Kastalon. Engineered to fit.

Tube Makers reduce costs while improving quality.

2010-05-14T15:36:00.000-07:00

Increasingly, competitive markets are pushing tube makers to reduce costs while improving quality.

The surface and edge condition of incoming coils has a significant impact on processing cost and quality. Scratch-free surfaces are important when processing polished, plated, or painted tube. However, scratches also can lead to weaknesses in the tube wall. This can be important for pressure tubing as well as mechanical tubing. Stresses can concentrate along scratches in mechanical tubing that is bulged or formed. Scratches can also concentrate stress in pressure tubing and create a weakness in the wall. This consideration is more critical for nonferrous materials.

Incoming material with a poor edge condition can lead to increased cost because of additional reprocessing, reduced yield, inspection cost, and the general inconvenience of returning the material and seeking credit for defective material from suppliers.

Producing, rolling, and processing coils influence its surface and edge condition. Surfaces and edges can also be compromised when they are handled during basic processes such as slitting, painting, annealing, and rolling.

Coil handling and protection also influence surface quality. This article examines typical problems in coil handling and how to maintain quality stock on the warehouse and mill floor.

Coil Handling Challenges and Answers
Beginning with the final stage of production, the finished metal surface is vulnerable to damage. Worn bridle, passline, pinch, tension, or other rollers that contact the metal as it is rolled can scratch surfaces. Slippage through or across rollers also contributes to scratching. To prevent slippage, these rollers can be covered with materials that provide traction and are softer than the metal, including rubber, polyurethane, and plastic.

Winding. Another potential source of damage is the expanding mandrel used to hold the coil while it is unwound and rewound during processing. These mandrels open and close when loading and unloading coil. To make this movement possible, the mandrel has segmented leafs that have gaps between them when expanded. The edges of these leafs can mark the inside of the coil.

When the metal is wound, it may bend at the edge to wind in a straight line to the next leaf edge. This is a condition called reel break. These breaks can print through many wraps before they soften enough to stop deforming the metal. In some severe cases, breaks can cause damage extending as much as 1/2 inch into the coil, potentially resulting in the loss of a 1-inch thick portion of metal out of the coil eye.

Excessive mandrel wear causes the leafs to get out of level and exacerbates reel breaks. Rubber or polyurethane sleeved (also call boots) can be used to minimize or eliminate this damage. A mandrel sleeve cushions the edge of the leaf and distributes the bending force over a wider area, helping to eliminate plastic deformation of the metal.

Storage and Transportation. Once the coil is wound, it must be removed from the mandrel, moved to storage, stored, and transported. Large, basic coil producers and processors generally have automated handling systems, coil cars, and conveyors. These units remove the coil from the mandrel and transfer it to a station, where more traditional equipment, such as C-hooks, ram trucks, and coil tongs, are used to move the coil.

Various flat pads or cushions may be attached to the coil contact areas. These are usually made of rubber, polyurethane, plastic, or some other material that is softer than metal.

When the coil is removed from the conveyor, forklift/ram trucks, C-hooks, or tongs are usually used to transport the metal. These devices can damage the coil’s edges. One mishap, such as a bump, can severely damage the entire edge of the coil. The only way to correct this damage is to slit the coil to a narrower width. However, this requires additional processing and wastes material. This waste can be substantial, depending on the amount of trim required to reach the next usable coil width.

The best method of protecting the metal during these operations is to cushion the areas contacting the coil, such as the sides and the back sides of the transport devices.

When coils are stored, stacking is not recommended. However, when space limitations make stacking a must, coils should be stored not more than three high because the weight on the bottom coil can deform it and make it square. This usually renders the deformed coil scrap.

Prepainted, coated, polished, or soft metals may need further protection when stored.

Coils can be stored in pads or racks when floors are wet, dirty, debris-covered, uneven. These devices isolate the coils from the floor and help prevent damage caused by hard set-down or placing coils on debris (which can dent the material).

Cost of Quality
Whenever and wherever coils are handled, damage can occur. Incurring or repairing damage, either at a vendor’s facility or at a tube mill, adds cost and compromises quality.

When reviewing processes or auditing suppliers, tube manufacturers should consider these problems and their simple resolutions. Excess cost anywhere in the supply chain adversely affects everyone’s bottom line.

+ + +
Al DiZanni is a Field Sales Engineer specializing in steel handling and steel processing from Kastalon, Inc., 4100 W. 124th Place, Alsip, Illinois 60803, phone 708-389-2210, fax 709-389-0432, Website: www.kastalon.com

Kastalon is a manufacturer of polyurethane coil storage, handling, and protection products. This article originally appeared in an issue of TPJ, a FMA Communications, Inc publication.

Expanding Mandrel Sleeves – Titan Steel

2009-08-31T17:20:00.000-07:00

Challenge/Problem/Issue -

Titan Steel was not satisfied with the scrap rate they were experiencing on the coil processing lines and wanted to find a way to maximize their output.

As one of the worlds largest distributors of tinmill and an important distributor of steel plate including pressure vessel plate, hot and cold rolled steel, coated steel products including galvanized steel and prepainted steel, efficiencies are extremely important.

Solution

Kastalon engineered expanding mandrel sleeves made from specifically formulated Kastalon Polyurethane® with exceptional wear properties and expansion capabilities. The mandrel sleeve not only increased the diameter of the mandrel but significantly reduced the damage and reduced the manpower required for change-outs.

