Volume 80 October 2013 Number 5

Published by HARRISON STEEL CASTINGS COMPANY, ATTICA, INDIANA

Mazak E1850 vertical turning and machining center ready to go on line.

First, I would like to thank allof our employees for a job well doneduring this difficult time. Second, Iwould like to say that we have everyintention of Harrison Steel being herefor a long time. I would like to pointout some of the positive things thatare currently going on at HarrisonSteel.

We have finally been able tobring in additional support to ourSales Team. We have been search-ing for the right individual for a whileand we are excited to welcome ToddStillwell to the HS Sales Team. Toddstarted a couple weeks ago and heand Kevin Cherry are deep into shak-ing the bushes.

We have a lot to be proud of atHarrison Steel, from our improve-ments in Safety, Quality, the way wetake care of our facilities and equip-ment to our latest expansion of ourmachining capabilities. None of thiscould have happened without greatemployees.

So far this year we have beengiven orders for 17 new part num-bers from 5 different customers andanother 3 part numbers from a “New”Customer. 4 of the 20 new part num-bers will be finish machined in thenew facility. The added machiningcapabilities have created a lot of in-terest in the marketplace and thequote activity has been very high.

HS will be introducing a newwebsite, which should be up and run-ning by the time this Tapping Out ispublished. We have also startedsending out monthly web blasts toexisting and prospective customers.The first web blast went out on Sep-tember 25th and the next one will goout on October 21st.

Besides the Sales and Market-ing activities I would be remise if Idid not make mention of the manycontinuous improvement projectsgoing on in operations. Below is alist of some of the projects that willbetter prepare HS to exceed our cus-tomers’ expectations in the future.

On Time Delivery Rapid Im-provement Workshop (RIW)

Binder Trials for improved workenvironment

Kronos Time and Attendance

System Implementation

5S projects everywhere

Extensive Equipment Rebuilds

Puzzle Plate Development

6 Sigma Cleaning Room Effi-ciency Project

Zero Gravity Grinding Project

Digital Radiography Project

Shroud Installation Project

Automated Shroud DepthMeasurement

Energize Indiana Lighting Ef-ficiency Projects

Work Safe, Work Smart andGod Bless

Geoff Curtis

MANAGEMENTCORNER

Employee BenefitsMike Wrighthouse

Medical

Once again, the flu shot pro-gram was a success. The staff fromour WeCare Clinic gave 223 flu shotsand 11 pneumonia shots. This is inaddition to a number they had al-ready given at the clinic. Employeeswho are not covered by the BenefitPlan can still get their shot at nocharge at the WeCare Clinic, justnotify HR that you are going. Ofcourse, anyone who is covered by thePlan can go to the Clinic and get theirshot.

In the next few weeks, we willbe having meetings to inform you ofan exciting new enhancement to theBenefit Plan, BridgeHealth Medical.If a covered individual needs surgery,there is a new option for quality sur-gical care at a top rated hospital withno out of network penalties and lowerout of pocket costs. Patients will haveaccess to a network of hospitals withsome of the best outcomes in thecountry. In the meetings, which willprobably be held during the first twoweeks in November, we will providemore details about this great newoption for you. Meeting dates andtimes will be sent out soon.

Profit Sharing

The year is winding down andthe Dow is still showing positive num-bers. We can only hope that keepsup for the rest of the year.

Our article was missed from theAugust/September Tapping Out, sowe apologize for the late condolences,but wanted these people to know thatthey were thought of and not over-looked at their time of sorrow. Wewould like to offer our condolencesto Evan Mickle (Rough Machining) onthe passing of his wife. This wasMonte Mickle’s (Finish Machining)daughter-in law. We would also liketo offer our condolences to EricDismore (New Machine Shop) andDerek Dismore (Maintenance Ma-chining) on the passing of their auntwhile we were off this summer.

Our 2nd machine has been de-livered and installed in the New Ma-chine Shop. If you haven’t had achance to go in the new MachineShop and look around, please feelfree to do so.

