power Quality Metering

& Energy Management
Nexus
1500+
Power Quality
Metering
Measure and record harmful
power quality events
Conduct harmonic studies
Understand feeder
efficiency & load balance
Create automated power quality reports
Energy
Management
Log energy usage at each circuit

Calculate cost allocation
to different processes
Control loads to reduce demand
Generate automated
energy reports for executives
1-877-EIMETER | www.electroind.com
Control circuit fuses have a variety of different voltage ratings,

ranging from 32 to 600 V, and interrupting ratings up to 100 kA.
As the physical size of these fuses does not vary with voltage or
interrupting rating, the most common cause of misapplication is
due to improper voltage or interrupting rating selection. When a
system fault occurs and an improperly sized fuse tries to interrupt
an overcurrent event, there can be adverse consequences. This
mistake can lead to compromised system integrityimpacting
personnel and equipment safety.
Type, voltage, interrupt rating
Find the right control circuit or supplemental fuse in three simple

steps:
1. Select the fuse type. Select from time-delay fuses for inductive loads or fast-acting fuses for resistive loads.
2. Select the voltage rating required. The voltage rating
must be equal to or greater than the circuit voltage for the proper
application of an overcurrent protective device. The device can
have a higher rating, but not a lower one; when an overcurrent protective device is applied beyond its rating, there may
be potential for fire and arcing energy, posing a severe fire risk
to other components in
the panel.
3. Verify that the
interrupting rating of
the selected fuse is sufficient for the circuit application. The interrupting
rating must be equal to
or greater than the available short-circuit current. An overcurrent protective device must be
Eatons Bussmann series Fuses
able to safely interrupt
Made Simple program helps make
short-circuit currents to
it easier to identify the right device
which the equipment can
by clearly indicating the voltage
be subjected. If the fault
and interrupting rating on the fuse
current exceeds a level
label. The voltage rating is easily
beyond the capacity of
identified by both the color code
the protective device,
and large print on the fuse label,
the device may rupand the interrupting rating is printture, causing additional
ed on the side of each fuse. Image
damage. Therefore, it is
courtesy: Eatons Bussmann
important to use a fuse
that can sustain the largest potential short-circuit currents. Failure to apply fuses with the
appropriate interrupting rating can be a serious safety hazard. PE
Nick Offerman is a product manager at Eatons Bussmann Division.
12 September 2015
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IN fOCUS
OEE vs. MTBF: Which is the right metric?
Either can help drive specific behaviorsif correctly applied.
By Mike Gehloff
Allied Reliability Group
If you have had some level of classic reliability or maintenance-related

training, then you may have likely at
least had an exposure to some of the
more commonly used metrics such
as OEE (overall equipment effectiveness) and MTBF (mean time between
failure). Both of these metrics can be
very informative and drive some specific behaviors when applied correctly.
However, when applied incorrectly,
they will likely lead to confusion and
frustration.
While I dont intend to make anyone an expert at these two commonly
used metrics in this forum, I do want to
share some insight on how and where
we might best apply these metrics to
get the greatest impact.
Overall equipment effectiveness (OEE)
The laymans version of OEE is simply defined as what percentage of the

time that you were capable of running good product at full capacity and
with acceptable quality did you do so?
Perfection at OEE is 100%. Anything
more than that and you are breaking
a few laws of physics, but we will
save that trip down the rabbit hole for
another time.
The generally accepted formula for
OEE is as follows:
OEE (%) = Availability (%) x Performance Efficiency (%)
x Quality Rate (%)
With a simple definition
of the components being:
Availability = The percentage of the time that
you actually ran and produced something.
Performance efficiency
= During this time that you
actually produced, at what
percentage of your rated
capacity (speed, throughput, etc.) did you actually
run.
14 September 2015
plant engineering
Quality rate = For all of the units

that you produced, what percentage of
them were acceptable for sale to the
customer, meeting the stated quality
requirements.
For example:
Availability = 80%
Performance Efficiency = 90%
Quality Rate = 99%
OEE = 80% x 90% x 99%
OEE = 71.28%
Both of the OEE and MTBF metrics
can be very informative and drive specific behaviors when applied correctly.
However, when applied incorrectly,
they will likely lead to confusion and
frustration. I think that OEE is a fantastic measure for a few important reasons.
Nowhere in the definition do the
words maintenance or operations
appear. It brings us together under one
common measure. It facilitates two
teams who can easily work at crosspurposes to work together. For example,
availability losses can be experienced
as a result of both maintenance and
operating practices.
It forces us to focus on the loss of
potential rather than what we have
Assessing whether to use OEE and MTBF
as a metric for your plant largely will
depend on your industry and the sophistication of your current operation. Image
courtesy: CFE Media
accomplished with no idea of what might

be possible.
It brings together three aspects that
are critical to meeting our customers
needs. For example, if we only measured
availability, we might overlook the fact
that we ran at 50% speed.
I look at OEE as the universal measure. Mix with it some safety and cost
awareness and you have a great start
to a complete performance scorecard.
Mean time between failure (MTBF)
As the name implies, the Mean Time

Between Failure tells us how often, on
average (mean), we should expect to see
an asset fail to fulfill its function. Higher
MTBF is always considered to be better.
A simple definition for MTBF is:
MTBF = Operating Hours Number
of Failures
Operating Hours = The time frame
(frequency of measurement).
Number of Failures = The number of
occurrences where the asset failed to fulfill its function.
Note: MTBF is the reciprocal of the
Failure Rate (1/MTBF = Failure Rate).
For example:
Assume we measure MTBF on a
monthly basis (30 days or 720 hours),
and we have experienced 10 failures in
this time frame.
MTBF = 720 hours 10 failures = 72
hours
MTBF = 30 days 10 failures = 3 days
This means that under current conditions, we should
expect to experience a failure every 72 hours.
MTBF is a relative measure. Measuring MTBF on a
highly critical asset or group
of assets can be very meaningful. Measuring MTBF
across an entire department
or facility provides less value.
The key to leveraging
MTBF is to understand
where these failures come
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IN fOCUS
from, and to develop lasting strategies
that will eliminate them. Your RCFA
ability becomes very important when
you are measuring MTBF.
tion and refining, and many petrochemical processes fall into this category.
Unfortunately, in these types of environments, OEE might not serve our purposes for the following reasons:
Availability is often so critical in process industries that we see a high level of
redundant equipment (with a corresponding capital investment). If we experience
a failure of one piece of equipment, we
switch over to the redundant unit and
continue on. For this reason, availability losses are usually greatly minimized.
Performance efficiency losses can
exist, but rather than run slow, we often
immediately bring the backup unit online
and begin a fix to the underperforming
unit.
It is often difficult, if not impossible, to
identify quality losses in process industries. What does a bad kilowatt look like?
In these situations, establishing MTBF
as a meaningful measure on specific
highly critical assets and trending your
performance upward will likely provide
much more value than OEE.
Which is right for you?
My short answer to this question is that

if you can measure OEE in a meaningful way, then this is the metric for you.
Sadly, OEE does not fit in all situations.
Discrete Manufacturing
Discrete manufacturing is the production of distinct items. Automobiles, furniture, toys, smartphones, and airplanes
are examples of discrete manufacturing
products.
If this definition fits, then OEE is for
you. You should be concerned about factors such as availability, performance
efficiency, and quality rate. These factors are central to your success.
Process industries
Process industries are those who run
a continuous batch where distinction
between one unit and another is not easily
identified. Power generation, oil produc-
Keeping it simple
Metrics are a funny thing. When used

correctly and with the right application,
they can provide a lot of value and focus
to an organization. Used incorrectly,
they tend to cause more harm than good.
When selecting the best metrics
for your team, consider the following
advice:
Keep it simple. Too many measures
cloud the focus.
Make sure we know what actions to
take in order to improve the performance of each metric. What must we
do differently in order to improve?
It sounds obvious, but surprisingly
it is often overlooked.
Talk about it often. A metric is only
as good as the leader who draws the
team together to own it. PE
Mike Gehloff is principal at the
Allied Reliability Group (ARG). ARG
is a content partner of CFE Media.
This article originally appeared on the
Maintenance Phoenix blog.
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IN fOCUS
PMI stumbles to 51.1% in August over global concerns
By Bob Vavra, Content Manager, CFE Media
The August decline of the monthly Purchasing Managers Index (PMI) Index from
the Institute for Supply Management (ISM)
reflected the general malaise in the global
markets. Even though the underlying growth
in the manufacturing sector continues, the

drop of 1.6 percentage points proves there
are plenty of frayed nerves.
The PMI fell to 51.1% in August, down
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level for the PMI since a 50.1% reading in

May 2013. The index had slipped as low as
51.5% in March and April of 2015 before
rallying over the summer.
All major indices that make up the PMI
were lower in August, including a 4.8 percentage point drop in the New Order Index
to 51.7% and a fall of 2.4 percentage points
in the Production Index to 53.6%.
While any figure above 50% in the PMI
indicates growth in manufacturing ISM
manufacturing business survey committee
chairman Bradley Holcomb said the global
markets were weighing on the survey committee. Comments from the panel reflect
a mix of modest to strong growth depending upon the specific industry, the positive impact of lower raw materials prices,
but also a continuing concern over export
growth, said Holcomb in a press release.
Among the comments from committee
members:
Falling crude oil prices are benefiting
all resin based purchases as well as
positively impacting fuel surcharges
for inbound products. (Food, Beverage & Tobacco Products)
We are oversold. (Paper Products)
Business is still strong but has slowed
slightly. (Transportation Equipment)
Modest growth slightly ahead of
GDP. Optimistic for the remainder of
the year as we have little international
exposure. (Chemical Products)
(Foreign Exchange) continues to
be a challenge, especially in Europe.
Overall though, the mood is fairly
upbeat regarding (the second half of
2015) as we ramp up for a new product launch. (Computer & Electronic
Products)
Our business is good due to the
increase in commercial construction.
(Fabricated Metal Products)
Raw metals price decreases will
impact our business favorably. (Miscellaneous Manufacturing)
Business is guarded but steady. Margins are tight. Markets are very competitive. China is lackluster. (Wood
Products)
Automotive companies are investing heavily in upgrading their equipment. (Machinery) PE
18 September 2015
plant engineering
research
2015 WORKFORCE DEVELOPMENT STUDY:
Five key findings on

the unskilled workforce struggle
espondents to the CFE Media

2015 Workforce Development
Study identified five high-level
findings impacting the manufacturing industries today:
4. Actions taken: In an effort to com-
manufacturing facility today has 5%

of jobs currently unfilled, down from
7% in 2014. Despite the decrease,
64% of respondents still believe that
their facilitys workforce shortage will
increase over the next 3 to 5 years.
bat the workforce shortage, 44% of

facilities have taken to online recruitment and job postings, 40% have
instituted or increased in-house training, and 35% have reached out to local
technical schools for assistance. Nine
in 10 respondents believe that their
facilities still need to increase internal
education/training programs and provide clear career paths for each new
employee in order to better appeal to
the younger workforce.
2. Causes: When asked about the pri-
5. Manufacturings image: More than
1. Workforce shortage: The average
mary causes of the workforce shortage,

56% of respondents said there arent
enough skilled applicants to fill the
roles of the growing number of retirees, and another 34% agree that their
hiring rates arent keeping up with
manufacturings rapid expansion.
3. Unskilled workforce: According
to respondents, the younger workforce

most lacks problem solving (57%),
instrumentation (55%), project management (51%), and electrical knowledge (50%); but they remain proficient
in computer knowledge (60%) and
other basic skills (31%).
half of respondents still dont believe

that manufacturing is portrayed as a
positive career choice in the U.S. Sixtythree percent agree that offering apprenticeship programs would help to improve
manufacturings image, and another
57% think introducing this career choice
at an earlier education levelas well
as improving salaries, benefits, and job
securityare key action items.
View more information at
www.plantengineering.com/
2015WorkforceDevelopment.
Amanda Pelliccione is research
director at CFE Media.
3 in 10 facilities shut
down specialized automated
production machinery only once
a year for scheduled maintenance. Source: Plant Engineering
2015 Maintenance Study
48% of facilities conduct
regular energy audits; most

audits are performed annually
(62%), 16% quarterly, and 7%
twice a year. Source: Plant
Engineering 2015 Energy
Management Study
2/3 of survey respondents
claim that the lack of available

skilled workers has not kept
their facilities from expanding
operations. Source: Plant
Engineering 2015 Workforce
Development Study
MORE RESEARCH
All graphics courtesy: Plant Engineering, CFE Media
20 September 2015
PLANT ENGINEERING
Plant Engineering surveys its

audience on five topics each
year: Salary survey, maintenance,
energy management, safety,
and workforce development. All
reports are available at
www.plantengineering.com/research.
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Choosing a Compressor Solely Based on HP could

Negatively Impact your Overall Operating Expenses
Steve Bruno | Atlas Copco Product Marketing Manager
When considering an air compressor, a primary concern
should be; how can I get the most amount of compressed
air for the lowest overall cost?
CFM (Cubic Feet per Minute) describes the volume flow
rate of compressed air. The first step in choosing the proper
compressor is finding the CFM demand that your plant
requires. Improperly sizing your compressor because you
skipped through this step can cost you thousands of dollars
in wasted electricity if you selected an oversized compressor. On the other hand, if you had more demand than
you originally thought, the new compressor that you just
purchased may be insufficient.
As time goes on,
technology improves
and upgraded designs
become more energy
efficient. Air compressors
are no different. Engineers
work hard to improve
the efficiency of air
compressors by
producing more air than
previous generations.
If you are replacing an
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check your CFM rating and
choose a new compressor with the same CFM rating.
Do not simply swap out a compressor for another one
with the same horsepower rating because a newer model
is likely able to produce more CFM. A compressor with a
smaller HP, but equal rate of airflow can lower your energy
cost without any reduction in your plants productivity.
A higher horsepower
air compressor uses
more electricity
than a smaller one,
so the important
question is Am I
getting any more
CFM for my increased
electricity cost?
For compressors with the same advertised horsepower,
the CFM output can vary by as much as 25% between
companies and models. As an educated customer, you
want the right amount of CFM at your
necessary pressure, for the smallest
horsepower. This will allow you to
manufacture your products at the lowest
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A group of air compressor manufacturers
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Download the paper at: www.atlascopco.us/usus/aboutus/sales/compressors_generators/ct_whitepapers.aspx