Customer Value

According to the Plant Manager, "Kastalon's Expanding Mandrel Sleeves virtually paid for themselves the moment we unwound our first coil. With coil prices at a premium, every effort to maximize our output must be made and we look to Kastalon to help design products such as Mandrel Sleeves. An initial investment on our part has optimized our production, giving our customers an excellent finished product while maximizing our operating profits."

Running 180,000lbs per day, Titan Steel calculated a yield of 50-75 more sheet-per-coil on their blanking line using Kastalon’s Expanded Mandrel Sleeves. At a estimated cost of $2.00 per sheet, that represents a savings of $800-1000 per day, which does not include the huge cost savings in the manpower required to scrap the previously damaged sheets.

Fork-Kushions® - Masonite

2009-06-21T10:51:00.000-07:00

Challenge/Problem/Issue
Exemplifying manufacturing excellence, one of the a world’s leading manufacturer of interior doors, entry doors, french doors and glass doors felt it important to address the scratches and dents being caused by the forklifts transporting their product throughout the production facility and shipping area. The challenge was to find a process improvement that could realistically and economically prove effective, and increase the volume of quality going out the door.

Solution
Having heard of the new innovative bumper system developed by Kastalon, the plant management enlisted our assistance in matching the right bumper for the application. Kastalon recommended a soft grade Fork-Kushion® to absorb the doors impact while providing a non-scratching, non-marring surface for the doors to rest as the load is shifted back on the forks.

Customer Value
Customer immediately saw a reduction in their damage. The improvement not only saved significant dollars in the time and material used to touch-up and repair the damage, but it also improved the shipment times. Within 30 days, the reduction in damage was so significant that management issued a mandate that all forklift trucks be outfitted with a set of Fork-Kushions.

Fork-Kushions® - Siding Manufacturer

2009-06-21T10:47:00.000-07:00

Challenge/Problem/Issue
A quality control supervisor of a globally recognized manufacturer of engineered wood siding was continually experiencing significant damage caused by their forklifts picking up bundles of siding. Unique to the industry, their siding boards are denser and more rigid than traditional strand board siding, however, this rigidness also makes the sharp edge more susceptible to damage when coming in contact with the back of a lift truck. As a result, the supervisor searched for possible solutions.

Solution
Upon investigation, the supervisor learned of a revolutionary forklift bumper system called Fork-Kushions® that had proven to provide impressive damage control. Due to the sharp edge of the siding, it was determined that the “cut-resistant” style with its durable outer surface and it’s shock absorbent center would be the best fit to test against their application.

Customer Value
After 2 weeks of putting the Bumper into service they saw a 30% reduction in Broken Board. There was also a reduction in Siding interlocking with itself when the forklift picked up the tiers of newly milled siding. Although this was not a defect, it did cause safety and ergonomic issues and was greatly reduced by using the bumpers. The only concern they had was that they were going to have to purchase a longer fork for the forklifts to make up for the 1 1/2" they lost for the bumper and it's bracket.

After a full 3 months in service, the Fork-Kushions combined with the hydraulic carriage dampers for the fork lifts resulted in about an impressive 60% reduction of in process damaged board.

Koat-A-Roll - Doncaster Gear Products

2009-06-21T10:45:00.000-07:00

Challenge/Problem/Issue
Doncaster Gear Products specialize in forging and machining their own gears. As part of the forging process, they blast many different parts. For this process they make steel fixtures to set the parts on as they are fed into the automatic blaster. These fixtures represent a significant investment as hundreds are made annually, however, the blaster wears them away over time.

Solution
Attempting to find a way to give these fixtures a longer life, Doncaster Gear purchased Koat-A-Roll® polyurethane sleeves to put over the fixtures. Although not a standard application for Koat-A-Roll conveyer roller sleeves, the exception wear properties of the material and the cylindrical shape made it a perfect fit.

Customer Value
Within the first year, Doncaster realized a $2,000-$3,000 savings in material and machining cost. According to Dave Quarnstrom, “Although this is an unconventional use of the product, it was a great investment.”

Filler Plates - Cargill Steel

2009-06-21T10:41:00.000-07:00

Challenge/Problem/Issue
As the global demand continues to grow for light gauge metals in the automotive, appliance and building material markets, the metal coil processors must adapt to the unique challenges of producing surface-sensitive materials.

Because the pre-finished metal surface is more susceptible to scratches or damage, they must pay extra attention to the equipment and the handling of the coils.

Solution
Cargill Steel, East Chicago addressed their desire to successfully process light gauge materials by purchasing a new re-coiler reel for this application. Unfortunately, they continued to experience creasing, “head-in” damage, and marks on their finished product. They made several process changes as well as modifications to the reel but could not obtain an end product that they believed would be acceptable to the market that they were trying to attract. As a result, they moved away from those customers.

Cargill Steel started investigating ways to eliminate the damage they were experiencing and sought the assistance of Kastalon Polyurethane Products, who are well known for their coil protection solutions. After many months of design and engineering reviews, Kastalon made the recommendation to outfit the reel with a multi-segment bolt-on set of engineered polyurethane filler plates.

Once the filler plates were installed and put into service, several different gauges were run. The first was a .070/.071 thickness. This coil ran twice through the line and re-coiled twice on the filler plates. No markings could be felt. The second coil run was considered light gauge at .017 thickness. This coil also ran through the line and re-coiled twice on the filler plates. Again, the Quality Control Supervisor reported no marks.

Customer Value
The success of these coils has since allowed Cargill Steel to go after the light gauge market. In addition to the added business opportunity, the Kastalon Polyurethane Filler Plates are far lighter than steel, thereby allowing for faster change-outs and reduced maintenance costs have further improved operating efficiencies.

