Author: Bethany Tap

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Department Spotlight Manufacturing

Improvements in Inspection

Productivity Improvements in Inspection

In recent months, Inspection has made great strides in improving productivity through our mini game, which started in May and ran through July. Mini games are part of playing the Great Game of Business, which Fastco has been doing for over two years. The purpose of the mini-games is to bring focus and awareness to a particular area needing improvement and to motivate and incentivize the team members involved to improve in that area.

The goal of this mini-game was to increase the department’s labor productivity and volume produced on a monthly basis, averaged over the three months. For 2023, Inspection’s labor productivity goal is 57% and our volume produced goals is 67%.  We worked hard and finished strong, beating our goal in May, June, and July.

Inspection’s Overall Goal

Productivity improvements in Inspection have helped us meet our department’s #1 goal, which is to positively impact net income and on-time delivery. With open-book management, the team has gained awareness of how each department impacts one another. In addition, it has helped us develop a line of sight to reaching our goal.

Personal and Professional Development

As we grow as a department, I’m eager to help each sort crew member meet their development and career goals, along with their personal goals. This includes goals outside of the workplace.

As Fastco continues to progress with open-book management, I hope we continue to focus on beginning with the right leadership. Having the right people in the right places is important. In addition, it is important to build a strong foundation of servant leadership for each team member. We can all be servant leaders in our areas.

by Julie Rogers, Inspection Team Leader

Categories
Manufacturing

Visual Sorting: Human vs. Robot

a woman is visual sorting parts on an ez sort machine

Visual Sorting:

Human vs. Robot

At Fastco, we use have a few different options for visual sorting parts. There’s EZ sort (shown in the video) in which parts feed down a track and a person inspects them as they pass. There is also table sorting, in which a person picks up and inspects parts by hand. And finally, there’s our 6-axis robot, Ellie.

So which is better: the human eye or a robot?

Here’s a quick breakdown.

 

Team Robot

Robots don’t need breaks or vacation.

Robots don’t lapse in attention. They are 100% binary and will always find the defect they’ve been programmed to find.

 

Team Human

Humans can find other potential flaws, not just what they are “programmed” to find.

Humans can visually sort very quickly. EZ sort is fast, though not as thorough as table sorting.

Visual Sorting Winner

Sorry to disappoint, but this one is a draw. There is no definitive “better” method of visual sorting. There are benefits to each sorting method and different parts call for different methods of inspection. In addition to Ellie, Fastco has many other state-of-the-art machines capable of sorting for everything from length under head to presence of patch or threads to hardness and cracks.

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About Fastco Manufacturing

The Process of Cold Heading Manufacturing

 

The Process of Cold Heading Manufacturing

What does the process of producing cold headed fasteners look like? And how does raw material become a fastener? This infographic outlines the process of cold heading manufacturing in 7 steps.

Cold Heading Process Description
Learn more on our LinkedIn page.

Step 1: Raw Material

First, we establish the rod size and material type based on print and progression.

Step 2: Tooling Created and Designed

Fastco’s engineering team makes prints and designs tooling. Then, our tool room builds the tools and purchasing orders anything we can’t make in-house.

Step 3: Cold Heading

A Cold Heading Setup Tech sets up the job on the machine. The machine forms parts via a series of high-speed, high-pressure punches and blows.

Step 4: Thread Roll

The Thread Roll machine rolls the cold headed blanks between two dies to form threads, knurls, or fetters. In addition to thread rolling, some parts may bet secondary machining on one of our 3 pointers. 

Step 5: Outside Processing

This step could include Heat Treatment, Plating, Patch, or Outside Secondary Machining. Fastco has an in-house wash to clean parts as well.

Step 6: Inspection / Sort

Next, parts are received in and sorted for quality assurance. Then, our inspection team packages the parts for shipment.

Step 7: Store and Ship

Boxed parts are stored in our distribution building. Fastco ships these parts to customers per purchase order agreements.