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Keeping the US Mail Moving

VIBRATION ANALYSIS ON A CONVEYOR DRIVE UNIT
Mike Johnson, P.E. | Senior Analyst and Program Manager, Azima DLI
To increase machine reliability and reduce overall costs, the United States Post Offices Maintenance
Technical Support Center in Oklahoma initiated a project to provide the bulk mail centers (BMC) maintenance offices with vibration analysis equipment and training to help support the maintenance process.
Conveyors and other similar equipment can be found across multiple industries. They are often critical assets to production facilities
where unplanned downtime can have significant financial impact beyond the parts and repair costs. Catastrophic failure usually
causes collateral damage (which results in significantly more down time and repair costs) and typically happens at the worst
possible time. By implementing a predictive maintenance program, an organization can increase uptime and avoid production loss.
This case study shares how vibration analysis using demodulated spectra assisted the Maintenance Technical Support Center
in keeping the Cincinnati Bulk Mailing Center operational during the increased holiday mail volume.
Explore how predictive maintenance technologies can identify a significant problem on critical assets,
evaluate the risk of continued operation and anticipate the repair and parts BEFORE failure occurs.
Condition based monitoring can increase machine reliability and reduce overall costs including
costly unplanned downtime.
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8/21/2015 11:36:37 AM
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Troubleshooting VFD Motor System Problems

Despite the growing number and importance of variable-frequency drive (VFD) motor/machine systems
in industrial applications, predictive maintenance professionals arent often aware of what is necessary to
identify faults to avert unexpected, premature motor failures.The complexity of the symptoms exceeds
the capabilities of common RMS handheld instrumentation, most of which is incapable of discerning
symptoms or root causes. A variable-frequency drive exposes a motor to millions of impulses, which in
turn requires proper installation and maintenance of both motor and drive. Protective devices such as line and load reactors,
line traps and MOV surge arresters are necessary even if their return on investment is not immediately apparent.
Tools available to field maintenance electricians are often limited to RMS current and voltage meters, which are inadequate
when in comes to diagnostics of a given VFDs variable operation in a motor-load system. While there are a few articles on
debug and root-cause analysis of VFDs, authoritative and comprehensive technical references for analysis of VFD-related
problems are not so readily available. The transient nature of VFDs, which interact dynamically with the
motor and load system components, severely limits the usefulness of standard RMS and waveform types
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Turning Air Compressors

into an Energy Source
Werner Rauer | Product Manager for Screw Compressors, Kaeser Compressors, Inc.
Michael Camber | Marketing Services Manager, Kaeser Compressors, Inc.
The rise in energy prices is an unwelcome reality in

todays manufacturing and business environment.
While the rate of price increases for natural gas,
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Industrial compressed air users looking for new ways
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One important way operational efficiencies can be
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Kaeser Compressors, Inc.s whitepaper,
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Valve Postitioners Offer Improved Control Valve Performance

David Matherly | Product Manager Controls and Instrumentation
Control valve designs and the concept of controlling fluids
within a system have been around since the eighteenth century.
In particular, rising stem, linear modulating types have been
utilized within processes to precisely control the amount of flow
and pressure of those fluids. But manually setting and changing
valve positions based upon downstream system demand changes
quickly became impractical. Pneumatically or electrically
actuating valves via a remote signal gained popularity after
reliable actuator designs and automatic controllers were
introduced; automatically moving a valves position dictated by
a controllers set-point increased system accuracy.
This greatly influenced product quality and reduced waste
associated with manufacturing processes. When specific sensors
were added to feed-back information to the controller concerning the manufacturing process and the variable being controlled,
system accuracy was once again

increased. The control loop was now
closed between the controller, sensor,
and automatic valve.
Although performance was improved
through the use of closed-loop control
systems, control valve and actuator
designs determined total system accuracy. The addition of valve
positioners has radically changed the way actuated control valves
respond within a process control loop. This white paper details
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a basic, pneumatically actuated control valve package.
Download the paper at: http://bit.ly/1VvJlks
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How do you stop sensor drift?

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8/17/2015 11:46:27 AM
Stacey Bales (left)

and Sara Mortensen
(right) with a picture
of their father
Steven, who started
the family metal
surfacing business
in the 1980s. The
sisters inherited the
company after their
fathers death six
years ago and are
reshaping it in new
ways. All images
courtesy: CFE Media
Sister act
Stacey Bales and Sara Mortensen chart a fresh course for the family business.
By Bob Vavra
Content Manager, Plant Engineering
tacey Bales is the analytical one,

leading the change to improve
operations and grow the family business. Sara Mortensen is
the creative one, bringing her
people skills to help customers
solve problems.
As sisters, they are two sides of the same
coin; each the parts of their father Steven
Bales, who began the familys metal-finishing plant with his brother Mike in Downers
Grove, Ill., in the 1980s. His daughters
would tag along with him while they were
still in school.
When we were younger, Dad used to
bring us down here, give us masking tape,
and let us do etched-glass projects, said
Bales. I used to look forward to going to
work with Dad for the day. He was a good
role model.
When Mike Bales retired in 2009, Steven
Bales prepared to take the business forward.
Stacey had a keen interest in architecture
and drafting and was working full time at
the company. Sara, who had just given birth
to a daughter, was working part-time in the

front office. And then Steven Bales died in
November 2009 at age 53, and everything
changed.
A light went out around here, said
Bales. A big presence was lost. We were
only closed a few days, and all of our
employees stayed with us. Their faith in
us made it easier to keep trucking.
As you tour Bales Metal Surfacing Solutions today, you hear of the plans for growth
and expansionthe new lines for production, the plans to expand their laboratory
and to take a strategic approach to growth.
There are the subtle changes as wella
rebranding campaign, an emphasis on social
media, and the brighter orange-and-blue
corporate colors.
Bales, 32, is president of Bales Metal
Surfacing Solutions, tackling the strategic
vision. Mortensen, 31, is vice president and
heads up the sales and marketing effort.
They are leading their company, and their
fathers legacy, into the future.
PLANT ENGINEERING
September 2015 27
Taking the reins
The skill of employees, and

their willingness to stick
with the business, has been
a key factor as Bales Metal
Surfacing Solutions builds
its business under the
leadership of Steven Bales
daughters.
28 September 2015
When Steven Bales died, his daughters

were 26 and 25 years old. There was no
formal succession plan, because no one
saw this coming. The sisters were forced to
face critical questions about the company
almost immediately. The first issue they
faced was a matter of trust. Some people
suggested to them the company assets
should be liquidated. Mortensen and Bales
werent interested in that solution.
The biggest difficulty was finding a
good group of advisors, said Bales. At
first, we didnt get the guidance we needed.
It was a matter of switching advisors and
finding good resources.
One of those resources was Dean Tufano,
the companys technical services manager.
He had been hired by Steven Bales just
weeks before his passing, and Tufano
admits he had doubts at first.
I thought it was going to be rough, but I
was proven wrong in a few months, Tufano
said. I was weighing if I was going to stay.
They took the horse by the reins.
Everybody stood behind us, said Bales,
who credits Tufano and technical services
manager Harry Raimondi for helping them
steer the ship then and now.
Most people were there to
support us and help us. They
have more expertise than we
do, and we leveraged their
experience a great deal. A lot
of it was being able to admit
you dont know what you
dont know. You cant think
you have all the answers.
Today, as they guide Bales
Metal Surface Solutions
into the future, Bales and
Mortensen face the same
i s s u e s m o s t m a n u f a c t u ring businesses facetraining, benefits, and employee
retention. Theyve rewritten
and tightened up the company handbook to focus on
enforceable policies. Our
old employee handbook read
like a technical manual, said
Mortensen. We tried to put a
little more fun and personality into it.
Theyve struggled with
health insurance costs, and
yet have retained one of their
plant engineering
When we were younger, Dad
used to bring us down here, give

us masking tape, and let us do
etched-glass projects. I used to
look forward to going to work
with Dad for the day. He was a
good role model.
Stacey Bales, Bales Metal Surfacing Solutions
fathers unique benefitsa paid day off on

your birthday.
Theyve also worked to improve training
and outreach to develop the next generation
of their workforce. Were trying hard to
reach out to the high school level, but were
still a couple of years away, said Bales.
For us, its harder; no one grows up and
says they want to be a chrome plater. We
train in-house, but its kind of a dying art
form. We try to attract younger workers by
having a robust benefits package.
Unique challenges
Bales and Mortensen recognize they are an

anomaly in their industry. At trade events,
they are likely among a handful of women
at the show. Even fewer have executive
titles after their names.
If anything, I think its an advantage,
said Bales. Well go to PMA (Precision
Metalforming Association) events, and
well be a couple of the only women in
a room. People tend to remember you if
youre one of only a few women in a sea
of men. If anything, its helped the networking.
Ive had experiences at trade shows
where Ive almost made a game out of
it, said Mortensen. When Im there
with Dean, half the time Im answering
someones question, but theyre looking
at Dean.
Bales also has joined Women in Manufacturing (WIM), a spinoff organization of
PMA that provides a forum for professionals
Continued on page 32
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Better training leads

to a stronger workforce
By Randy Pearson
Siemens Industry Inc.
The metalworking
industry as a whole
benefits from the
ongoing cooperation
of controls suppliers,
the machine builder
community, and
educational
institutions, whether
high school shop
classes, vocation
schools, or university engineering
departments.
30 September 2015
rising tide lifts all boats. That

quote typically is ascribed to
John F. Kennedy back in the
1960s, when my metalworking involvement consisted of
playing on the jungle gym at the school playground. Actually, his speechwriter borrowed
the quote from a local chamber of commerce,
who had the same idea I present to you here.
The metalworking industry as a whole benefits from the ongoing cooperation of controls
suppliers, the machine builder community, and
educational institutions, whether high school
shop classes, vocation schools, or university
engineering departments. It also benefits from
everyone in the end-user world, from the fiveman job shop to the production department
of a major original equipment manufacturer
(OEM). This is not pie-in-the-sky or Pollyannaish behavior; it is serious business.
For example, my company has formed an
alliance with the Tooling and Manufacturing
Association (TMA), formerly the Tool and
Die Institute, located near Chicago. This association changed its name when it broadened
its scope to include more companies, larger
companies, and more affiliate members among
the industry supply base. This was done to
expand the input, thinking, and direction of
the groupsomething from which we can all
benefit.
The members are still related to metalworking, but they include stampers, weld shops,
chipcutters of all sorts, and even the machine
builders and dealers who supply the industry. They find that they have much more in
common when running their businesses, and
those perspectives are useful to all the members. Were helping to sponsor competitions
among the members and the students at local
schools, with an eye on raising the baror
water level in this analogyto improve the
skill sets of current workforce as well as the
next generation of machine operators, programmers, machine designers, and maintenance engineers.
Meanwhile, the feedback we get from these
various groups helps us design controls that
are more flexible, more responsive to user
plant engineering
needs, more adaptive to the rapidly changing

landscape in machine shop operations today,
and, maybe most importantly, look ahead to
the future of manufacturing in America.
I think of the speed with which we transitioned from manual machines to numerical
control tape drives to computerized numerical control (CNC) machines. Now we have
robotic articulation, machine-to-machine
communications, transfer-line technology for
blank to finished workpiece flow, and even
the elimination of the zone controllers on fully
automated production/assembly lines. After all
this change, its obvious that controls suppliers must make a commitment to follow every
development in the market.
This is not done to make us richer, as our
involvement in most training enterprises is
offered gratis. Rather, its done to make us a
better supplier, to make our customers build
better machines, and to make the industry
more viable and more competitive worldwide.
In the end, everyone wins.
Several machine build customers are now
sending their students and customer workforces our way for specific training on CNC
technology.
In the field, too, better training means a
better operator workforce thats capable of
running multiple and very different types of
machines. The days when an operator of Brand
X lathe wouldnt even consider working on a
Brand Y lathe are goneand thank goodness
they ARE gone, because U.S. shops wouldnt
survive with that mindset anymore.
Through the cooperation of controls suppliers, machine builders, educational institutions,
and the end-user community, the boats will
indeed all rise and prosper. PE
Randy Pearson, a long-time veteran of the
machine tool industry, is the Siemens sales
support manager for U.S. dealers and OEMs.
His special interest is the many levels of training on CNC machine tools. He conducts
various seminars, workshops, and classes
the company conducts at Siemens training
facilities around the country. His e-mail is
randy.pearson@siemens.com.
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Continued from page 28

in the manufacturing sector. They now have
500 members and will hold their annual
convention in Minneapolis on Sept. 23-25.
I just started to participate. It kind of
makes you feel not so all alone, she said.
There are a lot of women in ownership positions. Im hoping to build a solid network of
people I can call on and collaborate with.
The family approach
Stacey Bales and Sara

Mortensen have brought a
lighter touch to the business, including a new color
scheme and a new motto for
employees to wear.
32 September 2015
The work each day is to create engineered

plating and coating solutions of all kinds of
metal surfaces. Bales customers are in the
automotive, medical, packaging, lighting,
and electrical industries, and the company
includes a satellite facility in Harlingen,
Texas. But as owners of a family business,
Bales and Mortensen are acutely aware of
tempering the organization in the same way
their workers temper metal.
They have families of their own: Bales
is a single mother of 15-year-old Sarina;
Mortensen and her husband, Dave, and
their 8-year-old
daughter, Laney, all
have earned their
black belts in karate.
They are now looking into succession
planning for the
company, something
that wasnt in place
when their father
passed away, so that
the future for Bales
Metal Surfacing
Solutions are secure.
The sisters understand the need for a
workplace that is
both firm and flexible, as needed.We
listen to a lot of
employees. We listen to their issues at
home, said Bales.
We worry about
the family. We really
rely on our employees as much as possible.
There are a lot of
advantages to having
a female boss, said
Tufano. In an all-
plant engineering
Were trying to offer more
services without
overgrowing ourselves.
We want to be calculated and
strategic about our moves.
We want to take care of our
customer base first.
Stacey Bales, Bales Metal Surfacing Solutions
male organization, a lot of guys are unapproachable about issues.