Kastalon Awarded the Safety Award of Honor

2009-05-25T17:45:00.000-07:00

Kastalon, Inc. has won a Safety Award of Honor in the FMA/CNA 2009 Safety Award Contest sponsored by the Fabricators & Manufacturers Association, Int'l, and CNA Insurance. FMA/CNA Safety Awards are based on your company's 2008 safety results compared to the most recently published Bureau of Labor Statistics (BLS) incidence rate for your NAICS code. The Safety Award of Honor is awarded to companies having no recordable injuries or illnesses. The award recognizes your company for its commitment to providing a safe work environment for its most valuable asset - the employees.

Congratulations to Kastalon and all their employees for a job well done.

Entrepreneur takes Kastalon to new heights

2009-01-15T15:35:00.000-08:00

By Mike McNulty
Rubber & Plastics News Staff

AKRON—R. Bruce DeMent II thrives on the challenge of being an entrepreneur. The risks can be high, he admits, but the payoffs are big.

"The satisfaction that comes with seeing your business grow and succeed is amazing," the president and CEO of Alsip, Ill.-based Kastalon Inc., a designer and manufacturer of polyurethane goods, said during a recent interview in Akron . He was in town meeting with a company and officials from the University of Akron's engineering co-operative office to fill a need in the firm's new co-op program.

DeMent has been singled out for numerous honors over the years, but one of the highlights was his induction into the Chicago Area Entrepreneurial Hall of Fame in 2008. He was recognized for his entrepreneurial achievements and for making a lasting impact on Chicago's business landscape.

Since 1990, he has been the prime mover behind the implementation of a key cultural change at Kastalon, creating a highly functioning management structure and lean production practices, according to a spokeswoman for the Chicago Hall of Fame.

That led to growth of more than 300 percent in the last several years.

He also added and expanded a design and engineering department that has created numerous avenues for growth.

The manufacturer's polyurethane parts now are used in various critical systems, including deep sea, weapons handling in military applications, heavy equipment, metals, material handling and space exploration.

In addition, DeMent partnered in the start-up and management of several other successful small businesses in the Chicago area. He eventually sold his interest in all but a recently launched real estate development company.

Included was an innovative restaurant service company, which eventually created an industry because a service sector for handling grease traps at restaurants didn't exist at the time and his company developed methods to recycle the grease.

"I was nominated (for the hall of fame) by people I've met over the years who know me and Kastalon," he said. "They felt it was significant enough just to be nominated."

When the selection committee picked him for the top honor, DeMent was surprised because "I was just doing my job. It would not have been possible to even approach the changes at Kastalon without a dedicated, motivated and highly capable staff. They won the award."

Despite his downplay, DeMent was picked because he worked hard and used foresight to take a little company down new roads to success.

Today the firm is far removed from the one-man operation that was launched in 1963 by DeMent's father, Robert, to cast custom urethane parts. Its first customer was U.S. Steel, a corporation that has remained with Kastalon over the years.

The company was primarily a repair and maintenance business that operated out of a building the size of a one-car garage. In 1995, it moved to bigger quarters and employed five.

Bruce DeMent was a kid at the time but was fascinated by the business. He fully intended to be part of it one day, he said, which is why he went to the University of Akron to get his degree in industrial management.

He joined the business full time in 1974 (he had worked part time at the company since he was 13) after graduating from college, and his passion for industrial engineering quickly provided Kastalon with new growth opportunities.

For the next 16 years, he handled practically every job in the plant. The site's biggest expansion came after 1990 when DeMent began running the company. He officially became president in 1994. By then, he was guiding the firm in a new direction as a leader in the custom design and engineering of polyurethane goods, the hall of fame spokeswoman said.

Entrepreneurship within an existing company is entirely different than with a start-up, according to DeMent, who co-owns Kastalon with his brother Michael. "You're changing an existing culture rather than creating one.

"When my dad started the business, his goal was to make a good living for him and his family. A start-up is a job, and the personality of the founder is imprinted on everything. But it's not a job any more; it's a business in and of itself, with or without the owner. It has professional management systems and structure and can survive without the owner. It won't die because it has direction, character and ability."

On the other hand, he said, in the 1960s and 1970s, if the owner died or left, the business would likely die.

Under DeMent's direction, Kastalon gained ISO certification and expanded regularly. It presently has a work force of 85 operating out of a 60,000-sq.-ft. plant in Alsip, a suburb south of Chicago .

"Business has been excellent à until recently when it slowed down a bit," he said. "It has become significantly more challenging. Our customers have been slowing down. Steel manufacturing, construction, everything has been curtailed in the last two quarters, which has a ripple affect.

"We have not suffered to the degree that our customers have, so I don't anticipate employee reductions."

Kastalon now has six major urethane product lines, all used in niche markets. "And we've maintained and expanded our custom molding operation," DeMent said.

Adding and expanding the design and engineering department—which he labeled as the firm's key growth area of the future' has allowed the company "to take on challenges to find solutions to very daunting applications, primarily in niche markets."

DeMent said he continues to head up Kastalon after working full time at the company for 34 years because "I love this business so much so that I want it to outlive me. I also do it because I make a fine living for myself and my family, and I want to build a future for my family and the people we work with.

"I've been able to do the things I've done at Kastalon because of the people who work here. They allow me to work on the business rather than in it."

