WJI August 2019 Feature Sample

WIRE JOURNAL AUGUST 2019

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INTERNATIONAL www.wirenet.org

O F F I C I A L P U B L I C AT I O N O F T H E W I R E A S S O C I AT I O N I N T E R N AT I O N A L

I T C Verona 20 19 WAI and the Italian Association of Wire and Cable Machinery Manufacturers (ACIMAF) have joined forces to stage Wire & Cable Verona, an international technical conference (ITC) to be held Oct. 21-22 in Verona, Italy.

The event partners are the Italian Ministry of Economic Development and the Italian Trading Agency. The event is supported by Expometals and industry organizations CET, IWCEA and IWMA. The program will include 22 presentations in ferrous and nonferrous tracks, a keynote presentation, tabletops, a gala dinner and a choice of plant tours.

ACIMAF President Ferruccio Bellina, president of the TKT Group, said that Wire & Cable Verona will be provide an exceptional opportunity to meet all the major operators in the sector. The program will include reports of high technical and scientific value by prestigious international companies and universities on innovations specific to the field of wire and cable. “The Verona conference will be an exceptional opportunity to meet all the major operators in the sector,” he said.

Samples of some products made by Mondini Cables.

PRODUCED BY:

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The conference will take place in the magnificent Palazzo della Gran Guardia, located in front of the historic Verona Arena, one of the most visited monuments in the world. The gala dinner will be held in the Palazzo Verità Poeta, a few steps from the conference venue. The conference will be held on Monday, Oct. 21, and the next day, delegates Ferruccio Bellina will be able to visit one of two plants near Verona.

The ferrous tour is of the Pittini Group’s operation in Verona. In 2015, the Pittini Group acquired Acciaierie di Verona SpA, and the next year it announced a plan to enhance “one of the historical sites in the Italian steelwork panorama, while creating one of the most innovative wire rod rolling plants in the world.” The plan, to be carried out through 2021, calls for an extensive technological upgrade to improve product quality.

The electrical tour is of Mondini Cables. Founded in 1970, the company manufactures nonferrous wires and copper cable products at its plant in Caprino Veronese.

The tours will conclude with a visit to the Serego Alighieri estate where the Masi Company produces an amarone known all over the world. Tour participants will also take part in a special wine tasting event.

Attendees who can extend their stay will not be disappointed. Since Roman times, when four consular roads intersected, Verona has been a main road junction as it is between Venice-Milan-Turin east-westbound and between Brenner-Modena-Bologna-Rome north-southbound. The city of Verona itself was declared a World Heritage Site by UNESCO, which observed, “In its urban structure and its

PARTNERS:

MONDAY, OCTOBER 21

Steel wire production at Acciaierie di Verona Spa. architecture, Verona is an outstanding example of a town that has developed progressively and uninterruptedly over two thousand years, incorporating artistic elements of the highest quality from each succeeding period.”

If you are interested in attending, exhibiting or sponsoring the event, it is recommended that you register now as availabilities are limited. For all information and registration you will find all the necessary details on the Wire & Cable Verona website: www.wirecable19.com.

The WAI has a legacy of organizing/supporting ITCs, most recently in Düsseldorf, Germany (2017); Monterrey, Mexico (2016); Düsseldorf, Germany, (2015); Milan, Italy (2013); Düsseldorf, Germany (2011); Monterrey, Mexico (2010); Istanbul, Turkey (2009); Monterrey, Mexico (2008); Bologna, Italy (2007); New Delhi, India (2006); The Czech Republic (2005); Mexico (2004); Italy (2003); Canada (2002); and the U.K. (2001).

REGISTER AT WWW.WIRECABLE19.COM 

08:30 – 11:00

Registration & Welcome Coffee

08:30

Tabletop Exhibition

09:30 – 10:00

Opening Remarks

10:00 – 11:15

Technical Sessions (Ferrous & Nonferrous)

11:15 – 11:45

Break

11:45 – 13:00

Technical Sessions (Ferrous & Nonferrous)

13:00 – 14:30

Lunch

14:30 – 15:45

Technical Sessions (Ferrous & Nonferrous)

15:45 – 16:15

Break

16:15 – 17:30

Technical Sessions (Ferrous & Nonferrous)

19:15

Reception – Palazzo Verita

20:00

Gala Dinner – Palazzo Verita Poeta

TUESDAY, OCTOBER 22 | PLANT TOURS 08:30

Tour Group Check-In

09:00

Tour Electrical - Mondini Cavi

Registration Fees

*EARLY REG. FEE BY OCT. 7

Conference with Gala Dinner

€220/$250

Conference (No Gala Dinner)