One more thing, Caleb Askren(Maintenance Machining) is going tobe a new dad. He says the baby isdue in early February. I learned whilewe were off in July that I am going tobe a Grandma. My son, Cameron,who is stationed in Fort Lewis, Wash-ington is going to be a daddy. Hislittle bundle of joy is due aroundMarch 25th. I am excited, other thanthe fact that it will be so far away. L

If you plan on taking your littleones around Trick or Treating in theVeedersburg area, stop by our house(604 N. Walnut St.) and get a hot dog,chips, and drink. We will be passingthese out to anyone who would likea free supper, even if you are not tak-ing little ones around. If you wouldrather just have candy, we have thattoo. This will be our 2nd year doingthis for the community. If you willbe in the Attica area instead, my auntand uncle plan on passing out hotdogs and candy at 110 Sherry Lanealso. This will be the 3rd year theyhave been doing this for the commu-nity.

Basketball season is fast ap-proaching. Go IU! I know they willprobably struggle this year, but a truefan supports them even in their “notso good” years.

MACHININGLori Scheurich

Too Many Close Calls . . . . . . .

We are still having reports of close calls between PIV’s (Powered Indus-trial Vehicles, themselves) and pedestrians. Whenever there is a Near Miss(just short of having an incident), we need to take the time to discover theroot cause and correct it. Most of the time we discover the root cause to thoseclose calls are related to not following the basic OSHA requirements andcompany safety Rules. Here’s what OSHA say’s must happen when operat-ing a PIV:

• Always operate at a safe speed for the area and conditions you areoperating in

• Always slow down and honk your horn at all blind inter-section ordoor ways

• If the corner has a stop sign or other traffic instructions, they mustbe followed as posted

• Utilize the provided mirrors to help see around blind corners

As you can see from the pictures below, this is one of our busiest blind

doorways. It is located between the North Machine Shop and the large Shake-

Out sand area (near the lift top oven and scrape area). We have alreadytaken some major precautions for this area by enacting certain mandatessuch as banning high-lifts from using this door way. All the traffic signs areclearly posted to remind operators to follow the safety precautions necessaryto avoid an incident.

If you drive a PIV, please always be on the look-out for other PIV’s andpedestrians. Always slow down and honk your horn at the inter-sections anddoorways, EVERY TIME. As you walk through the plant, please always stayto the side of the traffic aisles and respect the PIV operator’s right to get theirjob done safety. Working together, we can surly avoid an incident that couldhurt someone.

SAFETYJim Murphy

Hey to all, like to send outcongrats to all the winning teams inthe golf outing back in Sept. DuckMartin’s in 1st , BJ Newton’s in 2ndRick Holtkamp’s in 3rd, and last butnot least Kathy McMurtrie’s in lastplace. Way to go on the women’s long-est drive Tracey Bartlett, high five!!It was a fun day even though it rainedon us. Hopefully the weather will besunnier next year.

A word to the wise, a friend re-cently told me that if a bargain comesaround and it sounds too good to betrue, the “buzz” word is let it “bee”.Gotta keep your eyes open for thetakers and users out there.

I just found out that EdBlankenship’s favorite day is “Humpday”aka Wednesday, so all his col-

leagues went together and bought t-shirts with slogans pertaining tohump day. The ladies had pink t-shirts and the guys were in tan. Theyall had their shirts on to surpriseEddie B in the Wednesday morningmeeting. It was said that Eddie wasjust ecstatic over the gesture. GoEddie, go Eddie!! If you see Ed outand about, go on and wish him ahappy Wednesday.

To the person who bought thebowls from George V’s wife at the yardsale, he still has the lids. If that per-son would like to stop by and pickthem up.

So until next time, be safe andkeep smiling.