Read more at www.rubbernews.com

Poly Provides Life Saving Solutions

2008-07-24T16:37:00.000-07:00

For more than a decade, the survival of the endangered manatees has improved thanks to the researchers at Harbor Branch Oceanographic Institute at Florida Atlantic University and Kastalon Polyurethane Products.

Engineers of the Institute not only invented, but have continually improved on an acoustic detection system that has successfully kept manatees from being injured or killed by floodgates and boat locks, which rank among the main causes leading to the demise of these slow moving creatures. The system uses sound waves and is so responsive it can stop the gates less than a 10th of a second after they detect the manatee.

Teaming up with Kastalon Polyurethane Products satisfied the concerns of the design team in sourcing a material that could withstand years of continuous submersion in brackish water and dramatic impact caused by boats and moving debris. Kastalon, a leading custom polyurethane components manufacturer located outside Chicago, developed a specially formulated urethane that would withstand harsh environmental stress with strong mechanical properties, resistance to UV rays, and could exceed the design life expectancies.

According to Larry Taylor, Harbor Branch’s project manager, “it’s all about solutions and we knew that Kastalon had the right chemistries.”

Currently, Harbor Branch and Kastalon are again working together on the latest version of the acoustic detection system which involves several intricate parts including underwater sensor cartridges designed from the specially formulated acoustically invisible polyurethane. The improved system is smaller, faster and more reliable.

The success of this project has resulted in Harbor Branch receiving a $5.8 million federal contract from the U.S. Army Corps of Engineers to install the system on the six additional navigation locks around Lake Okeechobee, Florida.

For more information on Kastalon’s custom polyurethane capabilities, visit our website at www.kastalon.com or contact Lyn Thorne, Kastalon Polyurethane Products, Inc. 708-389-2210. For project information, contact Larry Taylor, Harbor Branch Oceanographic Institute at 772-465-2400, ext. 625.

Koat-A-Roll.com answers the call

2007-05-23T15:31:00.000-07:00

Already renown in the industry for providing answers to unique material handling situations, Kastalon proudly announces their latest conveying solution by introducing their newest website, www.koat-a-roll.com. This interactive site offers a wealth of information regarding the benefits of polyurethane across the full spectrum of system design and maintenance for conveyor systems. For the designer or maintenance manager looking to enhance their system with more friction, less noise or a non-marking surface, this website provides an easy to use reference.

More than 25 years ago, Kastalon pioneered the “orange sleeve” under the brand name of Koat-A-Roll® for conveyor rollers to enhance the conveyors performance. Best known as a designer, engineer and manufacturer of customized polyurethane products, Kastalon’s use of polyurethane has been expanded into countless applications and components. The superior wear properties of polyurethane lend itself to replace traditional metal parts throughout the system.

Made in America. For more information, contact Kastalon, Inc at 1-800-KASTLON (1-800- 527-8566) or visit www.koat-a-roll.com.

Kastalon Polyurethane Products Achieves ISO 9001:2000 Certification

2007-04-18T15:32:00.000-07:00

Kastalon, Inc has announced that the company successfully passed an extensive ISO 9001:2000 quality systems surveillance audit and received its quality system certification from NSF International System Registration, Inc.

ISO 9001:2000 is a process-based certification that recognizes an organization’s ability to incorporate business objectives with operating effectiveness. Companies that achieve Quality Management System certification to ISO 9001:2000 have demonstrated effective implementation of documentation and records management, efficient process control, measurement and analysis of key performance factors and institutionalized continual improvement.

According to Bruce DeMent, President of the 3rd generation family owned company, “This certification was a vital step in meeting our goals as a leader in our industry. In addition to the fully effective practices now implemented by this certification process, we are equally proud to announce that our organization has also integrated a lean manufacturing philosophy to further our efficiencies and ability to meet our customer’s expectations.”

Since 1967, Kastalon Inc. has been manufacturing the highest quality elastomer products for all industrial applications. Kastalon’s years of technical and field experience have earned them worldwide recognition for problem solving and performance enhancement with innovative products and components.

Made in America. For more information, contact Kastalon, Inc at 1-800-KASTLON (1-800-527-8566) or visit www.kastalon.com.

Crane Bumper Calculator - Engineered to Fit

2007-01-15T15:28:00.000-08:00

Is your project out of the ordinary or would you like design assistance in choosing the right stops for your crane? That is where Kastalon shines. Start out by accessing the CRANE BUMPER CALCULATOR at www.kastalon.com to determine which standard crane bumper will fit your specifications. If your design requires a custom configuration, simply contact our design engineers through the website or by calling 1-800-527-8566 for assistance on modifying a crane bumper to suite your project.

Crane Bumpers - Thinking Outside the Box

2007-01-15T15:27:00.000-08:00

Beyond the ageless Crane Bridge and Trolley Bumper applications, new and exciting projects only limited by imagination have included Kastalon Crane Bumpers.

Minute Maid Park baseball stadium in Houston, TX features a retractable roof that allows the domed stadium to be outfitted with a natural grass field. A unique suspension system made possible using Kastalon’s unique polyurethane materials enables the roof system to open and close flawlessly. This is a sharp contrast to retractable roofs at other ballparks, where operational issues and significant maintenance costs are common.

The roof also employs Kastalon Crane Bumpers specifically designed to stop the 14.7 million pound roof and protect it from over travel collision damage. Kastalon’s engineers worked closely with the mechanical and architectural design team in developing bumpers that provide absolute protection for the all glass roof.

From the most challenging energy control applications to fundamental crane applications, Kastalon Crane Bumpers have provided decades of reliable, safe, and consistent performance.