€160/$180

Tabletop Display

€800/$900

Tour Acciaierie Di Verona (Ferrous)

€60/$70

Tour Mondini Cavi (Electrical)

€60/$70

F ERROU S TR AC K THERMO-MECHANICAL AND AIR PATENTING IN MODERN ROLLING: CHARACTERISTICS AND ADVANTAGES In modern rolling process, thermal treatment during the whole implementation, along with the air patenting at the final stage, plays a key role in order to achieve high-quality rolled products. During the whole rolling phase, temperature is kept under control by five cooling units before gauging and final air patenting, which allows to: define the austenite grain size with greater precision; and achieve better elongation properties and better necking.

Luciano Del Pin, Pittini Group

CATHODIC PLASMA ELECTROLYSIS: A NOVEL METALCOATING DEPOSITION TECHNIQUE In this talk, we will present a feasibility study for a hydrometallurgical process, based on the employment of Cathodic Plasma Electrolysis (CPE), aimed at galvanizing steel using directly Zn-containing solutions obtained by leaching of EAF dusts, thus avoiding any intermediate step of zinc metal recovery (e.g., through classical electrowinning).

Mirko Magni and Stefano P. Trasatti, Unimilano

WITH SUPPORT FROM: IWMA

CET . ..

INTERNATIONAL WIRE & MACHINERY ASSOCIATION

Comité Européen de la Tréfilerie

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EVENT PREVIEW

Verona Summary Schedule

FEATURE

PACKAGING: an industry staple At Interwire, the exhibits included a slew of options for packaging of wire and cable, a niche that while essential, can be easy to take for granted. Below, some suppliers of reels, spools and more that were represented in Atlanta discuss their fields. Of note, the most cited challenge they face has little to do with technology or prices. Also, see “Products,” which starts on p. 78.

WJI: What is the single biggest challenge you face in your day-to-day operations?  The universal issue of recruiting new talent from a very shallow pool of candidates is challenging. Finding new people requires a creative approach. Getting out of the crowd of other companies doing the same old thing. We’ve had success with interns who get a taste of our culture and want to return, sometimes even continuing their service parttime during the school year. While manufacturing may not be on top of the new generation’s minds, once employ-

Carris notes that every staffer is part of its responses. ees remain for three to six months, we have great success in retention. Change in a high-tenure company can be difficult. Building an innovative culture requires constant re-invigoration in our continuous improvement programs.

Opening minds is a regular necessity with the advent of technology opportunities. What we achieved yesterday may well change in a short period of time. As an employee-owned company, our people have a clear view as to what growth and productivity translate to their share price.

This is the “line of sight” that enables a nimble culture.

Carris Reels.

Our biggest day-to-day challenge is to match worldwide demand in all our operations in Brazil, Colombia, Mexico, the U.S., Spain and Bahrain. Logistics and currency exchanges can make this plan difficult, but we are quite flexible at meeting customer requirements. Leandro Mazzocato, sales director, Madem Reels Group.

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Because REELEX is the sole supplier for figure-eightbased packaging technology, we are tasked with simultaneously supporting the current technology and looking towards the future. Our greatest challenge right now is allocating engineering resources away from day-to-day production to focus more on R&D projects. We have a huge number of exciting innovations we can’t wait to develop, but finding the time and resources to flush them out can be challenging. Tim Copp, vice president, business development, REELEX. Our customers depend on us to have the best quality reels ready for them when needed. To maintain that trust and service level, we have to be careful about who we include in our workforce. With unemployment so low, that has become our biggest challenge.

Many large employers have undervalued their labor force over recent years. So a very low percentage of labor candidates today can envision or appreciate how doing a good job for a good company can positively affect their lives, their careers, their families, and their community. Safety and quality are the highest priorities at Sonoco. New hires have to Winebarger demonstrate a desire to craft the best reels in the industry while respecting their co-workers and customers. Likewise, a keen attention to workplace safety is critical to achieving the standards embraced by Sonoco worldwide. Our company operates in hundreds of communities, so we are motivated to establish Sonoco as a solid local employer that provides fair compensation and benefits, a safe workplace, and the opportunity to build a career, whether in that community or in other places and industries around the world.

Dave Winebarger, vice president and general manager, Sonoco Reels and Plugs.