FOUNDRYDrema Wood

THE SAFE WAY IS THE RIGHT WAY

Harrison Steel Castings Com-pany has been a member of the U.S.Environmental Protection AgenciesEnergy Star Challenge since 2009,and a participant in the Departmentof Energy’s Better Buildings Chal-lenge since 2010. To date, we haveachieved an 8.9% decrease in energyconsumption from our baseline(2009). The savings achieved thus farcould not have been attained with-out the help of every single employee.

We still have a long way to go inachieving our goal of a 20% reduc-tion by 2020, and it is a time for allof us to think about reducing energyuse and costs across our operations.Here are some quick tips that you canuse every day to help us reach ourambitious energy savings goal of 2%reduction in energy usage for the fis-cal year 2014:

Turn off lighting in unoccu-pied areas: An area with (20) 400WHigh Pressure Sodium lights left onover a weekend period (48 HR) wastes$384.00/annual in energy costs. Anexample of this wattage light can befound in the core room. If you noticelow traffic areas that would benefitfrom motion sensing devices, pleasecontact an Energy Team member.

Turn off equipment when notin use: A dust collector (150HP) lefton for a 30 minute lunch break, 5-days a week, wastes $1,320.00/yearin energy costs! Operators and su-pervisors are our first line of defensein ensuring that we are turning offunnesessary equipment duringbreaks and shift changes. Ensurethat unnessary lights, vent fans,heaters, man fans, and equipment isturned OFF at the end of your sched-uled shift. If you have questions withregards to equipment (i.e. can it beturned off), please contact an EnergyTeam member.

Keep overhead doors closedwhen not in use: The Departmentof Energy estimates that facilities cansave up to 15% in energy costs overthe winter period by ensuring theoverhead doors and other opening areproperly sealed. The HVAC systemhas to work overtime when heatlosses occur through openings in thebuildings structure. Both gas andelectric consumption increase dras-

ENERGY STARKyle Long

tically to compensate for theselosses.

Compressed air savings op-portunity: Due to the excessivenoise in the plant, operators andsupervisors are our first line of de-fense in finding/reporting air leaks.A 1/8" leak in a 90 PSI airline wastesapproximately $1,964.15/year inenergy costs. Compressed air is oneof the most expensive uses of energyin a manufacturing plant. About 8hpof fuel is used to generate the elec-tricity required for 1hp of com-pressed air, making it the least effi-cient and sustainable plant utility.While there are applications thatrequire the use of compressed air,many uses of compressed air can beeliminated to save money. Improperuse of compressed air is anotherwaste which significantly increasethe energy cost. Please contact anenergy team member if you havesuggestions to replace compressedair with electric power.

Energy Champions of theMonth: Maintenance Department

Actions: The MaintenanceDepartment has been performing aweekly weekend energy savingswalk-through of the facility. This in-cludes identifying and turning offunused lighting and equipmentthroughout the facility over theweekend period. To date, the main-tenance department’s actions havesaved an estimated $9,858.00 inannual energy costs.

For energy savings sugges-tions, or if you would like to be-come a member of the EnergyTeam, please contact any of thefollowing Energy Star Team mem-bers: Kyle Long, Blaine Gretencord,Jack Foster, Anoop Balakrishnan,Pete Bodine, Ralph DeFlorio ,TomAnderson, David Wittenmyer, DerekHughes, Levi Knowlton

Megan Searcy SecurityDillan Wheeldon Plant SanitationMeriah Green-Wright SecurityElizabeth Williams SecurityTodd Stillwell SalesWilbur Hutson SecurityKyle Furr GrinderSteven Beedle Heat Follower

New Employees sinceour last issue:

First off, we would like to ex-tend our grateful thanks to the com-pany for the generosity of helping theemployees with the insurance premi-ums and again for the bountiful sup-ply of fresh vegetables from the sum-mer garden project we had earlier thisyear.