Kastalon Crane Bumpers - Simple & High Performance Can Be One & the Same

2007-01-15T15:26:00.000-08:00

For more than 40 years, Kastalon supplies crane bumpers into every imaginable environment around the world.

From ports and shipyards to steel mills and industrial facilities, Kastalon bumpers are unaffected by extreme environmental conditions, and are highly effective in temperature extremes from less than -51°C (-60°F) to 107°C (225°F).

Approved for use on nuclear fueling cranes by the U.S. Navy and for nuclear power house cranes, Kastalon crane bumpers are virtually unaffected by gamma ray exposures in excess of 1x109 Roentgens.

Whether you are purchasing new equipment or are replacing existing bumpers, specify Kastalon Crane Bumpers.

To assist you in sizing or customizing bumpers, Kastalon offers an interactive web site for calculating the exact bumpers to meet any requirements.

Access the Kastalon Crane Bumper Calculator by visiting www.kastalon.com or contact us directly and an applications engineer will help select your optimum bumper.

Kastalon Crane Bumpers Are Pure Value And The Proof Is In The Poly!

2007-01-15T15:24:00.000-08:00

Kastalon Polyurethane Crane Bumpers are fully effective for dissipating the impact energy from a crane colliding with its end stops or another crane and have set new standards for performance and durability. They are tough, resilient, and economical lasting up to 50 times longer than hydraulic, spring, rubber and standard elastomer bumpers. Kastalon’s Crane Bumpers meet all specifications of OSHA, CMAA, ANSI, and AISE. They have a highly engineered structure with no moving parts, requiring no maintenance and are much lower in cost than the alternatives. Unaffected by oil, grease, aging, temperature extremes and dirt, they stand up to extreme environmental conditions.

Standard sizes range from 1.6 inch diameter to 24 inch diameter in both U.S. and European configurations, fitting virtually every bumper requirement. Regardless of the size or application of the crane, Kastalon has the appropriate bumper available.

Lean Practices Deliver Growth for Kastalon, Inc.

2006-04-15T09:44:00.000-07:00

Investment in lean training boosts gross revenues

Over the last 18 months long time polyurethane products manufacturer Kastalon, Inc. of Alsip, Illinois, has enjoyed improved product delivery times, more satisfied customers and increased sales.

Kastalon President, Bruce DeMent, credits these benefits to the results of lean manufacturing principles and practices his business adopted about 18 months ago.

“Our gross revenue has increased about 18 percent in the last year, and about half of that increase is due to new services lean manufacturing has made possible,” DeMent said.

Kastalon was started by DeMent’s father in Chicago Ridge 43 years ago as a one man operation out of his one-car garage. Today the company has 76 employees.

Known best as a designer, engineer and manufacturer of customized polyurethane products like conveyor rollers and the like for industrial applications, Kastalon recently had a mixed reputation in its markets. “We were known for quality products, but slow delivery,” DeMent said. “We knew we had to change the latter.”

DeMent said the company’s first pass at improvement was to respond to its customers’ requests that it become iso 9002-2000 certified. The challenge was that ISO certification would in effect “freeze” the company’s processes as they were. The decision was made to table ISO certification and instead streamline Kastalon’s processes first.

Kastalon, leveraging programs sponsored by norbic and the Chicago Manufacturing Center (cmc), had several managers participate in Lean courses taught by cmc specialists at Moraine Valley Community College.

Next it brought cmc lean specialists into its own facilities to instruct its supervisors, foremen and lead people about lean and the “5S” organizational philosophy -- sort, straighten, sweep, standardize and sustain.

There, the Kastalon group also participated in a “hands-on” simulation of Lean manufacturing that illustrated the value of single part lot-size manufacturing.

These lessons helped Kastalon understand the process of value stream mapping, which helps management and others review every movement involved in a business, from handling paperwork to making a product. If any action involved doesn’t add value from the customer’s perspective it is waste and should be eliminated.

“In our business, much of our work is maintenance and repair of parts that are used in our customers’ processes,” DeMent said. “When one of those components breaks down it will generally come back to us for service.

“In this operation customers value fast turn-around. Therefore, our goal in Lean implementation was to compress our delivery time. In maintenance and repair operations the delivery times we quoted were meaningless – if a customer is ‘down’ or has exhausted critical spares they want quicker service,” he added.

“When we started our evolution to Lean the satisfaction of our customers’ requested delivery date was around 20 percent. After one year of Lean discipline throughout our operations I am happy to say that level is up around 76 percent.”

Kastalon found assistance for its improvement initiatives through the Small Business Development Center (sbdc) program that norbic offers in partnership with the us Small Business Administration and the Illinois Department of Commerce & Economic Opportunity. The sbdc helped Kastalon leverage norbic’s Employer Training Incentive Program (etip), which can reimburse Illinois companies for up to 50 percent of the cost of training their employees. norbic administers the etip program on behalf of the Illinois Department of Commerce & Economic Opportunity.

In total, Kastalon utilized training grants of about $8,500 to train all of its employees -- from the corner office to the custodial department -- about Lean principles and to implement Lean practices in all of its operations.

“That money was well spent because from it we were able to make an additional investment of $90,000 in repositioning our shop facilities and in purchasing new equipment to further implement additional Lean practices,” DeMent said.

“Today,” he added, “the market knows Kastalon in a new light – now the word on the street is you not only get quality from Kastalon but now you get it fast too!”

Fork-Kushions® - New muscle takes the Floor

2005-12-16T15:29:00.000-08:00

New patent pending Coil Saddle takes safety and stability to a whole new level.