Theyve brought their own personalities to
the job as well. Mortensen has led the effort
to put a fresh face on the companys external
message. Theyve hired a public relations
firm, rebranded the company, and provided
a lighter touch in many areas. For example,
workers have T-shirts that read We finish
what others start.
Im more than thrilled to be on the marketing side, going to trade shows, helping our
customers through the problems, and helping
them through the solutions, said Mortensen.
That leaves Bales to manage the business
strategy. Weve expanded our capacities and
linked up with more strategic customers,
she said. Were trying to be more creative
and work as Lean as possible. We were able
to create a second shift and get parts out to
customers faster, without raising overhead
costs. Were trying to offer more services
without overgrowing ourselves. We want to
be calculated and strategic about our moves.
We want to take care of our customer base
first.
Bales likes the board game Monopoly;
Mortensen prefers Scrabble. The sisters are
still sisters; you can see the interplay between
them during a photo session. They share an
office at the plant (The first time weve
shared a room since we were 2, Mortensen),
and their combined efforts are taking Bales
Metal Surface Solutions into the next generation. It is not the path they imagined, of
course, but their fathers memory and his best
individual characteristics are evenly divided
among his daughters, and thats helped them.
Weve got a lot of his good traits between
the two of us, said Bales. We can make
this work. PE
CFE Medias
Global System
Integrator Database
CFE Medias Global System Integrator Database is an interactive

community of global end-users and system integrators hosted by
Control Engineering, Plant Engineering, and our global partners in Asia and
Europe. Through this database you will be able to connect with System Integrators
by searching their corporate profiles which highlight: industries served,
engineering specialties, product experience, geography, and other pertinent data.
Find and connect with the most suitable service provider
for your unique application.
Start searching the Global System Integrator Database now!
www.plantengineering.com/global-si-database
Daniel Ackmann .........35
Amanda Pelliccione, Project Manager and Director of Research
Chad Albert .................35

Corey Arrick ................35
Joseph Bastone .........35
James Couto ..............36
Dave Denison .............36
Stephen Dora ..............36
Jesse Dorn ..................36
Alfredo Flores .............37
Michael Gagne ........... 37
Cassy Gardner ...........37
Miguel Gutierrez .........37
Bryant Jackson ..........38
Robert Jardel ..............38
Jayesh Jariwala .........38
Scott Lawless .............38
Hunter Longshore ..... 39
Sean Mascarenhas ....39
Abid Munawar ............39
Justin Nielsen .............39
Jayson Pestow ...........40
Jeff Poirier ...................40
Justin Robinson .........40
Carl-Johan Roos ........40
Kori Shane ..................41
Lee Smith ....................41
Bret Van Wyk ..............41
Chris Vitale ..................41
Nathan Wingate ..........42
David Ziskind ..............42
34 September 2015
The 2015 Engineering Leaders Under 40 are a dedicated group

of engineers that give hope to the future of manufacturing.
With the future
of manufacturing heavily relying on the younger

workforce, Control Engineering and Plant
Engineering are honored to present the
2015 Engineering Leaders Under 40. These
30 individuals are involved in a variety of
industries and responsibilities that force
them to sharpen their multi-tasking and
management skills daily.
The majority70%serve the engineering and system integration (SI) sectors, while
instrumentation and measurement (57%),
consulting (50%), and food, beverage, and
tobacco (50%) round out the top four segments in which they are involved.
Here is a quick look at this years Leaders:
Education: 90% of the Leaders have
earned their bachelors degrees, 20%
masters degrees, and 7% associates
degrees.
Job function: 23% are primarily
involved in SI roles, 17% control engineering, 10% general/corporate management, 10% consulting, 7% product
design, 7% manufacturing engineering,
and 6% plant management/engineering.
PLANT ENGINEERING
SI or engineering services: 79% provide

SI or engineering services to manufacturing organizations.
Products or systems: The top five products or systems purchased or specified by
this years Leaders are industrial control
equipment or systems (57%), software
(53%), I/O products or systems (53%),
instrumentation (53%), and programmable logic controllers (53%).
Machines for resale: 37% design, build,
or install machines for resale to other
companies; 47% design, build, or install
machines for use within their companies.
The 2015 Engineering Leaders Under
40 are featured in the following section
and with more information online at
www.plantengineering.com, and will be
honored at the 2016 Engineering Awards
in Manufacturing dinner hosted by Control
Engineering and Plant Engineering on
Monday, March 21, 2016, in downtown
Chicago. For information on how to
nominate for 2016, visit
www.plantengineering.com/EngineeringLeaders.
Daniel Ackmann, CEM, LEED AP BD+C, 28
Chad Albert, 30
Project Manager; Energy Engineer; Enviro-Management &

Research Inc.; Springfield, Va.
Engineering Manager;
Bluff Manufacturing; Fort Worth, Texas
BS Civil Engineering, Purdue University
BS Civil Engineering,
Western Michigan University
ckmann enjoys the nonroutine nature of working with multiple

federal agencies, of helping find out-of-the-box solutions to save
energy and money, and of having a considerable indirect impact on
so many people. He has consulted for federal agencies looking to
optimize performanceincluding the U.S. Dept. of Defense, where
he assisted in achieving federally mandated energy and greenhouse
gas (GHG) reduction goals, developed and maintained GHG inventories, analyzed utility bills and rate structures for opportunities to lower
costs, and identified energy conservation capital investments and
lower cost opportunities. In response to the American Energy Manufacturing Technical Corrections Act of 2012, Ackmann was the lead
writer and researcher in identifying advanced meter best practices in
federal facilities, buildings, and equipment for the U.S. Dept. of Energy. Ackmann manages the development and operation of the Architect
of the Capitols utility metering enterprise system and bill verification
system to ensure that all U.S. Capitol facilities effectively manage
energy use and retain data to establish near- and long-term utility
budget goals. Ackmann has authored federal guidance for procuring
public utility and energy management services through area wide
and utility energy service contracts for the General Services Administration. Recently, he and his wife vacationed in Iceland to enjoy the
people, geology, and beauty of the country.
lbert brings his advanced skills in

creating automation systems for
the engineering team at Bluff Manufacturing. As an innovator, Albert
drives new product development and
redesigns existing products for greater manufacturing efficiency. He
consistently leads his team to deliver solutions and value to their customers, increasing revenue for his company. Albert has transformed
the way Bluffs products are created with his process development
framework designed for the engineering department. He also has created automated tools to streamline the customer ordering process and
systematize products, resulting in decreased ordering cycles. In the
engineering industry, Albert has been the Bluff member representative
of the Loading Dock Equipment Manufacturers group of the Material
Handling Institute, which reviews, discusses, and revises the standards for the design, performance, and proper operation of loading
dock equipment. Outside of work, Albert enjoys spending time with his
2- and 4-year-old sons. He is involved with community service, including mission trips to Central America and helping with Hurricane Katrina
cleanup in Alabama. Albert volunteers for his church through community cleanup projects and assisting the homeless in Fort Worth.
Corey Arrick, 38
Joseph Bastone, 37
Engineering Manager, BAE Companies,

Philadelphia
Marketing Manager; Honeywell;

Fort Washington, Pa.
BS Agricultural & Biological

Engineering, Purdue University
BS Chemical Engineering,
Rensselaer Polytechnic Institute
rrick has broad experience as

a process engineer and project manager working in the food,
pharmaceutical, and health/personal
care industries. He has worked as a
design and construction engineer for
various clients, ranging from Godiva Chocolatier to GlaxoSmithKline.
He also has worked in plant operations and as a quality specialist in
the meat industry. Recently, Arrick managed the operations team and
acted as the start-up engineer at a meat import and processing facility. He manages the quality department for the companys products,
achieving U.S. Dept. of Agriculture import and domestic status and
leading the facility to Safe Quality Food certification. In 2001, Arrick
received an Operational Achievement Award at Godiva Chocolatier
for the installation and start-up of a caramel-cooking process, and
in 2012 he received a PRIDE AwardProfessionals Recognizing
Individuals who Demonstrate Excellenceat Barry-Wehmiller Design
Group. Arrick has five U.S. patents and two European patents for
hot-beverage products. Arrick is a motorcycle enthusiast and enjoys
experimenting with foods and drink by brewing his own beer, wine,
and ciders and making his own yogurt and cheese.
astone uses his strong analytical

capabilities to consistently prioritize tasks for effective commercialization of prominent developments
at Honeywell in Fort Washington,
Pa. He manages the Experion PKS
Control and I/O portfolio, which includes five product manager direct
reports who represent more than 100 years of experience. Starting as
an application engineer, Bastone spent his first 8 years with Honeywell in the field with key customers. He later joined the product marketing team as the product manager for Experion controllers and was
selected to launch derivatives of Experion PKS, for which he received
a Corporate Marketing award in 2012. Bastone is now the marketing
manager for this product, and he recently launched the Universal I/O
for Experion. He is also a key contributor for the LEAP initiative at
Honeywell Process Solutions, challenging how automation projects
are implemented and deployed. For this, he also won a Corporate
Marketing award in 2015. Bastone always has been drawn to technology and the path it offers: exposure to new, high technologies while
managing a business. At home, he does time-lapse photography with
his two children, along with a student robotics platform.
PLANT ENGINEERING
September 2015 35
James Couto, 32
Dave Denison, 39
Project Manager; Autopro Automation

Consultants Ltd.; Calgary, Alberta
Director, DeltaV Product Marketing;

Emerson Process Management;
Round Rock, Texas
BS Electrical Engineering, Lakehead University; MBA, University of Calgary
outo is currently the youngest project manager contracted at Autopro Automation Consultants. Couto
also manages his own company,
Couto Consulting, and a separate
software-as-a-service business. He is
recognized at Autopro as a strong leader and an effective team builder,
and he is always looking for ways to improve processes and drive efficiency in projects. Coutos broad range of skills and experience, including an excellent balance of people and technical skills, contributes to his
tremendous ability to mentor others, even staff members more senior
than he is. In the past year, Couto successfully completed his MBA at
the University of Calgary, an achievement that consumed all of his spare
time. The desire to broaden his experience and move away from a pure
technical focus to one that includes the business perspective prompted
him to pursue the degree independent of financial support from the company. Off the clock, Couto volunteers with Engineers Without Borders
and works on the corporate engagement team to establish awareness of
the organization. He participated in the 2012 Enbridge Ride to Conquer
Cancer and raised more than $5,000 for the Alberta Cancer Foundation.
BS Computer Engineering, Iowa State

University; MBA, St. Edwards University
ver the past 16 years at Emerson

Process Management, Denison
collaborates cross-functionally to create a compelling product and technology vision based on customer needs
and new innovations. He contributed to the DeltaV distributed control
system (DCS) as a software engineer, software development manager,
and director of software applications and is a DeltaV product marketing
director. Denison wrote real-time software responsible for running control logic and interfacing to multiple I/O technologies within the DeltaV
controller. Denison led the effort to design and certify the DeltaV SIS
with the Electronic Marshalling product. Denison is a recognized innovator and has been awarded seven patents associated with DeltaV.
Denison planned and directed multiple programs within the product
areas of operations environment, engineering clients and servers, virtualization, and remote monitoring. Denisons move into product marketing has increased his responsibilities and ownership of the DeltaV
product lifecycle. During free time, Denison plays softball, basketball,
and golf, and coaches his daughters youth basketball team.
Stephen Dora, 33
Jesse Dorn, 32
Engineering Specialist, Plant Planning;

Toyota Motor Engineering & Manufacturing
North America Inc. (TEMA); Erlanger, Ky.
Project/Maintenance Manager,
Manufacturing; Victaulic; Easton, Pa.
BS Electrical Engineering,
Rose-Hulman Institute of Technology
AAS Tool Making Technology & BS

Manufacturing Engineering,
Pennsylvania College of Technology
ora demonstrates leadership in

his role as project leader for the
TEMA Plant Planning Section for
specification, design, construction,
and handover as the owner for Toyota
manufacturing plants in North America. At Toyota Motor Manufacturing
Kentucky he exhibited continued growth in leadership roles for plant
expansion to bring the Lexus brand to the U.S. Dora has advanced
from his background of electrical engineering through building components and systems, including civil/structural, mechanical and piping,
and electrical power and distribution. He has brought and led innovative
cost-effective design and construction improvements while Toyota budgets and schedules have compressed. He participates in seminars and
conventions to continue professional development. Dora is a leader for
Toyota projects primary commitment to construction safety by obtaining
his Occupational Safety and Health Administration 30-hour credentials
as well as participating in all Toyota electrical safety and lockout training. He has authored several Toyota training courses on power distribution and electrical systems. Dora married in July 2015, and he and his
wife enjoy running 5 and 10k races, traveling, and yard saling.
36 September 2015
PLANT ENGINEERING
orns intelligence, self-motivation,

and professionalism has allowed
him to be successful in multiple roles
within Victaulic, including his present
position as the project/maintenance
manager in manufacturing. Dorn began his career at Victaulic in 2007
in the rotational engineering program and has rapidly advanced while
undertaking various leadership roles. He has served as a cost reduction team leader and municipal operations facility manager to his current position. With a strong understanding of U.S. operations, Dorn has
been instrumental in implementing effective process improvements
that have enabled Victaulic to achieve major savings while boosting
productivity, improving manufacturing output, and enhancing on-time
product delivery for customers. Dorn is skilled in process improvement,
including finding ways to secure local efficiency gains and manufacture
products close to customers. He has a strong passion for locomotives,
specifically fixing and performing maintenance on steam trains. He volunteers at several tourist railroads. When not working on trains, Dorn
likes spending time with his wife, two children and other family, out on
the river in his kayak, or riding dirt bikes and four wheelers with friends.
Alfredo Flores, 31
Michael Gagne, 28
Senior Controls Engineer; RedViking;