Categories
Department Spotlight Manufacturing

Thread Roll Update

Thread Roll Update 2023

Thread Roll Update Panoramic Photo of the Factory Floor

Thread Roll’s Improvement in Cost of Poor Quality

This year, Thread Roll’s greatest achievement has been reducing our cost of poor quality. As of the end of June, we were at about half the  COPQ as we were at this time in 2022, so this is a huge achievement. We are meeting our COPQ goal for the year and I’m really proud of my people for this. We have been emphasizing visual inspections along with parts being in spec and the team has been keeping their eyes on the parts. Our goal for 2023 is to be at less than half the COPQ that we had in 2022 and we are well on our way to meeting that goal.

Thread Roll Department West

 

Thread Roll Update on Productivity

Another big achievement for Thread Roll this year has been our productivity. We have even been able to incorporate additional volume from an cold header that was struggling to keep up with their thread roll volume. I have been pleased with how everyone has come together to add these parts into the mix. Receiving bonus checks as a result of our hard work has helped show the team the importance of working together and the impact of what we can accomplish. In addition, the quarterly incentive profit shares, financial education, and huddles have helped me, the Thread Roll team, and many other team members understand the financials in an eye-opening way that has motivated us to do.

by Matt Kik, Thread Roll Team Leader

Categories
Industry News

Cooling Inflation and Improving Supply Chains

American Flag, Fastener Manufacturer in the USA

Cooling Inflation and Improving Supply Chains:

Lessons from the Chaos

 

The latest inflation report from the Fed shows that inflation continues to cool. This year through May, overall U.S. consumer prices rose 4%, not including the volatile markets of food and energy (core CPI was 5.33%). This is the slowest rate of growth in more than two years. Still, it is twice the rate of what was considered normal growth before the pandemic. Steel prices, which matter acutely to companies in fastener industry and our supply chains, remain well above pre-pandemic levels.

But the good news is that inflation is trending in the right direction. And most economists predict that it will continue to moderate. Similar to cooling inflation, disruptions to supply chains, while still persistent in many sectors, are beginning, and should continue, to lessen. Given the cause-and-effect relationship between supply chain disruption and inflation, it makes sense that healthier supply chain would go hand-in-hand with inflation reduction.

Given these positive developments, it may be tempting to settle into a more complacent, less proactive mentality in terms of spending and supply chain management. While the Fed has not ruled out interest rate hikes and inflation is still a concern, we are looking toward a (hopefully) more stabilized economy. Here are some key lessons that we should take with us from this period of extreme disruption:

Quality Matters

To ensure a robust and healthy supply chain, you must have quality product. Sometimes, this means paying more money, but the return that you will get is worth it. The costs of poor quality are about more than just dollars; poor quality creates a timing disruption as well. It is important to have quality suppliers with meticulous control plans and fair labor practices, quality customers who are financially secure and share your values, and quality team members who care about the company and are engaged in the culture.

inspection
A team member inspects a part for quality assurance

 

Diversity is Paramount

It goes without saying that companies should not rely on a single source for any product they bring in. Diversity also matters in terms of customer base. A company serving many industries is more likely to survive a range of economic downturns because most economic slumps are industry-specific.

 

Invest in your People

Inflation has caused wages to go up as well. The average salary bump is now about 5%, as opposed to 2 or 3% previously. For employers, this may feel like just another rising expense, but paying your people fair wages that meet the demands of the time is important. A well-compensated, well-appreciated worker is more likely to be an engaged and loyal worker.

Fastco team members celebrate at a cookout.

Certainly, more lessons can be added to this list, but these are three that have mattered to Fastco, our supply chain, and our community. What lessons has your company learned post-pandemic?

 

 

Categories
Manufacturing

Cold Heading Initiatives

Plant Tour West Bay

 

Department Updates: Cold Heading Initiatives

In 2023, Cold Heading has been working on several initiatives. For this reason we have developed an “SQDC” board in every bay. SQDC stands for: Safety, Quality, Delivery, and Cost.

Safety, Quality Delivery, and Cost

First and foremost is Safety. Working safely every day is and always will be our department’s top priority. No other initiative is as important, since nothing can ever replace lost lives or limbs.