Alsip, IL - Kastalon, Inc. has blended portability and stability to create the Coil Saddle , a revolutionary coil storage device for any application. The deep cradle fits virtually any size coil and takes up minimal floor space. The unique design offers the versatility of using it as a moveable fixture in staging areas or affixed permanently to the storage area floor.

Made of bright safety yellow polyurethane and reinforced steel frames the Coil Saddle surprisingly only weighs 45# and can be easily moved out of the way when not in use, thus avoiding tripping hazards.

With the cost of metal continually increasing, the cost of scrap becomes a greater factor to your profitability. Coil Saddles is your front line weapon in scrap management by protecting surface sensitive metals from floor irregularities and contamination.

Kastalon has been a leader in the design, engineering and manufacturing of high quality, innovative polyurethane parts and products to protect metals. From the time metal is rolled, coated or processed Kastalon roller coverings, mandrel sleeves, filler plates, coil handling pads, fork truck bumpers and coil storage products are in service providing outstanding protection and increasing yields.

YieldSaver™ is a registered trademark of Kastalon, Inc.

Sound Value Being Added to the Workplace

2004-07-27T09:41:00.000-07:00

In 1987 society was introduced to a relatively new term called Ergonomics. By definition, the new buzz word means “The study of workplace equipment design or how to arrange and design devices, machines, or workspace so that people and things interact safely and most efficiently.” Countless organizations were formed and research groups began delving into the cause, effect and corrective action required to reduce the occupational injuries associated with the work environment.

As a result of studies and analysis done in the workplace, jobs have been made more efficient, less fatiguing and safer for the employee. OSHA has established a comprehensive strategy and has written a protocol for Developing Industry and Task Specific Ergonomic Guidelines published in June of 2004.

As we continue to search for ways to recognize and control potential hazards in the work place, nearly twenty years later, the newest safety concern to be brought to the forefront is Noise in the Workplace. Noise is often overlooked as a key “ergonomic” element in the workplace, however, the National Hearing Conservation Association has proven otherwise and has formed an alliance with OSHA to develop a hearing conservation programs that can be adopted by industry.

Studies have proven that excessive noise can cause lasting damage to hearing and can be considered dangerous if an employee is exposed to sound levels of 85 decibels or more for prolonged periods. Further, occupational noise has been written into General Industry Safety Orders for many states and has been named to the top 10 OSHA citation list with fines totaling over $206,000 in 2002.

According to OSHA’s 1981 estimates, at least one million workers in manufacturing and utilities had sustained occupational hearing impairments greater than OSHA’s definition of hearing handicap.

Unfortunately, although loss of hearing is the second highest self-reported workplace injury or illness in the United States, it is considered to be 100% preventable.

As automation continues to revolutionize industry, more and more facilities have integrated a material handling conveying system into their work flow in order to move product more efficiently. A conveying system not only brings an efficiency factor but adds an additional noise factor, as well. In conveying environments noise is created by not only the machinery itself, but also the product being conveyed across the belt or metal rollers. In addition, noise can be accentuated by conveying systems being operated at higher speeds.

According to a report published by the Conveyor Product Section of the Material Handling Industry “The primary goal should always be to reduce noise at its source.”

Different conveyor designs create different noise issues to be dealt with. For example Roller tube ringing is a common source of noise in roller based conveying systems. By covering metal rollers with Kastalon Koat-A-Roll® polyurethane conveyor roller sleeves, the roller surface is transformed to a non-marking, shock-absorbing, rugged “slip-on” polyurethane coated conveyor roller. Product is now transported across the urethane material and does not come in contact with the metal roller. Independent field tests have found that simple addition of polyurethane sleeves results in an impressive reduction in operating noise measuring 7-10 decibels.

Benefits of Koat-A-Roll®
Utilizing innovative components such as Koat-A-Roll® conveyor roller sleeves, legacy systems can be retrofitted in the field with inexpensive non-marking, rugged “slip-on” polyurethane roller covers. The value is not only limited to immediate reduction in noise, but the cost effectiveness becomes even more substantial when considering the greater friction and longer component life that is achieved.

For more information about Kastalon Polyurethane Products, visit www.kastalon.com or contact their client relations staff at 800-527-8566.

Helping Gentle Giants

2002-07-20T09:35:00.000-07:00

Design engineers rely on specially formulated monolithic urethane to protect manatees from injury and death.

Endangered manatees are getting a helping hand from design technology. Thanks to the efforts of engineers at the Harbor Branch Oceanographic Institution and the materials technology at Kastalon Inc., these gentle creatures have a better chance of staying alive. The Florida manatee is one of the most threatened marine animals in the United States. They are often killed by collisions with boats or from entrapment in man-made structures. In fact, only a few thousand of these friendly "sea cows" can be found in the shallow rivers, bays, canals, and coastal areas of the Florida peninsula.

South Florida Water
Management, which operates a series of remote controlled gates that regulate the water level in its vast system of canals, knew more had to be done to save these sea wonders. The canals, full of warm brackish water, attract numerous manatees. Finding warm water is a matter of survival for them. If manatees remain in the Gulf of Mexico after the water turns cold, they risk catching a fatal respiratory illness. However, the warm waters of the canals can also prove fatal to the slow-moving manatee. The vertical gates that regulate water flow between the canals and ocean are unmanned. Manatees, which measure about 12 feet long and weigh about 1,000 pounds, are often trapped when the 20- to 33-foot-wide gates close. Since no one is around to rescue them, the manatees die. Making matters worse is the turbulent flow of water through the gates, which carries all manner of debris from floating branches to illegally discarded washing machines.