Plymouth, Mich.
Senior Software Engineer; Kepware Technologies; Portland, Maine
BS Mechatronic Engineering,
Monterrey Institute of Technology and
Higher Education, Quertaro (ITESM)
BS Electrical & Computer Engineering, University of Maine
lores is a detail-oriented leader

in implementing standards that
unify RedVikings processes across
diverse business units. From his
origins in mechanical design, Flores
has shown aptitude for quickly acquiring new skills and leads in electrical engineering, controls engineering, and project management for the
manufacturing execution systems (MES) and manufacturing and assembly solutions teams. At age 25, Flores took over a factory information
systems launch project with great success. At 27, he managed a staff of
eight engineers to successfully implement a complete tracking and error
proofing system (EPS) in a new plant, before conveyors were installed.
Flores EPS worked flawlessly upon launch without time for the normal
debugging process. He recently designed a unique controls architecture
for RedVikings battery-free inductively powered automated guided
vehicle system, Wingspan. Flores is the new knowledge leader and has
designed a new approach to make the AGVs controls-agnostic. In his
free time, Flores is studying for his Masters degree in engineering management and enjoys playing outdoor sports with his two young children.
agnes extremely versatile skill set allows him to lead projects in

all of Kepwares major markets. He is well respected among his
peers, serving as a mentor to new hires and contributing to key decisions behind Kepwares major product releases. In 2009, Gagne was
one of the first recipients of Kepwares Scholarship for Excellence in
Engineering. This recognition led to an internship with the company
followed by his graduation in 2010. From there, he quickly advanced
his career, moving from software engineer to senior software engineer. Gagne played a major role in the design and development of the
Scheduler, a data optimization tool integrated within the companys
flagship product, KEPServerEX. As lead engineer of the project, he
ensured the technology maintained its core purpose and functionality
from inception to release. His ability to contribute across many areas
of the business makes him an invaluable asset to the company and
enables him to lead future initiatives. Currently, Gagne is spearheading the development of Kepwares OPC Unified Architecture implementation. Gagne also promotes science, technology, engineering,
and mathematics (STEM) education by volunteering in local career
fairs, encouraging students with his own story to pursue careers in
technical industries.When hes not overseeing engineering projects,
Gagne spends free time homebrewing his own craft beers, having
recently joined the American Homebrewers Association.
Cassy Gardner, 24
Miguel Gutierrez, 35
Engineer; Banks Integration Group;

Vacaville, Calif.
Project Manager; Maverick

Technologies; Santa Ana, Calif.
BS Biological Systems Engineering, University of California, Davis
BS History, California State University,

Fullerton
hough Gardner is in an entrylevel position at Banks Integration Group, she has significantly
impacted her company and continues to help reshape its direction and
culture. Gardner is actively involved
in creating a positive environment at Banks; she has taken the lead
role in Bright Ideas, one of Banks managements initiatives aimed at
improving employee engagement. In this role, Gardner has engaged
and collaborated with employees of all levels within her company.
Gardner has developed the infrastructure to help employees make
a positive impact and influence the direction of the company through
this iniative. In addition to her contributions at Banks, Gardner enjoys
working with children to foster interest in the science, technology,
engineering, and mathematics fields. She recently participated as
a mentor in the Women in Science and Engineering program at UC
Davis and helped execute and coordinate an outreach presentation
at the local Boys & Girls Club of America. She actively participates in
the local International Society for Pharmaceutical Engineering (ISPE)
chapter planning and organizing events and also has spoken at the
local student chapter of ISPE about controls engineering.
utierrez combines many first-rate

skills to make him an effective engineering leader at Maverick
Technologies. He quickly learned the
necessary technical skills early in his
career and still demonstrates an ongoing personal drive to always know more. He engages with customers to
understand their needs and with coworkers to encourage, help, and train
them. Gutierrez knows what it takes to execute a project right the first
time with the highest quality, keeping the team focused so that the customer is delighted and Maverick is the preferred choice for customers
and employees. A liberal arts background forms the foundation of Gutierrezs experiences. However, as he worked through school he acquired
database programming experience that quickly transitioned him into the
automation industry where he found an aptitude for human-machine
interface and programmable logic controller development. He has
consistently gained skills and executed increasingly complex projects
through his career, pushing himself to excel in each task. He is a regular
contributor to company blog posts that promote excellent work skills.
When hes not working, Gutierrez can be found at the paintball park with
friends or preparing for his next Zombie Run or dragon boat race.
PLANT ENGINEERING
September 2015 37
Bryant Jackson, 28
Robert Jardel, 30
Systems Engineer/Task Manager;

Leidos Engineering; Walled Lake, Mich.
Controls Engineer; Airline Hydraulics;

Bensalem, Pa.
BS Electrical Engineering Technology,

Michigan Technological University
AAS Mechanical Engineering,

Camden County College
Jayesh Jariwala, PE, 39
Scott Lawless, 35
Project Manager; Applied Control

Engineering Inc. (ACE); Owings Mills, Md.
Project Manager; Leidos Engineering;

Walled Lake, Mich.
University of Delaware
BS Electrical Engineering & Computer

Engineering, Kettering University
ackson is an eager, capable

young professional who has
quickly risen at Leidos because of his
outstanding talent and aptitude. His
ambition is apparent to all that work
with him. Jackson enjoys a challenge
and volunteers for new and difficult responsibilities, resulting in him
quickly becoming a leader within Leidos as a systems engineer and
project manager. He is willing to tackle any task, running straight toward
a problem to find the solution. Jackson was hired at Leidos immediately
following his graduation from college in 2010. He took on additional
responsibilities, even outside the expectations of his managers. He is
most proud of his work at a casting facility in Toluca, Mexicoa very
difficult project that he encountered in his career. He started as the
lead project engineer, responsible for the design, implementation, and
commissioning of a new utility control system to be tied into an energy
management system. He is currently the main point of contact for the
majority of this customers projects.Jackson spends his time away from
work with his wife and their 5-month-old daughter. He also volunteers
for philanthropic walks and is active in other similar events.
ariwala possesses expertise in

classic control systems including
human-machine interfaces and programmable logic controllers. Jariwala
differentiates himself with a breadth of
knowledge on plant historians, database schemas, reporting applications, and custom programming applications. Strengths include designing systems to capture critical process data
and developing dynamic Web-based reports for a variety of users. He has
also worked with customers to bring plant floor data into manufacturing
execution systems and enterprise systems. Since graduating from the
University of Delaware, Jariwala has enjoyed a career as a process control engineer at ACE. He began his career in ACEs Newark, Del., office
and then transitioned to be a senior technical resource for ACEs Chesapeake Region office in 2010. Throughout his career at ACE, he has been
a highly sought-after resource internally and to ACEs customers. Jariwala
is also the FIRST chair of the Baltimore/Washington D.C. section of the
International Society of Automation (ISA). For the past 5 years, he has
volunteered as a mentor for the FIRST Robotics Competition. Jariwala
mentors an all-girls robotics team from Western High School in Baltimore,
providing programming training and troubleshooting support.
38 September 2015
PLANT ENGINEERING
ardel is the type of person who

can pick up a book or manual,
read it, and retain all the knowledge
inside. He is self-motivated, hardworking, and is always willing to go
above and beyond to help and teach
others in his spare time. Jardel quickly expanded his skill set when he
started with Cryovation LLC in 2013, which resulted in company growth.
He was quick to put his acquired skills to use, helping to develop new
processes for the company; this led to the release of two new products
that Jardel designed. Jardel also took leadership roles in a number of
startups, interfacing with multiple engineering disciplines, salesmen, as
well as the customer. Currently, Jardel is employed with Airline Hydraulics where he hopes to once again develop and implement innovative
solutions for a growing industry. At home, Jardel has set up a programmable logic controller (PLC) test station with human-machine interfaces, PLCs, and other automation controls in order to develop his skills
and discover new techniques for his profession. Even though his work
finds its way home every night he never misses an opportunity to spend
quality time with his fiance, Katie, and daughter, Caylen.
awless is a project manager

and engineer who consistently
performs and completes projects
successfully, gaining him the trust,
confidence, and respect of his clients.
Lawless has developed profitable
programs for major customers at Leidos Engineering and is a leader in
his part of the company. Lawless strengths lie with implementing system integration program solutions and teaching young engineers within
Leidos. His team is currently working on a fan array air handling system
program that is developing a standard control system design to meet the
requirements of his clients, Ford Motor Co. and General Motors. His team
is in the process of designing a modular chilled-water control system
that can be assembled and tested before shipment to the clients site.
Lawless is a certified energy manager through the Association of Energy
Engineers and a project management professional through the Project
Management Institute. Within the company he is a go-to person for system controls/integration questions and assistance. Lawless is close with
his family and friends, well connected, and respected in the community.
He has been involved with multiple kickball tournament fundraisers and
local charities and has a great camaraderie with his coworkers.
Hunter Longshore, 33
Sean Mascarenhas, 33
R&D ProfessionalControl Systems

Engineer; Sandvik Mining; Alachua, Fla.
Senior Engineer; Autopro Automation

Consultants Ltd.; Calgary, Alberta
University of Florida
B.Eng. Electrical Engineering,

McMaster University
Abid Munawar, 33
Justin Nielsen, 37
Central Engineering Lead; Intech Process Automation; Houston
ManagerControl Systems &

Instrumentation; Excel Engineering;
St. Paul, Minn.
ongshore is a talented, detailoriented, and hands-on control

systems engineer at Sandvik Mining.
Having taken a system lead role at the
Sandvik Automation Modules (SAM)
product line, he has responsibility for
upgrades, rollouts, investigating issues, providing hot fixes, and other
primary tasks related to SAM. Additionally, he has undertaken mine visits
where he engages the end user to suggest new features and capabilities
as well as conducting troubleshooting and training sessions. Longshore
has led several training classes within the Sandvik factory in Florida to
educate shop floor personnel whenever new features are released and
on testing. While studying at the University of Florida, Longshore found
a genuine interest in mechatronics and dedicated one of his senior projects to developing closed-loop control motor driver boards for a threeaxis computerized numerical control machine. Additionally, during his
college career, he spent a couple of summers in South Africa working at
a robotics lab where he was introduced to machine controls. Aside from
work, Longshore is also an avid cyclist and runner, often training with his
co-workers for off-road cycling events and half marathons.
BS Mechatronics Engineering, National

University of Sciences and Technology;
MBA, Virtual University of Pakistan
unawar has demonstrated leadership skills required at a management level to achieve his career
goals and to contribute in achieving
company targets. He is continually
striving to enhance his professional skills so that his team can improve
as a whole. Munawars main contribution has been in establishing a
central engineering lead function and managing a large pool of project
resources. He has developed and successfully run batches of trainee
engineers to harvest resources for meeting Intechs future needs.
Munawar has established an effective performance management
mechanism to not only evaluate performance periodically but to chalk
out a career road map and provide mentorship to younger engineers
so they can achieve their objectives. For this, he formulated a new
competency framework for his business unit by using his analytical
skills and mapped the existing competencies of the resources of his
department on the new framework for gap analysis. Munawar has led
a volunteer group that planted and cared for more than 3,000 trees
in Lahore, Pakistan. He recently relocated to Australia and is looking
forward to contributing to its automation and control society.
ascarenhas has progressed very

quickly since graduating from
McMaster University. He was responsible for major projects very early in
his careerwithin his first 5 years he
led a large distributed control system
upgrade project, including a successful shutdown and turnaround. When
Autopro opened its location in Pune, India, Mascarenhas was one of the
first people sent to train and mentor new technical staff, working long
hours to orientate them and get them ready to work on Autopros projects. More recently, he was electrical lead on a large greenfield project for
a major petrochemical producer, the largest project in Autopros 25-year
history. This involved managing a team of more than 20 technical staff,
in addition to interfacing with the client and subcontractors, and ensuring
that quality standards were met on all electrical deliverables. There was
a great deal of complexity in the number of engaged vendors, number of
Autopro branches that provided project staff, and new technologies that
were deployed on the project. For the past 6 years, Mascarenhas has
volunteered as a high school football coach. He loves football and sharing his passion for the game to develop leadership skills with youth.
Clarkson University
ielsen has provided a fresh perspective to broaden the services

provided by Excels Control Systems
group, as well as the client base that
Excel Engineering serves. He is able
to understand what the client needs, ensure that the individuals performing the work are performing optimally, and provide quality services to
Excels clients. He has a vested interest in sharing his knowledge with the
engineers who work with him and helping them succeed in their careers.
Nielsen has been involved in controls and automation engineering since
1999 and has a strong background in the pharmaceutical, chemical, and
power generation industries. Nielsen has been the lead for control system engineering on several multi-million dollar controls system upgrade
projects for key clients. Nielsens functions include developing new
business relationships, mentoring junior level engineers, and continuing
to broaden the services that engineers can provide. Nielsen is an International Society of Automation (ISA) member and an ISA-certified automation professional. Nielsen is a dedicated father of two boys, who are
7 and 9 years of age. He enjoys coaching their baseball and basketball
teams and participating in activities that capture his sons interests.
PLANT ENGINEERING
September 2015 39
Jayson Pestow, 31
Jeff Poirier, 39
Senior Controls Engineer, Functional

Safety Engineer (TV Rheinland);
Frakes Engineering; Indianapolis
Senior Controls Engineer;

RedViking; Plymouth, Mich.
BS Automation & Control Engineering,

Indiana State University
estow is very passionate about

machine safety and works hard to
help customers achieve a safer facility.
While in high school, Pestow participated in a 2-year technical program for
machine tool technology and was inducted into the National VocationalTechnical Honor Society. After graduating college, Pestow maintained his
commitment to the constant learning curve in engineering and technology. As a young engineer, he earned his Six Sigma Green Belt and used
those tools to lead Lean initiatives for several years. Working as an engineer comes with inherent risk, and being a witness to two nonfatal industrial accidents propelled him into the concentration of machine safety.
Frakes Engineering shares his commitment to safety and presented him
the opportunity to pursue a certification as a functional safety engineer
through TV Rheinland, a certification that fewer than 100 engineers
nationwide receive each year. Pestow has been a competitive runner and
triathlete for 6 years. In 2012, he proposed to his now-wife, Tara, at the
finish line of his first marathon. This past May he was a top-500 finisher in
the Indy 500 Mini-Marathon, a large U.S. half-marathon.
Justin Robinson, PE,