Nobody in our department hadanything newsworthy for this issueof Tapping Out so I thought I wouldshare a little bit of past history triviaabout Tapping Out that some of youmay not know. Did you know the firstTapping out was printed 70 yearsago? When the first issue was re-leased in December 1943, FranklinD Roosevelt was the President andthe United States was deep intoWWII; the Chicago Bears won the NFLchampionship and Frank Sinatra hadmade his radio debut (young readersprobably don’t have a clue who Frankwas). The layout of the Tapping Outhasn’t changed much over the yearswith the columns and cover pages.The early issues had “G.I. News”, andwhen glancing over an early issue youwill find it was common for the mili-tary men to write letters to HS or visitwhen on leave. Early editions werechock full of announcements, busi-ness and safety info, jokes, sports,and some friendly camaraderie. Backin ‘43 the information for the paperwas taken downtown to the localnewspaper print shop where it waslead type set, clamped and put in thepresses. Copper plates, like you seeat antique shops now, were used toprint the photos. It wasn’t until pur-chasing a large press in 1969 thatHS began printing in house. Daysspent in the dark room are now re-duced down to a few hours at a com-puter. For 70 years through hardtimes and prosperous times TappingOut has always made it to press as ameans of communication for a goodgroup of people. Congratulations on70 years and may the next 70 be fullof good news!

ENGINEERINGKenna Reynolds

Process Sequence andInteractionsDave Hollander

Have you heard the term “pro-cess sequence and interaction” inconjunction with the ISO QualityManagement System? This term isintroduced in paragraph 4.1 of ISO9001:2008, General Requirements.

The second sub-paragraph un-der 4.1 states, “The organization [HS]shall

a) Determine the processesneeded for the quality managementsystem and their applicationthroughout the organization,

b) Determine the sequence andinteraction of these processes.”

Following is a description ofhow Harrison Steel Castings hasdocumented compliance with para-graph 4.1.

For its core processes, HS haschosen

• Sales,

• APQP (Advanced ProductQuality Planning),

• Purchasing,

• Human Resources, and

• Manufacturing.

The core processes are includedin a flow chart entitled Process Se-quence and Interactions, documentnumber1000411A, which may beviewed in PDF format on the HarrisonSteel Process Tree. The flow chartshows the input from the customer(purchase orders) on the left andoutput to the customer (castings) onthe right.

The process sequence and in-teractions shown in the flow chartinclude:

· Quoting, contract review,order entry, planning – Sales andAPQP

· Process design, resourceneeds – APQP and Purchasing

· Procurement and receiving –Purchasing

• Pattern equipment, new pro-cesses, new equipment – Purchasingand APQP

• Sample and approval – APQP

· Production and shipping –Manufacturing

• All activities – Human Re-sources

Other elements included in theflow chart are

• Equipment and FacilitiesMaintenance – supports all produc-tion activities

• Continual Improvement –auditing, data analysis, correctiveand preventive action, managementreview, document control, recordscontrol – supports all activities.

Fall is here, and while I won’tmiss the heat, I will miss all the sum-mer activity. I love all the family andfriend get-togethers that I get to goto in the warmer weather.

Which “dyed in the wool” IU fanwas spotted at Purdue’s Homecom-ing football game? Ask Walt Black!

The golf outing was enjoyed byeveryone who went that I talked toafterward. Bill McMurtrie shared theresults with me for this issue. Theyare as follows:

1st place Duck Martin -9

2nd place BJ. Newton -8

3rd place Rick Holtkamp -8

Last Place Kathy McMurtrieteam, score unknown

Long Drive men BJ. Newton

Long Drive women TracyBartlett

CTP #2 Carri Swift

CTP #8 Chris Burks

CTP #12 Joseph Smith

CTP #17 Chuck Sundt

There are small prizes you canpick up at the golf shop.

Gift certificates will be given tothe captains to hand out for the first3 spots and Kathy’s team.

I would like to say good luckand God bless to Megan Samuels asshe moves on to a different job. Ihope it is everything you wish for.I’ll miss you lots!

