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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

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Department Spotlight Manufacturing

Fastco’s Purchasing Department

Fastco’s Purchasing Department

Fastco’s Purchasing Department’s unofficial mantra is “What we need, when we need it, and what provides the best value to Fastco.”  We do this by keeping inventory levels accurate and appropriately stocked, predicting future demand for tooling, supplies, and similar items, and finding an appropriate level of quality while negotiating the best price/value balance to sustain ongoing operations.  As the gatekeeper of the discretionary spend, this mindset has driven quantifiable savings year over year for the company, and every dollar not spent is a dollar on the bottom line!  We can’t forget our decentralized buyers either, in maintenance and accounting, who have significantly reduced cost in the Maintenance Department and office supply categories.

In-House Tooling - inserts and punches

In addition to the purchasing function, our shuttle operators’ staging of jobs for the headers and watchful eye over inventory levels keeps us ahead of the game and limit tooling related downtime to a minimum.  Our two shuttle operators (Ginny Beld & Tracy Eno) have both been the backbone of our data collection and recording over the past few years which is critically important to ID requirements, and their participation in streamlining processes and standardizing our inventory will pay dividends well into the future.

Communication is critical, not only for the Purchasing Department, but to the entire company. We encourage all departments to ask for what they need and to notice discrepancies and/or and bring them to our attention.

Overall, I am extremely appreciative of my team’s self-motivation and task management.  It’s a good feeling to know we’re all working to move the Purchasing Department in the same direction with the same goals in mind.

by Aaron Headrick, Purchasing Manager

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Department Spotlight Manufacturing

Fastco’s Cold Heading Department

Fastco’s Cold Heading Department

The primary function of the cold heading process is to produce the “blanks” that are the start of the manufacturing operation at Fastco. Cold Heading is a high-pressure, high-speed progressive forming process that uses a series of dies and blows to form parts. At Fastco, our Cold Heading Department manufactures pins and rivets complete and can form the blanks for screws, bolts, and studs.

Cold Heading’s Goal

Our goal is to manufacture quality parts on time and as close to the manufacturing order quantity (or 10% over) as we can. This is critical to the company because any mistakes or missed goals (defects, late delivery, short order quantities) cause problems in downstream operations. This also has a negative financial impact on the company. Conversely, when we perform well we can positively contribute to the financial health of the company.

Pride in Our Work

Our department takes pride in what we do. That being said, Fastco’s process is a complex one. As such, it is the result of the hard work of many people in many departments. Fastco’s Cold Heading Department takes defects very seriously; scrap and cost of poor quality reduction are significant strategic priorities for our Cold Heading and Thread Rolling.

Given the progressive nature of the manufacturing process, a delay or defect in Cold Heading has significant downstream operation impact. When we recognize an issue, we do our best to correct it for future runs. We are continuously innovating process improvements to avoid defects at every level. These include regular part checks and scrap reduction huddles, among other strategies.

As a team leader, I am very proud that the cold heading team is flexible and open to new ideas. Many of our long-term employees (aka old-timers) have seen a lot of changes over the years. Each time the team is tasked to consider a new challenge, they try to embrace the change the best they can and learn from past missteps. We have learned a lot collectively about what works and what doesn’t. We are constantly trying to adapt and improve.

 

by Jim Wolters, Cold Heading Team Leader

Categories
Department Spotlight Manufacturing

Engineering at Fastco

Engineering at Fastco

At Fastco, Engineering’s primary role is to develop new and improve on existing processes. The team is also responsible for the following functions:

  • Process print development
  • Tooling design
  • Sample development & simulation
  • Engineering Feasibility evaluation of potential new products
  • Develop all control plans
  • Create FEMA & PPAP
  • Troubleshooting support in all production areas (RRT)
  • Direct technical support to customers
  • ECR ownership and oversight
  • CAD Document control

Critical Department

What Engineering does is critical to Fastco’s success. Engineering is the only department that

  • Develops process prints, which is essential for producing parts.
  • Develops, designs, and makes tooling prints, which is essential for tooling up a new job.
  • Creates FEMAs, PPAPs, and control plans, which is essential for process control.

The Engineering team has various primary functions that are all equally important in their own way.  This means that they have to prioritize on a daily basis, multiple times a day, what is the most important to work on for Fastco as a whole.