Quality of product is our second focus. Making lots of parts and hitting our delivery or production targets are meaningless if the product is not useable.

Next is Delivery. As part of this focus, we use “heat maps,” which tell us what parts are due and how many are due each week. Being in tune with what is needed to help the downstream operations (thread roll, outside processing, sort) and to keep the customer supplied is critical.

Last, but certainly not least, is Cost. To this point, the primary way that cold heading helps contribute to the success and profitability of the company is to generate as little scrap as possible. This year, we continue to reduce the amount of scrap we generate compared to previous years. This is a never ending battle with the ultimate goal always being zero scrap.

For each of these categories, we have simple reporting systems. Because the process is new, we continue to learn how to use these boards in the best and most efficient ways possible.

Cold Heading Initiatives in Bay 2
Cold Heading Bay 2

 

Open Book Management Initiative in Cold Heading

These boards help support Fastco’s philosophy on open book management. Open book management has been a real eye opener for many reasons in Cold Heading.

For one, we now better understand the impact of raw material expenditures, the number one cost for our product. In addition, we also have a better understanding of how more we have to sell to make up for the losses associated with a quality issue. Finally, we have a better understanding of what our true profits are after expenses.

For me, it has been humbling to realize how long I worked in manufacturing without truly understanding how the business worked. The only comfort is to know I was not alone. It is a privilege to work for a company that educates us and involves us in strategic decisions.

by Jim Wolters, Cold Heading Team Leader

Categories
Manufacturing

Stainless Steel Alloy

Stainless Steel 304
304 Cold Heading Quality Stainless Steel

What exactly is a stainless steel alloy?

Simply put, stainless steel is an iron and chromium alloy containing at least 10.5% chromium. Other common additives include:

  1. Nickel – Nickel containing grades make up 75% of stainless steel production. In fact, more than two thirds of global nickel produced is used in the production of stainless steel alloys because nickel improves the formability, weldability, and ductility of the material.
  2. Carbon – To be clear, steels that are typically referred to as “carbon” steels contain less than the 10.5% chromium required to be stainless. Stainless steels have less than 1.2% carbon.
  3. Manganese – High-manganese (200 series austenitic) have lower nickel content, making them more affordable in the current market.
  4. Molybdenum – This element improves the resistances to pitting corrosion of stainless.
  5. Nitrogen – Nitrogen is a strong austenite stabilizer, increasing the strength, hardness, and brittleness of stainless steels.
  6. Copper – Copper can improve corrosion resistance in stainless steels.

 

Stainless Steel Alloys

In addition to improving corrosion resistance, adding other elements to stainless steel alloy may also:

  • Improve high or low temperature resistance
  • Improve weldability or formability
  • Control magnetism

Different stainless steel grades will contain different additives in different amounts. When selecting a stainless steel, the forming process and end application should be considered.

At Fastco, we work primarily with 300 and 400 series stainless steels, as well as high-nickel alloy A286. Learn more on our materials pages.

Got a stainless steel fastener need? Send us an RFQ on this form or give us a call at 616-453-5428.

Categories
Department Spotlight

Administrative Support Spotlight

Direct, In-House Administrative Support

The Finance/IT/HR department provides administrative support for the entire company. The primary function of this department is to support manufacturing by ensuring our network systems function smoothly, keeping our financials in order, and managing the employee life cycle.

The four members of the administrative support team
The four members of the administrative support team

These are functions that can be outsourced. However, having internal and direct support means quicker turnaround on tasks, less down time, and a more humanized approach to these processes.

Humans Helping Humans

I think it’s important that everyone at Fastco remembers that we are here to help you and make your jobs easier. But we are humans, too! We mess up from time to time and we don’t always have the answers, but we will always try to get them for you.

Cross-Training Improves Function

As a member of our department, I am really proud of how much cross training we have done. It makes it fairly smooth to ensure critical functions are still maintained whenever one of us needs time off. I’m also proud of how well we all get along with one another. We address any conflict right away and we don’t hold grudges.

by Kati Tap, HR Specialist

Categories
About Fastco

Core Values – Why do they Matter?