CAP, 30
Performance Excellence Specialist; Maverick Technologies; Columbia, Ill.
Auburn University
obinson has experience working

in an array of industrial manufacturing industries, on various distributed control system (DCS) platforms,
and in multiple roles on Maverick project teams. Robinson has led
significant DCS and human-machine interface migration projects. He
also supports coaching and mentoring of team members, and he is
the subject-matter expert of high-performance graphics within Maverick, supporting the technical leadership of projects. Robinson started
his career with Maverick as a process control engineer. He has since
been promoted from engineer I, engineer II, and senior engineer to a
principal engineer within 7 years due to his technical expertise, leadership, and customer support dedication. Robinson was most recently
promoted to a new role as a performance excellence specialist. Robinson says that learning new things is the most fulfilling aspect of this
career. Professionally, he enjoys learning coding, languages, processes, controls platforms, or work processes. When he is not working,
Robinson enjoys playing guitar with his churchs worship band as well
as expanding his cooking and handyman skill sets.
40 September 2015
PLANT ENGINEERING
University of Michigan
oirier designed first-of-its-kind

helicopter transmission flexible
testing software at RedViking that
enables motors to switch roles during
and between tests to accommodate
highly complex test profiles on one test
stand. The challenge of configuring four 3,000-hp motors to change roles
was unprecedented. In an example of a typical helicopter test stand,
Motor A might always control speed with Motor B slaved or geared to follow it with balanced torque. Motor C creates load, and Motor D absorbs
load and syncs to the first two motors. And all of these have to be synced
and balanced. Poirier has built software to allow the test operator to
change the system at the push of a button, so that the speed is now
controlled by Motor C and torque is controlled by Motors A and D. In the
same test or in the next test speed can be controlled by Motor B and
torque by Motors A and D. Poiriers software creates previously impossible flexibility in helicopter powertrain testing and provides outstanding
cost savings. Poirier is an avid mountain biker; while on his honeymoon
in Hawaii, he and his wife rented road bikes and used them to climb to
the top of the Haleakal volcano, an 83-mi ride with 10,700 ft of climb.
Carl-Johan Roos, 34
Functional Safety Officer;
Emerson Process Management,
Rosemount Division; Shakopee, Minn.
M.Sc. Electrical & Computer
Engineering, Chalmers University of
Technology; MS Electrical & Electronics
Engineering, Georgia Institute of Technology; MBA, University of Gothenburg
oos was one of the driving forces

behind a new standard for overfill
prevention that has been a major safety contribution to the oil industry.
Roos has built-up a global overfill prevention business with unique
competency based on thousands of installations. This know-how is now
used in a customer-centric approach where Emerson provides the global process industry with the equipment, solutions, and lifecycle services
compliant with functional safety standard IEC 61511 to minimize the
overfill risk. Roos has led the extension of modern level measurement
technologies into safety-critical applications. He has contributed significantly to product achievements at his company, including taking safety
to the next level by introducing the worlds first SIL 3 radar level gauge,
reducing installation costs considerably through a patented two-in-one
radar level gauge, and introducing new proof-testing technologies, such
as verification reflectors. Outside of work, Roos is a fanatic floorball player, which can be described as hockey but without the ice and the skates.
He and his wife have two sons, ages 9 months and 3 years old.
Kori Shane, 38
Lee Smith, 30
Safety and Environmental Manager;

Schneider Electric; Cedar Rapids, Iowa
Lead Software Engineer; Mettler Toledo

Safeline Ltd.; Manchester, England
BS Environmental Health,
Illinois State University
MS Software Engineering,
The University of Manchester (UMIST)
Bret Van Wyk, 32
Chris Vitale, 38
Program Manager; Interstates Control

Systems Inc.; Sioux Center, Iowa
Director of Marketing;
Turck; Plymouth, Minn.
BS Computer Science & Systems

Administration, Dordt College
Minnesota State UniversityMankato;
MBA, University of Phoenix
hane is an integral part of the

management team in the Schneider Electric Cedar Rapids facility,
providing leadership in the locations
direction beyond her primary function
of leading safety and environmental
activities. She is the leader of the plant safety committee at her facility
and a member of the plant emergency response team. Shane has led
the campaign for safety-improvement ideas as well as developed and
implemented the plants behavioral safety audits. She was responsible
for implementing the use of active release technique in her facility; a
technique that proactively treats injuries to prevent them from becoming
serious. She is also leading the development of the facilitys business
continuity planan action plan that actively anticipates the impact that
a crisis or disaster could have on a plant. Shane is the North American
representative to the GlobES Phase II Steering Committee, which integrates the global processes for safe chemical management. Beyond the
plant walls, Shane drives to take safety and environmental aspects into
her home. She has a passion and dedication to her children and works
to raise them in a safe and healthy environment.
an Wyk is a key resource in working with Interstates customers to

find solutions for supervisory control
and data acquisition (SCADA) computer systems, industrial networks,
and hosted virtualization platforms.
Van Wyk is a leader in the companys manufacturing information technology (MIT) services group, and his primary responsibility is in the
quality of project delivery. Van Wyk began his career with Interstates
as an MIT systems analyst and has assumed additional responsibilities
over the past several years. He has been heavily involved in developing an industrial patching solution for a Fortune 500 company that services all plant floor PCs. This process includes analyzing the software
on the system and offering approved Microsoft patches accordingly.
Van Wyk is now an Interstates program manager. In this position, he
is responsible for all projects within MIT, as well as developing internal
work processes for his team. Van Wyk is driven to find ways to continually improve his work. Because of Van Wyks push, the MIT team
has made progress in documentation, efficiency, and work accuracy.
Outside of work, Van Wyk enjoys learning how to use his new meat
smoker. He enjoys spending time with family and playing with his kids.
mith is a lead software engineer

for Mettler Toledos metal-detection
business. Based in Manchester,
England, he has strategic and technical ownership of the connectivity and
machine-integration capabilities for all
metal-detection products. In addition, he has responsibility at a divisional
level to define a harmonized approach to connectivity and machine integration across all of Mettler Toledos product-inspection systems. Smith is
one of Mettler Toledos Organization for Machine Automation and Control
(OMAC) representatives and is also a member of the PackML Technical
Advisory Board. He holds a masters degree in software engineering
from UMIST and is an elected Chartered Engineer on the UK Engineering Council. Smith recently presented at the OMAC PackML workshop
in Chicago where he provided a case study of Mettler Toledos PackML
implementation as well as examples of how to use PackML in combination with various industry standard protocols to offer customers a true
end-to-end integration solution. Smith and his wife spend free time with
their three young sons, including a recent visit to the Chill Factore indoor
snow parka new experience since the U.K. doesnt get much snow.
uring his 15 years with Turck,

Vitale has demonstrated a deep
understanding of how their products
work and make a difference in the
field. He has a passion for educating others about Turck technology and how it can be applied. He
is constantly searching for ways to evolve this skill, most recently
transitioning from a role as product manager of Turcks network and
interface division to serve as director of marketing. Vitale is skilled at
connecting and creating conversations between end users and engineers, and he continues this tradition in his current position. Vitale has
helped guide many products from concept to installation in customer
applications, including Turcks Multiprotocol Ethernet technology platform. After 6 years in the division, Vitale transitioned to lead the marketing department as its director in December 2014. He saw this as
an opportunity to apply his product knowledge and engineering mindset to the creative design and marketing skills of the team. Outside of
work, Vitale spends as much time as possible being outdoors and with
his family. His hobbies include hunting and fishing, working out, family
bike rides, and playing sports like Wallyball and basketball.
PLANT ENGINEERING
September 2015 41
Nathan Wingate, 26
David Ziskind, PE, 33
Utilitiesand Technology Manager; Cooper River Partners; Goose Creek, S.C.
Automation Engineer;
The Dennis Group LLC; Duluth, Ga.
BS Mechanical Engineering,
University of North CarolinaCharlotte
Georgia Institute of Technology
ingate exhibits the technical and

analytical skills of a competent
engineer and positive character and
moral foundation apparent to all who
work with him. He has a logical sense
of what is required of engineered systems, the analytical engineering knowledge to test his intuition, the curiosity to delve into working details, and the engineers fulfillment of accomplishment when his involvement has resulted in a more efficient and safer
plant operation. Wingate began his career as a maintenance engineer
and advanced to utilities and technology manager, which includes management of all operational utilities, process control systems, and information technology. Wingates diligence have contributed to an overall utility
uptime of 99.97% for three successive years in a facility that operates
round the clock. Wingate applies analysis skills to guide problem solving
and drive corrective action through the maintenance department and capital projects. Wingate understands that his professional and family responsibilities are intertwined. He is a leader in his community and church with a
deep interest in promoting missions to help underprivileged people.
eyond his direct automation and

electrical engineering responsibilities, Ziskind leads recruiting efforts
for The Dennis Groups Atlanta office,
which has seen personnel growth of
more than 60% over the past 2 years.
Part of this strategy includes building relationships with more than eight
colleges, universities, and trade schools. Additionally, Ziskind has built
a co-operative program from the ground up, a program which now has
more than 10 co-op participants performing engineering work for the
company. Ziskind started in the industry as a co-op at Polytron in 2001.
Six years later, he managed the companys design group, including
rolling out Autodesks AutoCAD Electrical throughout the organization and leading the effort to outsource modular design work. Ziskind
led the electrical and startup effort for a major revamp of a cold-fill
beverage line for a Fortune 500 company, successfully leading to the
products market debut. Ziskind enjoys traveling, having visited South
America and hiking the Inca Trail with friends in 2009. Ziskind and his
wife, Miriam, reside in Atlanta with their two sons.
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Johnny Campbell, a
machine cell operator
in welding, is one of
the Pratt & Whitney
employees who have
benefitted from the
companys onboarding program. All images courtesy: Pratt &
Whitney
A return to apprenticeships delivers

skilled workers to Pratt & Whitney
Community college partnership a key to growth in Maine.
By John Mayo
Pratt & Whitney
s aircraft-engine maker Pratt

& Whitney looks to ramp-up
engine production to a level
that the company hasnt seen
in decades, it has committed
significant resources to modernizing its manufacturing processes and
expanding its assembly and supply chain
operations. Partnering with local community
colleges to develop skills of future manufacturing workers is critical to the companys success, and it has created programs
near its facilities to train current and future
employees.
One example, which will benefit from the
coming growth, is the companys Pratt &
WhitneyNorth Berwick (PWNB), Maine,
facility. The plant is the largest manufacturing facility under one roof in the state, and
manufactures and repairs commercial and
military aircraft parts.
Our challenge is to add a significant number of skilled manufacturing employees to

meet the demand, said Leo Dionne, manager
of strategic sourcing/transitions at Pratt &
Whitney. We got together as a team to talk
about our employment strategy and develop
a plan. Its been a tremendous challenge to
find skilled tradespeople not just in Maine,
but across the country. To that end, Pratt
& Whitney has community college partnerships near its facilities in several other states,
including Connecticut, Georgia, and Florida.
Dionne is uniquely qualified to lead a
transition effort, as hes seen a lot of it
over his 31-year career at North Berwick.
I can understand what these new employees are going through as I started my career
here as a machinist in a 4-year apprentice
program, he said.
Over the years, Dionne has held managerial
positions in engineering, shop supervision,
PLANT ENGINEERING
September 2015 43
onboarding training program, is structured

to give new employees all the basic skills
to become a machine operator, including an
introduction toquality to quality and environment and health and safety concepts,
which are critical building blocks to a successful career at Pratt & Whitney. The program includes classroom learning, as well as
exposure to manufacturing techniques both
at the PWNB facility and YCCCs modern
machine shop at its Sanford, Maine, facility. Over the past two years, approximately
30 employees have graduated, with all of
them being placed in manufacturing positions at PWNB.
Expanding apprenticeships
Lauren Johnson works on a coordinate measuring machine and inspects a

blade outer air seal at the Pratt & Whitney plant in Maine.
business unit management, and quality. In

his transition role, hes helping to manage
the transformation of the company.
In the beginning, PWNB was able to recruit
from local businesses, but soon found it was
running out of candidates with necessary skill
sets. Thats when a unique public-private
partnership was formed with Pratt & Whitney,
the state of Maine, and York County Community College (YCCC) in Wells, Maine.
The North Berwick facility is benefiting
from two programs being run in conjunction
with the local school. The first, a 6-week
44 September 2015
plant engineering
The second, more ambitious course is an

8,000-hr apprenticeship program in which
Pratt & Whitney employees take part in a
trades technology curriculum that results
in an Associate of Applied Science degree.
While the program gives participants exposure to the latest in manufacturing technology, it also incorporates an academics
portion and rotational assignments throughout the North Berwick facility. Participants
spend their 8-hr day learning and working in
both the facility and the classroom. Fifteen
students are set to graduate in the first wave
early next year and will be placed in assignments that use their manufacturing, business,
and leadership skills.
Given the growth path were on over the
next several years, our partnership with the
state of Maine and the community college
system is a crucial part of our employment
strategy, said PWNB General Manager Mike
Papp. YCCCs ability to accommodate and
tailor its curriculum to support our onboarding and apprenticeship programs is proving
to be very effective in helping our facility
train new employees for technical positions
with a minimal negative impact to the facility.
With the apprenticeship program, weve
been able to work with the school to create a degree program which complements
our technical apprenticeship program and
also to create a curriculum comprised of
both Pratt &Whitney-specific and YCCCspecific content. The jointly developed curriculum is intended to give new employees
critical foundational skills as they begin their
assigned tasks, he added. Both programs
are critical in helping us prepare employees
to serve our requirements at all levels of our
hourly workforce, while also preparing them
for possible entry into our salaried workforce

down the road.
From massage to manufacturing
Apprentice Lauren Johnson had been a Pratt