Team Work

While the engineers may have disagreements or have strong differing opinions on something, the team works in a cohesive manner. Once a resolution has been come to, there is no subsequent drama.  Everyone in the department will pick up the slack when someone is gone, and not blink an eye at it.  They aren’t afraid of failing, but understand it’s not okay to just not try.  The team looks forward to doing “hard” things, like difficult samples, or developing a new process.  If they took the attitude of “let’s not do that because it’s too hard to do,” Fastco would only quote weld bolts, and would squeeze ourselves out of the industry.

by Josh Symon, Engineering Manager

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Department Spotlight

Sales at Fastco

Sales at Fastco

At Fastco, the Sales team doesn’t just sell parts; we perform a wide variety of tasks, from marketing & advertising, to quoting new business, to managing the sample process, to handling price increases and general customer relationship management for established customers. Managing customer relationships is a broad and ongoing job. It requires us to work closely with numerous other departments.

 

As a customer-centered department, Sales has a high-level of visibility at Fastco and a big impact on the company’s success. Every person in Sales has to understand how their job affects the company as a whole, looking up and downstream to see how tasks fit into the big picture. We are constantly working to improve our processes and are all very self-critical and self-sufficient workers.

Hard Work, Team Work

In 2022, our team set an aggressive goal for new business awards and we blew it out of the water. Of course, it wasn’t just the Sales team that made this happen. Engineering, Customer Service, Manufacturing, Finance, and Purchasing all work to help Fastco win new work to varying degrees. And certainly, winning work and keeping customers happy depends  on the work of every single team member at Fastco.

That being said, Sales should be given a lot of credit for the ongoing success in new business awards. It speaks to a highly motivated team who doggedly pursues new work and does our best to keep our customer’s coming back for more parts.

Interested in learning more about what Fastco does and how our sales team can help you? Request a quote from us or give us call at 616-453-5428.

Categories
Department Spotlight Manufacturing

Thread Rolling Team at Fastco

The Thread Rolling Team at Fastco is responsible for rolling threads, knurls, and/or fetters onto cold headed blanks.

 

What is Thread Rolling?

The threads form when dies press against cold headed blanks. The same process is used for knurling.

Thread rolling is the most efficient and cost effective for large production runs, since machine run rates are around one piece per second. Benefits of the rolling threads include:

  • No fine metal chips.
  • Material savings of 15-20% in the blank by weight.
  • Stronger, more accurate threads

MAThread® Supplier

Fastco is a licensed supplier of MAThread® and MATpoint®, so we can produce the following MAThread fasteners:

6 different MAThread types of thread rolling
Visit mathread.com for more information.

 

Rolling SEMS Parts

In addition, Fastco has a dedicated SEMS unit, enabling us to assemble SEMS bolt/washers. SEMS fasteners are pre-assembled washer/bolt combinations that are fast and easy to handle and fit into larger assemblies.

Our Thread Rolling Team

Made up of a combination of new and experienced team members, Fastco’s Thread Rolling team works hard to improve and problem solve solutions for customers. Currently, they are working hard on scrap reduction initiatives to improve profitability and reduce waste. As more of our junior members gain knowledge and experience, we look forward to seeing the torch pass to the next generation of manufacturing professionals.

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Department Spotlight

Production Control

Production Control at Fastco

The Production Control department’s primary role is to move product. Whether it is keeping the cold heading department supplied with raw material, moving bins of product to the next step, or taking product to and from the outside processors, our team makes it happen. Every team member in the Production Control (PC) department contributes to the company’s goals and helps get every dollar of sales out the door every month.

Not everything is controllable

While our job is to control product, many key factors that impact production are outside of the control of PC team members. The material handler cannot bring material to the header if we do not have it here. The truck drivers cannot bring product back in if it is not completed at the outside processor. Raw material, especially, has been a challenge for the last couple years. The PC department, like Fastco and many other companies, is at the mercy of the industry.

Production Control Fastco Semi-Truck

Controlling what we can

Despite this, the PC department works hard to improve the things they can control. I am proud that each member of the PC department knows their job and how to do it. The team members are always willing to help each other out. They do a lot behind the scenes of manufacturing that may not get the recognition it deserves.

Fastco is grateful for all the work put in by team members in the PC department, from the material handlers and parts washer to the truck drivers and the logistics support staff.