I have to agree with Dave. We’ve had to be very creative in how we find and recruit skilled, motivated labor. Our plants maintain relationships with technical and commu-

The wide product breadth that we have and manage is a challenge we take on well. We do not just supply simple steel reels, but get into more complex machined and mechanically adjustable reels as well as handling equipment. This requires internal systems to properly manage all the moving parts to come together efficiently. We operate with ISO 9001:2000 standards and have an internal ERP system to allow us good oversight and planning for all the various projects and parts being handled. When building collapsible reels there are numerous operations and some outside suppliers needed to fabricate and design such reels.

Boxy is unique in its ability to offer such product breadth and 50 years of expertise which is efficiently managed through the modern electronic planning systems as well as a strong team of professionals. Alberto Tononi, managing director, Boxy SpA. GMP Slovakia has been in the wire and cable industry business for many years, and the market situation today is completely different from when we started. Probably the biggest challenge is to convince customers that quality products are the best investment for their money. There are many reels manufacturers in the market, more than in the past, so GMP Slovakia must make customers see our dedication to our customers. We have invested in equipment and new technology so our production department

can save manufacturing time and provide quality products at a fair cost, supported by reliable delivery and the extensive know-how of our technical service. One clear sign of this commitment is the ISO 9001:2015 certification of our Quality Management System. GMP Slovakia.

Our biggest challenge is labor related. It seems that work-ethics and dedication are a lacking skill these days. Our customers place great emphasis on us delivering in short lead-times and maintaining high-quality standards. We often struggle keeping welders motivated and efficient to meet the timelines we place on ourselves to meet customer expectations. It is not rare that workers desire higher wages, but it is difficult Chris Hauer at Interwire. to see them contribute to ways of getting these goals accomplished. Common issues are absenteeism and unwillingness to work overtime, which creates ripple effects throughout the production floor. Chris Hauer, HOWAR Steel Reels.

Report: industrial cable reel market should see small yet steady gains to 2026 A report from Persistence Market Research (PRM) PMR sees modest yet steady growth for the industrial cable reels market through 2026, when the market should top US$3.4 billion.

A press release said that the long-term outlook for the global industrial cable reels market will remain positive to 2026, with a CAGR increase 4.0% during the forecast period. It states that the spring-loaded industrial cable reels segment should see healthy growth due its growing adoption in manufacturing plants. The four-core to six-core industrial cable reels segment is expected to account for more than half of revenues, with the four-core reels the leader.

Sector growth in 2018, which saw revenues of U$2.48 billion, was estimated to have been 4% greater than in 2017. In terms of volume, China was estimated to have accounted for 22% of the total global market by the end of 2018, and is expected to retain its position in the industrial cable reels market during the forecast period. The North America market, a high value region, should dominate in terms of sales over the forecast period, but China and Southeast Asia and the Pacific Region are expected to grow at an above-average growth rate.

Some of the key drivers for the flourishing industrial sector includes manufacturing, mining, construction, utilities and oil and gas. Demand for industrial cable reels continues to be driven by both public and private sector construction projects across the globe. Many suppliers of industrial cable reels “are entering markets in Asia-Pacific and Middle East and Africa with the hope of capitalizing on demand and thus, expand their geographical footprint.�

This directions, in turn, requires companies to develop products that comply with the operational standards in local markets.

To request a sample copy of the report, go to www.persistencemarketresearch.com/samples/25111.

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FEATURE

nity colleges as well as recruit at job fairs whenever we can. Jay Swetenburg, Sonoco Plastics Account Manager-Global Plastics.

FEATURE

4.0: the evolution continues

The electronic journey of Industry 4.0 (4.0) has become more recognized, if not yet warmly welcomed, in the wire and cable industry. This feature reflects the enthusiasm of solution providers and the understandably more cautious embrace of OEMs. And, for a different view, do see Industry Voices on p. 20.