& Whitney employee for about 1 years
when she saw a posting about the program.
She took an entrance test, passed it, and is
now part of the first apprenticeship class.
This is my first time going through a formal college program, Johnson said. Not
only will I come out with an associates
degree, but also the education Im receiving
in machine skills, academics, business processes, and people and management skills is
preparing me for my career.
Johnson said shes come a long way
already. Prior to working at Pratt & Whitney I was a massage therapist, and I decided
it was time for a career change. When I first
joined the company, I was overwhelmed with
the size, the noise, and the number of people.
But my dad was a mechanic and Im a very
hands-on person and enjoy the manufacturing side very much.
Johnson cant stress enough how valuable her training in people skills has been.
You need to make a good reputation for
yourself, she added. Understanding the
business and the technology is crucial. But
its just as important to be able to relate
and communicate and establish relationships
with all the people with their different personalities that you encounter. You cant be
productive if you dont connect with those
around you.
While the onboarding program addresses
the lions share of manufacturing employment needs at the facility, the apprenticeship
programs success is crucial to replacing
high-level hourly leaders, many of whom
are beginning to retire after long careers
with the company. And the right curriculum
is the key.
When we began working with YCCC, we
formed a cross-functional team at Pratt made
up of shop operators, supervisors, working

leaders, business unit leaders, and others
who had come up through the ranks, to help
build the right curriculum, Dionne said.We
answered the basic question: In which attributes and skill sets do we need to train new
employees? Then we got together with the
school and asked, Can you develop a curriculum to support this? YCCC has been
very responsive to our needs and weve been
very pleased with the results.
A career opportunity
Johnny Campbell, a machine cell operator in welding, joined the company in

January 2015 and immediately joined the
onboarding program. I had been welding
at another company and came to Pratt &
Whitney looking for more welding experience, Campbell said. The program has
taught me so much morefrom how to
operate different machinery, to manufacturing terminology, to blueprint reading, to
measuring product tolerances. It definitely
gave me a broader picture of the manufacturing opportunities across the company.
These programs are offering not just
a job opportunity, but a career opportunity, Dionne said. Given the advanced
state of manufacturing technology, we need
highly skilled, business-oriented people.
Were starting at the beginning, investing
in adaptable, hard-working individuals who
want to have careers with us.
Dionne said the company is now reaching out at the high school level, meeting
with high school counselors within a 30- to
40-mile radius of the facility. For years,
high schools have been driving students
toward 4-year colleges and away from the
trades, believing that industry was dead.
Were a testament to the fact that its alive
and well and offering highly skilled, meaningful career opportunities. Partnerships
like the one we have with YCCC prove that
it can work. PE
While the onboarding program addresses
the lions share of manufacturing employment needs at the

facility, the apprenticeship programs success is crucial to
replacing high-level hourly leaders, many of whom are beginning
to retire after long careers with the company.
plant engineering
September 2015 45
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MECHANICALSOLUTIONS
A facility can spend between 10% and 30% of their total electric costs to generate compressed air, and
as much as 10% of the initial system cost on annual maintenance, and still may waste up to 50% of the
air they create. Yet, the focus on equipment costs often trumps the issues of maintenance and reliability.
All images courtesy: Ingersoll Rand
Take a total system approach

to compressed air reliability
Understanding how systems work together can lead to savings.
By Chad Larrabee
Ingersoll Rand
irtually every modern manufacturing

facility uses compressed air in their production processes. Its clean, easy to
store, and can be used for a vast number
of applications, from operating power tools to
conveying or lifting materials to controlling
robotics. The plant manager is responsible for
maintaining reliable compressed air power
while upholding process requirements and
keeping costs in check.
By taking a total systems approach, plant
operations can increase performance and reduce
inefficiencies for significant bottom-line benefits.
Understanding the total impact of running a compressed air system and identifying the necessary
actions based on unique compressed air needs
can reduce energy costs by as much as 20%.
A one-sided view can prove costly
Many companies have a limited view of

compressed air system performance, often
focusing on routine compressor maintenance
and power consumption. While compressor
technology is important, focusing on supplywww.plantengineering.com
side components alone wont guarantee cost

savings or performance improvements. Factors such as undersized downstream equipment, wasted air, and leaks can reduce potential savings and performance along the way.
Most plant managers are familiar with the
equipment in their compressor room and how
to remedy isolated issues that arise in this
environment. While knowing how to manage
the compressor room is essential, additional
factors such as air pressure and flow, heat
recovery, air quality issues at point-of-use,
and wasted air must also be assessed to effectively impact system performance, energy
use, and cost savings.
Even in cases where a system appears to
be running well, its likely that somewhere
along the line costly compressed air is being
wasted. Taking a total systems approach,
including a complete analysis of both the
supply and demand sides of your system, is
the only way to ensure constant and steady
system pressure, uninterrupted workflow, and
minimal downtime. A total systems approach
PLANT ENGINEERING
September 2015 47
MECHANICALSOLUTIONS
K
EY WORDS:
At www.plantengineering.com, KEYWORD: COMPRESSED AIR, youll find more
articles on this topic:
PREVENTING COMPRESSED AIR LEAKS: TAKING A PROACTIVE APPROACH

Much has been written about leak management programs, best practices and
the like, but little has been offered in terms of a proactive approach. That is,
when installing a new system or expanding or rerouting an existing one, what
can be done to prevent leaks? The pipe-joining method is an important decision that will impact maintenance programs down the road. Press-to-connect
pipe-joining systems can be a means to prevent air loss in compressed air
systems.
COMPRESSED AIR EFFICIENCY AT A DISTANCE
Until recently, compressed air system maintenance was reactivean unforeseen event required immediate intervention from a service technician. In this
scenario, the facility is in the dark about maintenance needs, suffers from
inefficiencies, and is at increased risk of breakdown. Remote monitoring of
compressed air equipment is one of the most effective strategies to help facilities avoid downtime. Whatever the facilitys production schedule, 24/7 remote
monitoring is constantly compiling compressed air data in real timedata that
can be analyzed for key performance indicators to predict potential problems.
THE BUSINESS CASE FOR COMPRESSED AIR SYSTEMS
Do you operate a compressed air system as a business, understanding the
financial consequences of your actions or as a misunderstood necessity? Do you
carefully consider additions and changes as you would with electricity or water?
If the answers to these questions are no, it may be difficult to understand why
management seems to place this critical asset so low on their priority list.
also is central to understanding your total
cost of ownership.
Constituents of supply
Excessive pressure dropfilters, dryers,
inadequately-sized piping.
Air losstimed condensate drains, cracked
valves, leaks at connections or instrumentation.
Inefficient control schememodulating
valves or load/unload with short cycling.
Constituents of demand
Air events where specific applications
create large swings in demand.
Leaks in transmission and point-of-use.
Inappropriate uses of air-venturi vacuums
or open blowing for cooling or drying.
Inefficient consumption equipment analysis, especially multiple regulation devices.
Flow restrictions or undersized hose at
point-of-use.
Rate of change in a facilitys overall
demand profile.
The real cost of air
A compressed air system is a significant

investment for any operation and requires
48 September 2015
PLANT ENGINEERING
When facility owners invest
in compressed air, they

want a good return on that
investmenttheyre looking for
something thats going to
last. Were here to make that
happen because, in the
end, theres no substitute
for reliability.
disciplined maintenance to ensure maximum

performance, payback, and system longevity.
For example, the initial cost of a 100-hp
compressor with air treatment can cost up
to $100,000 with installation. Following the
initial investment, a facility can expect to
spend between 10% and 30% of their total
electric costs to generate compressed air, and
as much as 10% of the initial system cost on
annual maintenance. Compressed air systems
are also notorious for inefficiencies and leaks
that, on average, waste from 30% to 50% of
compressed air.
Yet in the majority of cases, the idea of
total cost of ownership is trumped by the
initial equipment and installation investment
cost on paper. According to the Compressed
Air Industry Sourcebook, Many facilities
have no idea how much their compressed air
systems cost on an annual basis or how much
money they could save by improving the performance of these systems. In fact, an overwhelming majority of compressed air users
rate consistent and reliable air supply over
efficiency and energy savings. With priority
needs that include immediate reliability and
uptime, plant managers often consider the
cost of new or replacement equipment rather
than the complete and ongoing efficiency
of the systemleaving near- and long-term
dollars on the table.
You cant accurately determine savings
without looking at the entire system, part by
part, and how each element works together.
This includes supply-side components such
as compressor controls, air-treatment equipment, dryers, and filters as well as demandside equipment that includes heat-recovery
and point-of-use systems. How air-system
components work together to produce air and
Learn about the latest engineering

trends and technologies.
Check out our Plant Engineering
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mechanicalSOLUTIONS
Developing a compressed air system today
requires not just proper piping, but also sensors throughout the system to look for leaks
and inefficiencies.
delivery and storage infrastructure. Companies that take control with a total systems
approach not only reduce their total cost of
ownership, but also significantly boost their
operational performance.
When equipment providers and end users
come together with a shared focus on maximizing the total cost of ownership, its possible to turn the liabilities of an inefficient
system into a performance advantage. Implementing total systems programs help companies improve the energy efficiency and
performance of compressed air systems. PE
exactly whats happening throughout that

process to configure, calibrate, and maintain
optimal performance is what a total systems
approach is all about.
Advances in compressor technology are
making total system expertise not just desirable, but increasingly essential as many companies look to their equipment provider for
specialized know-how and component expertise. In addition, advanced analytics are now
available to help determine the right equipment configurations throughout the system
to optimize performance.
Know your options
Working with a compressor provider who

understands the demand and supply sides
of your compressed air system can help you
identify your requirements and maintain a
reliable supply of air while reducing your
overall energy and maintenance costs.
You will also want to protect your investment. Consider how an all-inclusive agreement, with access to experienced compressed air experts, can help manage your
air demand and supply system and related
assets with an eye to reducing operational
costs.
With a wide range of known inefficiencies and an obvious lack of controls, many
problems can arise within compressed air
50 September 2015
plant engineering
Chad Larrabee is director of services marketing in North America for Ingersoll Rands
Compressed Air & Gas business unit. Larrabee has 23 years of experience in the compressed air industry and currently serves as
education committee chairman for the Compressed Air and Gas Institute.
The BoTTom line:

Taking a total systems approach to compressed air, including a complete analysis
of both the supply and demand sides of
your system, is the only way to ensure
constant and steady system pressure,
uninterrupted workflow and minimal
downtime. A total systems approach also
is central to understanding your total cost
of ownership.
You cant accurately determine savings
without looking at the entire system, part
by part, and how each element works
together. This includes supply-side components such as compressor controls,
air-treatment equipment, dryers and
filters as well as demand-side equipment
which includes heat recovery and pointof-use systems.
Working with a compressor provider who
understands the demand and supply
sides of your compressed air system can
help you identify your requirements and
maintain a reliable supply of air while
reducing your overall energy and maintenance.
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mechanicalSOLUTIONS
Selecting a filler metal: Seven factors to consider
From matching the base material to picking the right equipment, consider the
process before starting to weld.
By Bruce Morrett
Hobart Brothers Co.
Using a filler metal that

provides the appropriate
mechanical and chemical
properties for the joband
is able to withstand the
service conditions the weld
encountersis critical.
Image courtesy: Hobart
Brothers Co.
sing a filler metal that provides the

appropriate mechanical and chemical
properties for the joband is able to
withstand the service conditions the weld
encountersis critical. It helps minimize the risk
of cracking, corrosion, and/or weld defects that
could lead to time-consuming and costly rework.
There are seven key factors to consider when
selecting a filler metal the base material to be
welded, the welding position, regulatory specifications and codes, design requirements, shielding gas, post-weld heat treatment, and welding
equipment. Below is a detailed look at each of
these factors and how they dictate which filler
metal to use.
Factor No. 1: the base material

to be welded
Joining together two materials is, for the most

part, a matter of chemistry: Which filler metal
best matches the base material? If the chemistry
of the materials matches, the mechanical properties (such as the tensile and yield strength) will
also match. Welding operators can rest assured
that their weld deposit will have the
same strength and properties as the
base material.
When materials being joined are not
the same strength, there are other considerations. As a rule of thumb, welding
operators should match the strength of
the filler metal to the lower strength
of the two base materials. During the
welding process, dilution from the higher-strength base material is sufficient
to strengthen the weld metal deposit.
Most base metals can easily be identified through tests based on appearance and reactions to magnets, fracture, chisel, and flames or sparks; and
a welding operator typically knows
what base material he or she is working with. In some casesusually during repair or rework weldingit may
be necessary to take a sample to a lab
that can conduct a chemical analysis.
Factor No. 2: the welding position
Whenever possible, welding opera-
52 September 2015
plant engineering
tors should rotate the part so it can be welded

in a flat position. Welding in a flat position is
always the most economical method, followed
by horizontal or vertical and, lastly, an overhead position.
If a welding operator must work with a large
weldment that cant be manipulated, however,
it forces the need to weld in multiple welding
positions. Out-of-position welding can be especially challenging if there is only one wire size
available. For example, a vertical weld-up using
a 3/32-in.-diameter wire may be extremely difficult or even impossible. A better choice would be
a wire ranging from .045 to 1/16 in. in diameter,
but it would require setting up an additional wire
feeder or another power source for the job. It
would also require a change in feed rolls and,
potentially, the welding gun. Companies should
keep in mind that changing welding positions
can slow the process and compromise efficiency,
and select a filler metal type and size that will
allow for the most versatility.
Factor No. 3: regulatory specifications

and codes
Job specifications often dictate what class of

wire to use. If not, welding operators should
carefully consider the service requirements the
welds may encounter.
For example, if a welding operator uses a
mild steel filler metal for applications exposed
to harsh elements, it is likely that the welds will
rust, deteriorate, and corrode at a faster rate than
the base material. This action could lead to weld
failures, especially if the end product is of critical importance, such as a pressure vessel used
in high-temperature environments or a bridge
that will be exposed to the elements.
In the end, whatever filler metal a welding
operator uses must also meet the service condition of the final product so that the weld deposit
lasts as long as the base material. Its equally
important when welding to code that the filler
metal should meet the qualifications or certification of that code.
Factor No. 4: Design requirements
In addition to following codes (when required),

it is important to select a filler metal that meets
K
EY WORDS:
At www.plantengineering.com, KEYWORD: WELDING, youll find
more articles on this topic:
BALANCE SAFETY, PRODUCTIVITY AND COMFORT WHEN