Fastco employees

Why Do Core Values Matter?

Core values are the fundamental beliefs and priorities that drive team members’ and the organization’s behaviors. Core values act as internal compass of principles that guide decision making.

But why do they matter? At Fastco, we manufacture cold-headed fasteners; that is what we do. We hope to make a profit doing it. Is that why we do it? It is certain a piece of it, but it can’t be the only reason.

Core Values Reflect a Shared Purpose

In order to fully appreciate what we do, we need to know why we do it. And it has to be about more than money. Money matters. It’s how we feed, house, and cloth ourselves and our families. It stabilizes our lives. But it does not create happiness nor add meaning to a life or a company.

A company’s values should work to align a company around a shared purpose. That is, the why behind what they do. Fastco’s shared purpose is to create value and stability for our customers, team members, and community. It’s why we exist as an organization.

Our core values are the guiding principles that help us achieve our shared purpose. Fastco’s core values are:

  1. Respects and helps all team members excel
  2. Completes tasks with enthusiasm
  3. Sweats the details
  4. Gives honest feedback, but follows the company’s directive
  5. Puts the interest of the company first
Fastco’s Shared Purpose

 

 

Every company needs to decide what its purpose is and what values its members will need to achieve that purpose. Ideally, this is done with company-wide buy-in. These values then serve as a metric against which to assess performance and to evaluate potential candidates.

Values Come From Teams, Not Managers

As a company evolves, their values may shift, since values are not necessarily imposed by management but discovered through the habits and behaviors of ideal team members. Over time, values may become better defined. The organization may choose to eliminate some values or replace them with others that better suit the culture and goals of the organization.

In the end, the main thing is to know who you are as a company and why you what you do. This is just as, if not more, important than what you do and how you do it.

 

Categories
About Fastco

Sustainability in Manufacturing

Chemical and Oil Storage for Sustainability in Oil Use

Sustainability in Manufacturing at Fastco

As the climate crisis continues, we will all be pressed to come up with innovative ways to reduce our waste and our carbon footprint. From governments to corporations to individuals, there is lots of room for improvement, specifically in the area of sustainability.

While every company needs to look closely at their business practices to come up with ways to increase sustainability (and, more than likely, reduce expenditures as well), we wanted to highlight some recent improvements that our company has made to make our practices more environmentally sustainable and to reduce costs at the same time.

Scrap Reduction

Scrap bins with minimal scrap for sustainability.
A scrap tub with minimal scrap

This one may seem obvious, but it’s not easy! We have a goal to reduce our scrap by 25% this year. While the majority of our metal scrap is recycled, it is better to just not waste it at all, from a cost and sustainability standpoint.

In addition to reducing our carbon footprint and wasting material, our company can save tens, even hundreds, of thousands of dollars per year by reducing our scrap. We make this happen with frequent and thorough part checks on machines to avoid cost of poor quality scrap. It is also a matter of paying attention, watching machines, and being intentional when setting up parts and running them.

As a rule, cold heading is a low-scrap process compared to processes like stamping or machining. This is makes it a more cost-effective and sustainable means of fastener production.

Reusing Oil

We’ve got some really innovative team members and one recently suggested that we buy an air pump to add to oil totes in order to recycle cold heading oil for use in thread roll. Reusing the oil not only saves the company money by purchasing less oil and paying less to haul it away as often, but it is also better for the environment.

Sustainability: Recycled Oil in a Tote
Recycled Oil

 

Timers and LED lighting

Over the last few years, we have been working to replace our old lighting with more efficient LED lights. In addition, many of those lights that are public areas are now on motion sensors to reduce usage.

Recently, one of our preventive maintenance technicians noticed that parts cleaners throughout the facility were always left on. He suggested adding timers to them as well to shut them off automatically when they are not in use.

 

What sustainable practices has your company put into place? Where do you see manufacturing continue to make sustainability improvements in the years to come?