A focus on digitization works best when an OEM and customer work together Germany’s Machinenfabrik Niehoff GmbH sees the hand optimum maintenance and repair. These are crucial essence of Industry 4.0 (4.0) as “digitization,” which is the benefits for our production.” heart of the company’s Niehoff Digital Assistant+ as the The app keeps Braunkabel informed anywhere and at app works as a web application simultaneously for iOS and any time of the current state of all important manufacturing Android and supports users of Niehoff machinery seeking parameters, such as machine speed, slide track temperasafe and economical production. ture, meter counter, remaining time, etc. It helps react 4.0 is about real-time data, and the Niehoff app evaluates immediately to any problem that might occur. It allows data that are recorded Braunkabel to plan and by sensors during the schedule service or mainoperation of Niehoff tenance works/repairs, machines. These data thus reducing unpredictreveal a lot about their able machine breakdowns. technical condition and When data are readily help increase the Overall available and commuEquipment Effectiveness nicated in real time, this (OEE). Via a protected process is quite efficient. user account, many func“The app makes many tions of the app can be things easier and faster for used, depending on the me since real time data are individual user requests. available even while I´m The Digital Assistant+ talking to the operator,” has three main functions: Müller said. “This means machine and process any relevant information is monitoring, identifion hand without somebody A screen view of Niehoff GmbH’s Digital Assistant+. cation of spare parts, running around searchand trouble-shooting. An example of how this translates ing for data. The app eases the workload and I can give the to production was described in a report that was recently planning department important information – quickly and published by Niehoff, and summarized as follows. reliably. This helps to optimize the stock of inventory and At wire Düsseldorf 2018, Niehoff had talks with as well as all processes, from ordering to the finished prodBraunkabel, a German cable manufacturer, about its goals uct.” for digitization. This ultimately led to a pilot phase of the Müller said that he frequently checks the app functions app. Marcus Müller, Braunkabel’s head of process engion his smartphone, including when he is not working, just neering, said that his company installed a separate network to see if everything is okay: “I´m always relieved to see for its Niehoff machines that exclusively allows Niehoff a that the temperature of the carriers slide track is correct safe access to their machines operating in the Braunkabel because then I´m sure that the next morning will not hold factory. The requirements for the security architecture were any nasty surprises in store; but everything runs trouworked out together. ble-free as planned.”

“Digitization of course is a big issue,” Müller said. “For The Niehoff app also provides improved ease of spare us it means the next logical step on our way to increase our parts, and a further capability, troubleshooting, is being Overall Equipment Effectiveness (OEE). Combining plandeveloped. The feature is not available yet, but it will allow ning and manufacturing processes on one data basis allows direct sending and tracking of malfunctions in a highly reliable process planning on the one hand, and on the other transparent model.

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Earlier this year, U.K.-based Cimteq, a supplier of industry software for cable designing and manufacturing (CableBuilder), real-time production monitoring and control (CableMes) and auto-generated images (CableBuilder 3D), launched an academy for Industry 4.0 at www.cimteq.com. Below, Marketing Manager Katy Harrison explains why.

WJI: What was the driving force that led your company to create the Cimteq Academy?

Harrison: There is a wealth of experience within Cimteq, and our CEO, Ali Shehab, is a regular contributor to industrial publications, conference papers and presentations. He’s well respected within the industry, combining in-depth technical knowledge and the ability to understand and approach issues from a business perspective.

We wanted to tap into this knowledge and offer our website visitors much more than just product information.

We decided to develop a section of the website that would be devoted solely to learning and development. From this, the idea of the Cimteq Academy was born.

WJI: What were your goals in designing the site? Was a big one based on frequently asked questions from puzzled customers?

Harrison: Many of our website visitors are trying to find a solution to a problem. The pinch point often comes when they have had a major issue within their manufacturing process. They recognize they have a major issue, but are not at the point in their journey where they understand how they can resolve it. The aim of the Cimteq Academy is to support skills growth in digital transformation across the sector, not only to improve today’s factory environment but to build resilience in the factory of tomorrow. It includes whitepapers, discussions by Cimteq and its partners on industry trends and case studies describing how Cimteq products have been successfully implemented across the globe. It also has FAQs, videos, e-learning and webinars on subjects that matter to the wire and cable industry.

WJI: You say you plan to grow the platform further: what do you expect that will include?

Harrison: The Cimteq Academy launch is just phase one. We plan to update the content on a regular basis by adding new case studies, webinars, videos and White Papers, as well as eventually developing an accredited e-learning course. We worked on this initiative with the team at Zebra Marketing and Communications, which worked closely with our staff and did a great job in helpHarrison ing us develop the content of the Academy.

WJI: Your site has just been launched…have you much in the way of traffic?

Harrison: It’s still early days for the Cimteq Academy, but we’ve seen a 23% increase in visits compared to the same period last year. We have had some fantastic responses from visitors to the site and some excellent feedback in terms of what the Academy offers. We welcome further feedback from readers who visit the Academy, as this will help us build a greater understanding of the needs of the cable and wire manufacturing industry and shape the development of future resources. It also helps us start to build relationships with our visitors, to work with them to help them solve their issues.

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FEATURE

Industry 4.0? It’s academic for a U.K. company’s new online industry resource