CHOOSING A WELDING HELMET
There are several factors to consider when choosing the proper
welding helmetsome critical, some more related to personal
stylebut the primary objective is to ensure that the eyes and
skin are protected from the hazardous by-products of the welding process.
WELDING CELLS ADAPTING TO MANUFACTURING CHANGES
Creating an adaptable weld cell goes beyond just improving the
physical space, but that is also a very important component.
WHY WELDING REMAINS VITAL FOR TODAYS MANUFACTURERS
One of the primary benefits of welding is its flexibility. Industrial
plants can weld materials in one location, ship them to the facility
for installation, and position them in various configurations.
or exceeds the needs of a joint design, as specified by the
engineers welding configuration. For instance,when welding
on thin material, it is important that the arc characteristics are
appropriatea wire that provides deep penetration may cause
the welding operator to burn through. On the other hand, if the
part to be welded is thick and features a single V joint, a filler
metal with better penetration characteristics allows for better
tie-in at the root and sides.
FACTOR NO. 5: Shielding gas
Its important to ensure the filler metal and shielding gas used
for an application are compatible.
Different shielding gases have different effectson filler metal.
For example, the addition of argon to carbon dioxide (CO2)
allows the welding operator to transfer more of the filler metals
chemistry into the weld deposit. This mixture provides consistent weld quality, offers good weldpool control, and generates
lower levels of spatter.
Conversely, using CO2 (an oxidizing gas) burns off some
of the filler metal elements. One hundred percent CO2 offers
the advantage of deep-weld penetration, which is desirable
when welding thicker materials. It does tend to have larger
ball transfer and can create more spatter than shielding gas
mixtures that are a combination of argon and CO2.
There are wires capable of operating with both straight CO2
and an argon/CO2 mixture. Companies should consider their
available gas supply and desired weld characteristics provided
by each when choosing a filler metal, and make sure that the
selected filler metal is compatible with the shielding gas chosen.
FACTOR NO. 6: Post-weld heat treatment
There are certain steels and material thicknesses that must be

preheated to a certain temperature before welding commences.
Preheating allows the part to cool down at a slow rate to avoid
weld-shrinking issues and cracking. Similarly, post-weld heat
treatment (PWHT) is used to reduce the stresses and slowly
PLANT ENGINEERING
September 2015 53
mechanicalSOLUTIONS
lower the residual heat introduced during
welding, allowing the weld joint and base
materials to return to the desired properties. On materials that require PWHT, it is
important to select a filler metal capable
of producing welds that respond appropriately to the application of heat.
Factor No. 7: Welding equipment
The type and size of equipment being used

impacts what filler metal is best for the job.
Specifically, the power source needs to
provide enough amperage for the diameter
of wire being used for the job. In the event
that there is not enough amperage it will be
necessary to either change wire diameters,
which could result in slower production to
complete the weld, or change to a highercapacity machine.
Its also important for the power source
to offer the proper welding current for the
filler metal chosen. Welding in the wrong
current can lead to spatter and poor weld
quality.
Determining the desired weld characteristics is equally important. Filler metals
that operate on reverse polarity (electrode

positive, or EP) provide great penetration,
while straight-polarity (electrode negative,
or EN) filler metals produce a more shallow
joint penetration.
Although the effect of various elements
in filler metals can be rather complex and
inter-related, a review of their general properties can also help welding operators determine which filler metal is ideal for the job.
Carbon, for example, generally increases
hardness, tensile strength, and wear resistance but decreases ductility, impact, and
machinability. Nickel, on the other hand,
increases hardness, tensile strength, impact,
and ductility but decreases the parts ability
to be machined. Similarly, there are various
alloying elements that have different properties to deoxidize, refine grain structures,or
improve ductility. It is important for welding operators to consider the properties
needed in a completed weld when making
the filler metal selection. PE
Bruce Morrett is a product manager
for Hobart Brothers Co.
The BoTTom line:

Whenever possible, welding operators should rotate the part so it can be
welded in a flat position. Welding in a
flat position is always the most economical, followed by horizontal or vertical and, lastly, an overhead position.
Whatever filler metal a welding operator uses must also meet the service
condition of the final product so that
the weld deposit lasts as long as the
base material. Its equally important
when welding to code that the filler
metal should meet the qualifications
or certification of that code.
The type and size of equipment being
used impacts what filler metal is best
for the job. Specifically, the power
source needs to provide enough
amperage for the diameter of wire
being used for the job.
2015
Workforce Development
Turning research into insights makes for better business decisions

The 2015 Workforce Development study asked key questions on the
causes and effects of the lack of a skilled workforce in the U.S., what
manufacturing plants are doing to combat this issue, and how facilities
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According to the study the lack of available skilled workers has
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recruitment and 40% offer in-house training for less
experienced applicants.
Access the full Plant Engineering 2015 Workforce
Development report with additional findings and insights.
www.plantengineering.com/2015WorkforceDevelopment
GLOBAL SYSTEM INTEGRATOR 2016 REPORT

INTEGRATE YOUR MESSAGE TO 146,000 ENGINEERS
In December, CFE Media will publish an enhanced Global System Integrator Report.
The December Report to the 146,000 readers of Control Engineering and Plant Engineering
will now feature a Corporate Close-Up, allowing system integrators to describe their
companys unique experience and success as an engineering service provider.
Below is an example of a half-page Corporate Close-Up:
Cimation
OPERATIONS TECHNOLOGY SOLUTIONS TO SUIT YOUR

AUTOMATION, INDUSTRIAL IT, AND CYBER SECURITY NEEDS
Van Wilson, Chief Operating Officer
Houston, Texas
Telephone: (713) 452-3350
info@cimation.com
www.cimation.com
Primary Industries
Chemicals, Petrochemicals
Oil & Gas Extraction (onshore, offshore)
Oil & Gas Refining
Pipelines
Information and communication
systems
Other office locations

Denver, CO
Pittsburgh, PA
New Orleans, LA
Lafayette, LA
Calgary, AB
London, UK
Cimation is an operations consulting company

delivering secure technology solutions to the
global energy industry. With experience in process automation, industrial IT, enterprise data,
and ICS cyber security solutions and more than
200 employees in 7 global offices, we are ready
to execute efficient strategies that converge IT
and operations technology.
Armed with diverse project experience, process
knowledge, and technical expertise, we improve
energy operations by engineering and integrating
industrial technology.
In our years, Cimation has executed thousands of reliable systems integration and engineering projects for oil
and gas, refining, chemical, power, utilities, and storage businesses. We understand the processes and objectives that drive industrial operations and help companies improve safety and efficiency through holistic solutions
customized to meet their business needs.
Since opening our doors in 2009, we have grown by developing trusted partnerships with both clients and
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companies, mid-size operators, and global super majors trust their operations technology infrastructure to Cimation. By tailoring our services to the unique needs and requirements, we help realize process efficiency and longterm cost-savings in spite of market volatility. Speak to one of our leading industry experts today to learn more!
Visit our Corporate Profile at www.cfemedia.com/global-si-database/Cimation
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To discuss advertising in the

Global System Integrator 2016 Report,
contact Brian Gross
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PLANT ENGINEERING

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Compressed Air System Installation Guide
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Layout Considerations for a

Reliable, Energy Efficient, and Safe
Compressed Air System
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Written by Kaesers team of engineers

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PLANT ENGINEERING
September 2015 57
IN NOVATIONS
Rotary screw compressor
The UP6S Series 15- to 30-hp fixed-speed rotary screw compressor adds several standard features to the standard unit, such as
progressive adaptive control (PAC) protection, O-ring face seals to
reduce leak points, and a totally enclosed fan-cooled (TEFC) motor.
The units TEFC design reduces the risk of particulates entering the
motor while also keeping it cool, so the compressor can be used
in harsh environments. Its NEMA Type 4 rating allows it to be used
indoors or outdoors, and the new Tri-Voltage motor enables it to
adapt to a variety of applications.
Ingersoll Rand
www.ingersollrand.com
Input #200 at www.plantengineering.com/information
Ground-shaft monitor
The Smart Ground Monitor is an innovative condition-monitoring system that provides users with
instant feedback on the performance of the current diverter ring (CDR) in diverting shaft currents
away from the bearings to ground. The monitor
provides a leading indicator of CDR performance.
A simple interface alerts users in real time if
there is not optimal contact between grounding
brushes and the shaft, preventing bearing failure.
If contact has been interrupted, routine maintenance can be performed to return shaft grounding
to peak performance. The Smart Ground Monitor
has external ports for safe and convenient oscilloscope readings and can be set up in standalone
or auto mode for performance indication.
Inpro/Seal
www.inpro-seal.com/smartcdr
Keyless lock
The Keyless Keypad Lock for drawer cabinets serves as an
alternative to the SL10 keyed locking option. The keyless lock
offers such benefits as the ability to program up to 25 different
user codes for unique user access and eliminating the need to
order and manage multiple locks and keys for different cabinets
within a facility. The mechanism includes a zinc-alloy lock housing with a motorized lock mechanism and retaining clip, and a
lock toggle and lock rod (based on cabinet depth).
Vidmar
www.stanleyvidmar.com
58 September 2015
PLANT ENGINEERING
Send new product releases to: peproducts@cfemedia.com
Casters
Current transducer
The RCTrms-3-ph current transducer delivers a
convenient, safe, and accurate solution for measuring current in three phases. It features a thin, cliparound, flexible sensor coil and provides accurate
true RMS measurement with 4- 20 mA or 0- 5 V output, enabling simple installation with PLCs, SCADA
systems, or automation equipment. With 18 current
ratings options from 100 to 50,000 A, and a choice of
300-, 500-, and 700-mm or custom coil lengths, the
RCTrms-3ph can be used in many applications and
connected to a wide variety of SCADA systems, PLCs,
data loggers, protection equipment, or motor controllers. The clip-around coil design allows fast and easy
positioning, and provides accurate results without
needing to be centralized around the conductor. An
isolated BNC-BNC cable-split option is available to
ease installation, such as when threading through
existing conduit.
Spinfinity is a line of heavy-duty, maintenance-free casters.

Incorporated into the kingpinless construction is special CNC
machining to host a large internal seal that is made from nitrile
butadiene rubber (NBR) and is completely enclosed inside the
swivel assembly. With no outside exposure, the swivel assembly is able to keep grease in and contaminants out. The top
plate and inner raceway are one forged steel piece to provide
strength in shock conditions.
Hamilton Caster
www.hamiltoncaster.com/spinfinity
Power Electronic Measurements Ltd

www.pemuk.com
Dust-collection diagnostics
The GoldLink system provides round-the-clock access to dust-collection operations
by monitoring four preset analog inputs and 16 preset digital inputs. Designed for
facilities that do not have building management systems, it is especially useful for
companies with many remote dust collectors, 24/7 operating schedules, sensitive
applications, and/or the need to generate reports for OSHA, the EPA, or other regulatory bodies. The GoldLink unit ships preprogrammed and is installed and connected
to the Internet; data is packaged in a usable format that allows customers and other
authorized personnel to monitor the health of their filtration systems via website.
Camfil
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PLANT ENGINEERING
September 2015 59
IN NOVATIONS
Send new product releases to: peproducts@cfemedia.com
HMI panel
The TP3000 series human machine interface (HMI) employs a rugged, allmetal housing with a fanless design that consumes less energy and
produces less heat. The free VISU+ EXPRESS programming software provides easy programming and features trending, alarming, logging, and recipe
handling.Screen sizes range from 5.7 to 15 in., with certain panels available
in a 16:9 aspect-ratio widescreen. The software supports many communication protocols, including Ethernet/IP, Modbus TCP, and OPC DA. This makes it
compatible with PLCs from a variety of manufacturers.
Phoenix Contact
www.phoenixcontact.com
Hydraulic hose
The E-Z Bend Hose has half the bend radius of standard hoses
for easier routing and more space savings. It is ideal for highpressure hydraulic oil lines in mobile hydraulic applications. E-Z
Bend Hose has four spiral layers of high-tensile steel-wire braid
to handle the most robust and demanding applications. The tube
material is oil-resistant synthetic rubber with reinforcement of
four spiral layers of high-tensile steel-wire braid. The working
temperature range for E-Z Bend Hose is -40 to 212 F and meets
flame-resistant MSHA designation.
Kurt Hydraulics
www.kurthydraulics.com
Turning machine
The VL 2 vertical turning machine is designed for the quality and costconscious manufacturer and subcontractor. A universal production tool that
impresses with its small footprint and an advantageous price-performance
ratio, it also includes automatic loading and unloading of the workpieces.
The workpieces are transported using O-automation, with the pick-up
principle being used to load and unload the VL 2. Workpieces are loaded
directly into the carrier prisms or, where necessary, into workpiece holders
inserted into the prisms. A measuring probe located outside the machining area adds an automatic, in-process quality assurance operation to the
cycle, with the measurements taken between finish-machining point and
workpiece removal.
EMAG LLC
www.emag.com
60 September 2015
PLANT ENGINEERING
PRODUCTMART
OIL MIST & SMOKE
IN YOUR SHOP?
www.mistcollectors.com
Why Should You

Filter Your Water?
Tel: 1-800-645-4174
STAY INFORMED
Stay current with technology and trends
in electrical, mechanical, maintenance
and automation.
Scale formation reduces the heat transfer rate and

increases the water pressure drop through the heat
exchanger and pipes. In fact, one study has shown
that .002" fouling will increase pumping needs by 20%.
The Best Engineered Water Filtering

Solution Always Costs Less
2 67 2 S . L a C i e n e g a B l v d . L o s A n g e l e s , C A 9 0 0 3 4 U S A
( 8 0 0 ) 3 3 6 - 194 2 ( 310 ) 8 3 9 - 2 8 2 8 F a x : ( 310 ) 8 3 9 - 6 87 8
w w w. t e k l e e n . c o m
info@tekleen.com
3.5" wide x 4.5" high

Pantone 382c
LETS CONNECT SOCIALLY...