Fortunately, seven sophisticated manatee protection systems are currently in place in the canal system, and an additional 13 have been contracted. These systems are sensitive enough to detect the soft body of a manatee and yet are not prone to false alarms triggered by debris.

The first system was installed on the Miami Canal in 1996. "This site had the worst record of manatee mortality before the system was installed," recalls Larry Taylor, Harbor Branch Oceanographic Institution's EE production manager and the project manager for manatee protection systems. "Since the system has been online, there has not been another injury."

The engineers at the Harbor Branch Oceanographic Institution invented the manatee protection system after extensive testing of various alarm mechanisms. Called the Manatee Piezo-Electric Detector bumper system, it allows the vertical gates, which move at a fixed speed of 6 inches per minute, to gently contact the manatee, stop, and then reverse without harming the animal. The system's sensor is sensitive enough to distinguish between a large object being violently pushed into the bumper and a manatee caught in the lowering gates. In addition, the unique shape of the bumper protects the sensor from impact.

"The bumper sensor design provides an extremely sensitive detector for the endangered manatee while including the ruggedness required for the industrial submerged environment," says Taylor. "Kastalon provided the custom molding capability and the perfect materials for us to meet the required 10-year service life of this system."

Kastalon, a manufacturer of polyurethane components located outside Chicago, developed the durable material needed for the bumper system. It's a specially formulated monolithic urethane engineered to withstand years of continuous submersion in brackish water as well as impact from surging water and moving debris. Designed to offer mechanical properties stronger and more durable than rubber, it also resists both UV rays and salt water.

During a demonstration of the manatee protection system, a plump tomato was used to simulate a manatee. When light pressure was applied to the tomato, the system activated without damaging the tomato. More important, the Harbor Branch Oceanographic Institution has confirmed dozens of cases in which a manatee has been spared from injury or death.
"Although a good design is always rewarding to an engineer, saving an endangered animal really makes this project special," says Taylor.

More information on polyurethanes and urethanes is available by contacting Kastalon Inc., 4100 W. 124th Place, Alsip, IL 60803 or calling (708) 389-2210. www.kastalon.com

Field Of Springs

2001-05-23T09:27:00.000-07:00

In the same city where Astroturf made its debut, another material technology Wrings Houston a new baseball marvel.

When the Houston Astrodome, baseball's first indoor stadium, opened in 1965, it had a natural grass field. The grass required a translucent roof, which produced glare and caused fielders to lose track of fly balls. To solve the problem, the stadium's roof was painted and the grass replaced with the newly invented artificial surface that we now call Astroturf.

No matter what you think about baseball on artificial turf, it is commonly agreed that Houston was at the forefront of baseball stadium innovation in the '60s. It continues that tradition today. The Astros still play ball under a roof but only when necessary. That's because the city erected Enron Field, a stadium with a retractable roof that makes natural grass possible. Although Enron Field is not the first stadium with a retractable roof, it does boast a special suspension system that is engineered to open and close the roof without glitches.

Bart Riberich, vice president of engineering at Uni- Systems, the Minneapolis-based firm that designed the roof travel mechanism, says that operating problems occur when the suspension system relies on bogies. They concentrate the load at a single point when the wheels hit a high spot on the rail, thereby thwarting smooth movement. Instead of bogies, Uni-Systems engineers turned to independent suspensions for each of the 142 wheels that carry the three huge roof sections atop Enron Field. To make the independent suspensions work, the engineers needed a suspension spring that would compress when the wheels met a high spot on the rail.

Finding the materials to make the springs was about as easy as hitting a Randy Johnson fastball. Almost from the start, Uni-Systems eliminated conventional metal springs because they couldn't achieve the targeted 25-year lifespan. The designers turned their attention to elastomers, which are not only highly resilient and durable but also able to handle heavy load capacity.

The Uni-Systems design team, along with engineers at Kastalon Polyurethane Products, Uni-Systems' partner on the project, selected Adiprene urethane prepolymer from Uniroyal Chemical to make the springs. "The springs had to be compact to make the design work," says Bruce DeMent, president of Kastalon. "The versatility of Adiprene urethanes allowed us to compound an elastomer that would give us the required performance."

The patented cylindrical springs installed at Enron Field consist of alternating layers of steel and urethane around a central shaft. Only 8 in. in diameter and 9 in. tall, the assemblies support a normal load of 125,000 lbs and peak loads up to 325,000 lbs. Now, the Astros can play ball come rain or shine.

More information on polyurethanes is available by contacting Kastalon Inc., 4100 W. 124th Place, Alsip, IL 60803 or calling (708) 389-2210.

Urethane Provides Smooth Stadium Roof Operation

2000-12-15T09:06:00.000-08:00

Enron Field, the new baseball stadium in Houston, Texas, features a retractable roof and a natural grass playing field. A unique suspension system reportedly enables the roof to operate flawlessly.

The roof travel mechanism was designed by Uni-Systems Inc., Minneapolis, Minn. It features independent suspensions for each of the 142 wheels that carry the three huge roof sections. The suspension springs compress a small amount when the wheel meets a high spot on the rail. Uni-Systems didn’t think that metal springs would be able to meet the 25 year working life criterion, so a system based on a urethane elastomer was chosen.