 

by Phil Kowalczyk, Logistics Manager

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Department Spotlight

Quality at Fastco

The Quality at Fastco

The primary function of the Quality Department is ensure standards are met. This includes all required specifications, checks, processes, and procedures. Quality is critical to reducing costs and failures. We work to ensure that our customers are getting what they pay for by having parts within specification.

Everyone is on the Quality Team!

The Quality Department is here to help improve, correct, and ensure things are done properly. It is important to recognize that EVERYONE at Fastco is responsible for the quality of the parts we produce, even if they are not technically a member of the Quality Department. Everyone that touches a part, from cold heading to washing to sorting to entering orders, are part of the Quality Team, in a broader (and important) sense. At Fastco, we all contribute to the quality of our products. Following procedures and processes ensures there are no extra costs or dramatic losses due to a failure.

Quality Control Image

 

Thank you, Quality Team!

Thank you to the Quality Department for their efforts to keep our company IATF compliant and to deliver on our promises to customers. When there are quality concerns, members of the Quality Department are always the first to answer the call to assist. They will help with extra sorting & audits and generally help on the production floor. The team regularly goes above and beyond without complaint.

by Brian Kropp, Quality Team Leader

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Department Spotlight

Fastco’s Inspection Department

The Inspection Department’s primary function is to get quality parts to our customers on-time. Delivering quality parts on-time is critical to Fastco’s success. We need to meet our customers’ expectations and demands in order to be a successful company.

Inspection Department to the Rescue!

Inspection is often treated as a “hail Mary” operation – it is the last step to getting parts out the door. If other operations run behind, the Inspection team feels it the most. Often, they get tubs in the day before parts are due and are expected to sort them and get them out the door on-time. It’s an unrealistic expectation born of the reality of manufacturing. The Inspection Department handles unrealistic expectations well.

inspectionWhat is IATF - a team member reaches into an inspection unitsorting and inspection

Trust the Process

In this department, team members are not just boxing up quality parts (although that may be the goal). They are also inspecting for quality concerns. For electronically sorted parts, they run each tub through multiple times due to false fallout and to reduce scrap. Quality and timing issues in cold heading and thread rolling all run downstream and affect inspection’s workload. Therefore, the more issues we catch on the machine, the better off the company is as a whole. Cold heading and thread rolling both work hard to stop quality defects on the machine before they reach the inspection department. But no one is perfect, which is why we work to have a process that is.

the inspection department team

Through it all, the Inspection Department will do whatever they can do with the timing they are given.  They continue to work hard and get parts out quickly. The department has a very high productivity rate and its members work well together as a team. It’s good to have a team that is so focused on meeting quality and timing demands, even when these two demands seem to conflict. The team trusts the process and serves our customers well.

PLUS – they have a robot on their team named Ellie. How cool is that?

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Department Spotlight

Maintenance at Fastco

Keeping heavy machinery such as cold heading equipment up and operational is no small task. At Fastco, we have an entire department of machine repair & preventive maintenance technicians, along with an onsite electrician that help keep our cold headers, thread rolling machines, inspection equipment, and general facilities running smoothly and efficiently.

Fastco’s maintenance department works diligently to keep production equipment running. The team performs repairs as needed and schedules planned maintenance to make sure that all key equipment is kept running without negatively impacting production because of machine down time.

A crew member on a blue riding floor scrubber performing general cleaning.
A crew member cleans the floors at Fastco.

Due to the ongoing nature of maintenance, this department has team members working onsite through all three shifts. They are here to help keep the facility running smoothly, days, nights, and sometimes weekends. The amount of time spent behind the scenes doing preventive maintenance on the equipment and the upkeep of facility itself is huge. It may often be invisible to other team members, but it matters.

Our maintenance crew team understands how much it matters as well. They know that they impact the company’s bottom line. Profitability depends on productivity, and productivity depends on having machines up and running efficiently. By doing their jobs thoroughly, our maintenance team works to prevent down time first, and then reduce any necessary down time.

Assorted tools and blue shelves with equipment in the main maintenance area at Fastco.
The main maintenance area at Fastco

These eleven team members are essential members of team Fastco and we want to say thank you to them for all the work they do. Maintenance at Fastco is critical and we appreciate everything you do.