No matter what your social networking preference is,

theres a way for you to connect with Plant Engineering!
Go online
to view the
weekly Top
5 Reader
Favorites!
Make the connection now...

www.plantengineering.com/connect/social-media.html
PLANT ENGINEERING
September 2015 61
For more information on how to advertise in Plant EnginEErings

Internet Connection, call Jim Langhenry at 630-571-4070 x2203
alliedelec.com
flexicon.com
seweurodrive.com
Allied Electronics is a small order, high service level distributor of electronic components and electromechanical
products with over 50 sales offices across the United
States and Canada.
Allied Electronics
Flexicon designs and manufactures bulk handling equipment and custom-engineered and integrated plant-wide
systems.
Flexicon Corp.
One of the largest global suppliers of drive technology,

SEW-EURODRIVE specializes in gear reducers, motors
and electronic motor controls.
SEW-EURODRIVE USA
atlascopco.us
flir.com
sullair.com
FLIR Systems designed, develops, manufactures, markets, and distributes thermal imaging infrared cameras.
FLIR Systems Inc.
Sullair is a designer and manufacturer of stationary and

portable rotary screw air compressors, air treatment
equipment, and pneumatic tools.
Sullair Corp.
Atlas Copco produces and markets compressed air equipment and generators, construction and mining equipment,
industrial tools, assembly systems, services and rentals.
Atlas Copco
automationdirect.com
AutomationDirect offers 6,500+ industrial automation
products through their free catalog and online store,
including PLCs, operator interfaces, sensors, and more.
AutomationDirect
avotraining.com
For almost 50 years, AVO has been helping organizations
create safe and reliable electrical systems.
AVO Training Institute
baldor.com
Baldor Electric designs, manufacturers, and markets a
broad line of industrial energy-efficient electric motors,
mechanical power transmission products, and more.
Baldor Electric Co.
camfilapc.com
Camfil Air Pollution Control (APC) is a leading global
manufacturer of industrial dust, fume and mist collection
equipment and is part of Camfil, the worlds largest air filtration company.
Camfil APC
cat.com
Caterpillar is a manufacturer of construction and mining
equipment, diesel and natural gas engines, industrial turbines and diesel-electric locomotives.
Caterpillar
electroind.com
Electro Industries specializes in power meters and smart
grid solutions that excel at revenue grade energy measurement, power quality and advanced telemetry.
Electro Industries/Gauge Tech
erectastep.com
Modular work platforms and aluminum stairs pre-engineered for unlimited configurations. Platforms and metal
steps bolts together with no fabrication required and are
easily repurposeable.
ErectaStep
exair.com
Exairs product line includes Vortex Tubes and products
utilizing Vortex Tubes, Air Amplifiers, Air Knives, air-operated vacuums and ionizing products for static elimination.
Exair Corp.
62 September 2015
plant engineering
us.kaeser.com
Manufacturer of air system products, including rotary
screw compressors, portable compressors, rotary lobe
blowers, vacuum packages, refrigerated and desiccant
dryers, filters, and condensate management systems.
Kaeser Compressors Inc.
klsummit.com
Industry leader in synthetic lubricant technology with a line
of over 200 products that can service almost any industrial
application.
Summit Industrial Products
keysight.com
unitedrentals.com
Keysight Technologies is an electronic measurement company that offers wireless, modular, and software solutions.
Keysight Technologies Inc.
United Rentals is the largest equipment rental company

in the world with locations in 49 states and 10 Canadian
provinces.
United Rentals Inc.
lubriplate.com
Lubriplate manufactures more than 200 high quality lubricants, including high performance synthetic lubricants and
NSF-H1 lubricants for food processing and beverage.
Lubriplate Lubricants Co.
oeo.com
yaskawa.com
Yaskawa is the worlds largest manufacturer of ac inverter
drives, servo and motion control, and robotics automation
systems.
Yaskawa America Inc.
OEOs mission is to deliver cost effective energy solutions

to businesses and institutions.
OEO Energy Solutions
orival.com
Orival is a leading manufacturer of self-cleaning water
filters, automatic water filters and strainers, for use as
industrial water filters, irrigation filters, cooling tower filters, and more.
Orival Inc.
procoproducts.com
Proco Products Inc. is a global leader in the design and
supply of piping/ducting system expansion joints and rubber check valves.
Proco Products Inc.
rittal-corp.com
Rittal manufactures the worlds leading industrial and IT
enclosures, racks and accessories, including high-efficiency, high-density climate control and power management
systems.
Rittal Corp.
rogers-machinery.com
Manufacturer of rotary screw and reciprocating air compressors, fixed and variable speed drives, rotary and centrifugal compressors, blowers, and vacuum systems.
Rogers Machinery
Place next to your computer or go online to www.plantengineering.com for hot links to these companies.
Remove at
Line
15
ber 20
m
e
t
Sep
CONTACTS
Advertiser Contacts for plant engineers
Request more information about products and advertisers in this issue by using the http://plantengineering.hotims.com
link and reader service number located near each. If youre reading the digital edition, the link will be live. When you contact a
company directly, please let them know you read about them in Plant Engineering.
Page
Number
Advertiser
Allied Electronics
800-433-5700
13
Atlas Copco Compressors

866-688-9611
17, 22
AutomationDirect
800-633-0405
RSC
Number
Send
Info
11
AVO Training Institute

877-594-3156
10
Azima DLI
800-654-2844
23
Orival, Inc
800-567-9767
16
www.atlascopco.us
Plant Engineering Electronic Newsletters

630-571-4070
51
Plant Engineering Webcasts

630-571-4070
49
19
www.AzimaDLI.com
31
www.baldor.com
Camfil APC
800-479-6801
4
31
CFE Media, Engineering Is Personal

630-571-4070
CFE Medias
Global System Integrator Database
630-571-4070
Electro Industies/GaugeTech
877-EIMETER
29
Rittal Corporation
800-477-4000
15
SEW-EURODRIVE, Inc.
864-439-7537
29
SKF
970-282-1200
23
Spirax Sarco Inc

800-883-4411
25
22
www.spiraxsarco.com/global/us
Sullair Industrial Products

219-879-5451
19
16
Summit Industrial Products

800-749-5823
18
15
26
24
www.flexicon.com
United Rentals
800-UR-RENTS
25
23
www.flir.com
Vaisala, Inc.
888-824-7252
26
www.NECatDealers.com/power
33
www.plantengineering.com/global-si-database
10
www.electroind.com
Exair Corp
800-903-9247
Flexicon Corp
888-353-9426
FLIR
800-GO-INFRA
21
17
Global System Integrator 2016 Report

630-571-4070
55
www.cfemedia.com/global-si-database
Lubriplate Lubricants Co
800-733-4755
www.plantengineering.com/webcasts
Plant Engineering
Workforce Development Research
54
630-571-4070
www.plantengineering.com/2015WorkfroceDevelopment
53
C-1, 11
Keysight Technologies, Inc

800-829-4444
www.orival.com
Rogers Machinery
800-394-6151
www.csemag.com
8
www.ErectAStep.com
1, 24
13
28
ErectAStep
888-878-1839
Kaeser Compressors, Inc

866-516-6888
www.oeo.com
53
42
12
Proco Products, Inc.

209-943-6088
www.camfilapc.com
Caterpillar - Northeast
Send
Info
12
WWW.AVOTRAINING.COM
C-4
RSC
Number
OEO Energy Solutions

800-553-2112
www.automationdirect.com
Baldor Electric Company

800-828-4920
Page
Number
www.alliedelec.com
14, 18
C-2
Advertiser
Yaskawa America, Inc

800-927-5292
www.procoproducts.com
www.knw-series.com
12
www.RittalEnclosures.com
25
www.seweurodrive.com
20
www.skf.com/emcm
www.sullair.com
www.klsummit.com
www.UnitedRentals.com
www.vaisala.com/calibrate
C-3
30
www.yaskawa.com
2, 21
www.kaeser.com/PE
2
46
3
www.keysight.com/find/TrueIRimager
27
www.lubriplate.com
Need More Info? FAX this page to: 630-214-4504
or mail to P LANT E NGINEERING magazine, 1111 West 22nd Street, Suite 250, Oakbrook, IL 60523
Name
Company
City
Telephone
Fax
Title
Address
State
e-mail
Zip
PLANT ENGINEERING does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the Advertiser contacts regardless of whether such errors result from negligence, accident, or any other cause whatsoever.
PLANT ENGINEERING
September 2015 63
INCONCLUSION
The workforce economics of supply and demand
I
Bob Vavra
Content Manager
You need to
sell your job

opportunities
with the same
enthusiasm
and with
the same
incentives
as you do
with your
sales force.
64 September 2015
slept through a good deal of Economics

101 in college. In my defense, it was a
large, warm lecture hall, and it was early
in the morning. I was a college student and,
after all, it was Economics 101. I did manage to make it through enough of the course
to earn a C and a passing knowledge of
supply and demand.
You dont need to be an economist, or even
awake, to grasp the basics of supply and
demand. Prices fall when supply is high and
demand is low, and prices rise when demand
is high and supply is low. The goal is to find
a way to consistently balance supply and
demand, which helps you maximize profits
and optimize production.
The supply and demand concept works well
with commodities, but people arent commodities, no matter what political candidates might
think. When you need more people to work in
your plant to help you grow your business, the
rules of supply and demand go out the window.
You have to focus on more than just money to
bring workers into your organization.
The continuing workforce shortage in manufacturing is reaching a critical point. With
a manufacturing economy in full recovery,
companies are looking to expand. After their
retirement plans were left in tatters seven years
ago, older plant workers now see a more stable
present and can look toward retirement with
more optimism and with less dependence on
their current jobs.
The combination of economic growth and
worker retirement will stretch our thin resources further, and automation and robotics will
only be able to do so much to stem this tide.
We need more people on our team.
Plant Engineering has touted for years the
importance of outreach by plant management
to attract, train, and retain this next generation
of workers. We need to assess the specific
needs of our plantswhat kind of worker
do we need to fill the roles? We then must
marshal resources to bring our manufacturing opportunities to the potential workforce,
and to show people how these manufacturing
opportunities create not just a job for today,
but a future for tomorrow.
In our articles this month that focus on
training and workforce development in
manufacturing, there were two compelling
quotes that sum up the issues that manufac-
PLANT ENGINEERING
turers and potential workers must consider.

One was from Stacey Bales, the president of
Bales Metal Surfacing Solutions, who said,
Were trying hard to reach out to the high
school level, but were still a couple of years
away. For us, its harder; no one grows up and
says they want to be a chrome plater. We train
in-house, but its kind of a dying art form.
We try to attract younger workers by having
a robust benefits package.
And then there was Leo Dionne, manager
of strategic sourcing/transitions at Pratt &
Whitney: These programs are offering not
just a job opportunity, but a career opportunity.
Given the advanced state of manufacturing
technology, we need highly skilled, businessoriented people. Were starting at the beginning, investing in adaptable, hard-working
individuals who want to have careers with us.
Some frustrated manufacturers might hear
all these platitudes and ask, Where do I find
these people? The obvious response is, Well,
where are you looking?
If youre just staring at your front door waiting for the workforce to break it down, youre
going to be waiting a long while. If youre setting up shop at job fairs, thats a better effort,
but not close to enough. You need to sell your
job opportunities with the same enthusiasm
and with the same incentivesas you do with
your sales force.
Your current employees should be your
best ambassadors for your company. Do you
offer a bounty for every new recruit they bring
through the door? Do you have an active program to train workers at the local community
college? If you invest in the school by providing them your equipment for training, will that
investment pay off in workers ready to step
in and produce on day one?
The numbers surrounding workforce development are obvious to all, but theyve stayed
roughly the same over the past decade. Weve
continued to grow manufacturing in that time,
but weve been living on mostly borrowed
time. We understand the problem, but at some
point that understanding has to translate into
action.
We lack the needed supply of workers. We
have to create a demand to work in our plants.
To do that, we need a supply of funds and
initiatives from our plant leadership. And we
have to demand it. PE
CELEBRATING
100 YEARS
Thank you to our customers, associates
and partners for 10 decades of success.
SEE IT ALL COME TOGETHER
Booth# C-4243
PACK EXPO International

September 28-30, 2015
Las Vegas, NV
Celebrating 100 years of proven

performance, Yaskawa is the worlds
largest manufacturer of ac drives,
motion control, and robotics.
YA S K A W A A M E R I C A , I N C .
DRIVES & MOTION DIVISION
1 - 8 0 0 - YA S K A W A | YA S K A W A . C O M
For more info:

http://Ez.com/yai813
2015 Yaskawa America Inc.
Poultry Proven.
BaldorDodge Quantis Ultra Kleen and Tigear-2

Ultra Kleen stainless steel gear reducers are the
ultimate choice for poultry and meat processing
applications. Completely sealed and made of premium
stainless steel, each gear reducer features long-life
gear construction, maintenance-free operation and
IP69K rated protection against high pressure and high
temperature washdown environments.
You can count on Quantis Ultra Kleen and Tigear-2
Ultra Kleen stainless steel gear reducers for the
superior reliability it takes to survive harsh washdown
applicationsday after day after day.
Call. 800-526-9328
Click. www.MotionIndustries.com
479-646-4711
Visit. Overbaldor.com
550 Locations
Premium Stainless Steel
Maintenance-free
Rounded Surfaces Prevent Water Pooling
IP69K Rated Protection
@BaldorElectric
Follow the story #PoultryProven
24-Hour Shipments Available
Download a QR reader app

and scan this code to download
the brochure.
http://esp.to/wtg04o
2015 Baldor Electric Company

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34 Meet the 2015 Engineering Leaders Under 40

Building on their fathers legacy, a new generation

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30 Better training leads to a stronger workforce

34 Meet the 2015 Engineering Leaders Under 40

43 A return to apprenticeships delivers

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47 Take a total system approach

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People and Training

Your most-read stories at www.plantengineering.com

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34 Meet the 2015 Engineering Leaders Under 40

Building on their fathers legacy, a new generation

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