Development work was conducted by Uni-Systems and Kastalon Polyurethane Products, Alsip, Ill. Kastalon already was involved in the project in designing a bumper stop assembly for the roof system. The team selected Adiprene urethane prepolymers from Uniroyal Chemical, a Crompton business, Middlebury, Conn.

The patented cylindrical springs consist of alternating layers of steel and urethane around a central shaft. The laminated assemblies are only 20 cm (8 in.) in diameter and 23 cm (9 in.) tall, yet they support a normal load of 555 kN (125,000 lbf), with peaks to 1.4 MN (325,000 lbf).

Other applications: Adiprene urethane also is used in the stadium’s roof tie-down system. Despite its great weight, the roof must still be tied down during high wind or hurricane conditions. Use of urethane enables the tie-down springs to maintain constant tension during the lift/drop cycles experienced during high winds.

For more information about urethane applications, contact Bruce DeMent, Kastalon Inc.; tel: 708-389- 2210; fax: 708-389-0432; Web: www.kastalon.com.

Maximizing Quality and Yield by Al DiZanni

1999-05-21T10:36:00.000-07:00

Increasingly, competitive markets are pushing tube makers to reduce costs while improving quality.

The surface and edge condition of incoming coils has a significant impact on processing cost and quality. Scratch-free surfaces are important when processing polished, plated, or painted tube. However, scratches also can lead to weaknesses in the tube wall. This can be important for pressure tubing as well as mechanical tubing. Stresses can concentrate along scratches in mechanical tubing that is bulged or formed. Scratches can also concentrate stress in pressure tubing and create a weakness in the wall. This consideration is more critical for nonferrous materials.

Incoming material with a poor edge condition can lead to increased cost because of additional reprocessing, reduced yield, inspection cost, and the general inconvenience of returning the material and seeking credit for defective material from suppliers.

Producing, rolling, and processing coils influence its surface and edge condition. Surfaces and edges can also be compromised when they are handled during basic processes such as slitting, painting, annealing, and rolling.

Coil handling and protection also influence surface quality. This article examines typical problems in coil handling and how to maintain quality stock on the warehouse and mill floor.

Coil Handling Challenges and Answers
Beginning with the final stage of production, the finished metal surface is vulnerable to damage. Worn bridle, passline, pinch, tension, or other rollers that contact the metal as it is rolled can scratch surfaces. Slippage through or across rollers also contributes to scratching. To prevent slippage, these rollers can be covered with materials that provide traction and are softer than the metal, including rubber, polyurethane, and plastic.

Winding. Another potential source of damage is the expanding mandrel used to hold the coil while it is unwound and rewound during processing. These mandrels open and close when loading and unloading coil. To make this movement possible, the mandrel has segmented leafs that have gaps between them when expanded. The edges of these leafs can mark the inside of the coil.

When the metal is wound, it may bend at the edge to wind in a straight line to the next leaf edge. This is a condition called reel break. These breaks can print through many wraps before they soften enough to stop deforming the metal. In some severe cases, breaks can cause damage extending as much as 1/2 inch into the coil, potentially resulting in the loss of a 1-inch thick portion of metal out of the coil eye.

Excessive mandrel wear causes the leafs to get out of level and exacerbates reel breaks. Rubber or polyurethane sleeved (also call boots) can be used to minimize or eliminate this damage. A mandrel sleeve cushions the edge of the leaf and distributes the bending force over a wider area, helping to eliminate plastic deformation of the metal.

Storage and Transportation. Once the coil is wound, it must be removed from the mandrel, moved to storage, stored, and transported. Large, basic coil producers and processors generally have automated handling systems, coil cars, and conveyors. These units remove the coil from the mandrel and transfer it to a station, where more traditional equipment, such as C-hooks, ram trucks, and coil tongs, are used to move the coil.

Various flat pads or cushions may be attached to the coil contact areas. These are usually made of rubber, polyurethane, plastic, or some other material that is softer than metal.

When the coil is removed from the conveyor, forklift/ram trucks, C-hooks, or tongs are usually used to transport the metal. These devices can damage the coil’s edges. One mishap, such as a bump, can severely damage the entire edge of the coil. The only way to correct this damage is to slit the coil to a narrower width. However, this requires additional processing and wastes material. This waste can be substantial, depending on the amount of trim required to reach the next usable coil width.

The best method of protecting the metal during these operations is to cushion the areas contacting the coil, such as the sides and the back sides of the transport devices.

When coils are stored, stacking is not recommended. However, when space limitations make stacking a must, coils should be stored not more than three high because the weight on the bottom coil can deform it and make it square. This usually renders the deformed coil scrap.
Prepainted, coated, polished, or soft metals may need further protection when stored.
Coils can be stored in pads or racks when floors are wet, dirty, debris-covered, uneven. These devices isolate the coils from the floor and help prevent damage caused by hard set-down or placing coils on debris (which can dent the material).

Cost of Quality
Whenever and wherever coils are handled, damage can occur. Incurring or repairing damage, either at a vendor’s facility or at a tube mill, adds cost and compromises quality.
When reviewing processes or auditing suppliers, tube manufacturers should consider these problems and their simple resolutions. Excess cost anywhere in the supply chain adversely affects everyone’s bottom line.

Al DiZanni is a Field Sales Engineer specializing in steel handling and steel processing from Kastalon, Inc., 4100 W. 124th Place, Alsip, Illinois 60803, phone 708-389-2210, fax 709-389-0432, Website: www.kastalon.com

Kastalon is a manufacturer of polyurethane coil storage, handling, and protection products.
This article originally appeared in an issue of TPJ, a FMA Communications, Inc publication.