Anyone with something toshare in an issue, please let meknow. I really enjoy having some-thing to contribute, but for now anduntil next time, God bless you all!

CLEANING ROOMHelen Lambka

Pattern ShopTony VanEtta

Congratulations to JerryWalker on his engagment to AllisonMyers. They have a wedding dateplanned for December 14th. Jerrywould like to thank Kathy Jones forintroducing him to Allison.

Joseph and Brooke Smith arethe proud parents on their new child

Kameron David Smith. Kameron wasborn on 9-10-2013 and was 7 lbs.7oz. and 19" long. He is home withhis big brother and sister Jacksonand Madilyn.

Stefan and CarmenDrambarean are proud first timegrandparents. Son Phillip and Sarahhad Syrus Asher Drambarean on 9-

12-2013 and he was 9lbs. 2oz.

We have been very busy in thePattern Shop this year building 13new patterns along with several en-gineering changes. We also have 4more new patterns that we are start-ing on right now. To go with the newpatterns we have 4 patterns beingshipped in to convert to HS produc-tion and 2 patterns that are for ex-perimental reasons.

In late October, Ben Myers,Spencer Grimm, and myself traveledto Cummins Midrange Engine Plantin Columbus, IN to learn about theirproduction system. This plant hasbeen in operation since 1991 and allof the engines there go in Dodge Ramtrucks. The first thing we noticed,upon arrival, is that all of their park-ing was on the rooftop. This gave theplant a feeling of a spaceship, readyto take off, like something out of StarWars.

We noticed many similaritiesto HPS. They also have metric boardswith charts, similar to our PQVCBoards. Their goals on each arealigned to the corporate goals, tomake sure important information isbeing tracked. They also have a Con-tinuous Improvement process verysimilar to ours. Their process had twomajor differences that worked outwell for them, and which we may tryto eventually update our process. Thefirst one was the amount of origina-tor involvement was much greaterthroughout the process. Instead ofsubmitting a card and someone elselooking into it, whoever submitted thecard was responsible for verifying theidea with the other shifts, their team,and the supervisors in the area tomake sure everyone agrees with theidea. The other difference their CIprocess had was that it was a team-focused idea: it required everyone onthe area and team to be involved inthat project. They are also involvedthroughout the entire process, andactually are responsible for complet-ing many of the quick-wins theywould like to see. This has a largebenefit of not having it get put into awaiting list, as it’s only a little thing,and then ends up taking six monthsto complete.

Each area at Cummins wasdivided up into teams of 6-8 employ-ees. In every team, there was a teamlead, a safety expert, a quality expert,and a velocity expert who attendeddifferent meetings each week, as theywere responsible for supporting theentire team in their specific area tomake improvements. Each teamwould also have daily meetings likeour start-of-shift meetings, wherethey were even so specific to list any

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Charlie Pilecki

HPSEric Carroll

parts that did not pass with First-Time-Quality (where it did not haveto go back to be welded a secondtime, etc.). Also, once a week, theyhad a 30-minute meeting to gothrough last week’s performance,quality issues, FTQ, projects, down-time, and where employees wereassigned new action items to handle(CI projects or similar).

Cummins also had a strongemphasis on Standard Work/WorkInstructions to drive down to the ex-act seconds a process should take.It was very impressive, but wasgeared towards an assembly line.Many of the steps involved puttingon a specific screw in this order withthis hand, so it was not as applicableto what we do here. Two other things

they thought were very beneficial totheir machining area was shifthandoffs (where the shifts had a for-malized document they filled out atthe end of the shift to relay informa-tion along to the next shift) and To-tal Productive Maintenance, whichthey believed has created the mostbenefit out of everything they havedone related to the production sys-tem.

Overall, it was a great tripand very neat to see their produc-tion system. We hope to be able toimplement some of the things we sawand learned about when HPS isready. However, an assembly line inthe automotive industry is a far cryfrom a foundry, so some things werenot applicable.