FASTENER ENGINEERING_DESIGN WORLD_SEPTEMBER 2021 by WTWH Media LLC

Engineering September 2021

A supplement of Design World

How data and automation can improve production processes

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EDITORIAL •• •• •

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Why resiliency matters Operational resilience is a form of risk mitigation and management. How well does your company anticipate, adapt to, and rebound from unexpected stressors or disruptions? Chances are you found out rather quickly in 2020 as the pandemic impacted everyday life and business. Uncertainty has always been a challenge. Manufacturers and suppliers have long faced fluctuating demands, supply-chain nuisances, escalating costs, and unplanned downtime. However, operational resiliency was likely untested to the degree it has been since the “new normal” kicked in. One outcome has been an increased reliance on technology. If nothing else, the pandemic accelerated the demand for automation and autonomous operations to mitigate workflow disruptions. In fact, statistics indicate that COVID-19 sped the adoption of digital technologies by several years. A McKinsey Global Survey found that companies accelerated the digitization of their internal operations, as well as their customer and supply-chain interactions, by three to four years. Priorities are also shifting. According to a recent IBM report, businesses are now focused on ensuring business security, cost management, and enterprise agility — in other words, operational resilience. For the fastener industry, this might look like integrated software (such as an ERP system, which better connects and manages supply chains) and automated equipment or processes for manufacturing and distribution. For example, automated precision equipment, including fastener feeding and driving machines, can ensure traceability, error-proofing, and quality control. Robotic adhesivedispensing systems also promise excellent repeatability for increased efficiency. Although technological advances support operational resilience, mindfulness is also important. The fear of job losses has accompanied technological advances since the Industrial Revolution. Labor-saving digitalization and automation are ideal until they result in major job cuts — or the fear of job cuts — for employees. Fortunately, these fears are often unfounded. Certainly, automation might replace some roles, but it can also lead to increases in others — including for the techs and engineers that maintain these systems. Automation can also lead to expanded production and greater productivity typically requires a larger workforce. As 3M shares in their article on automation (see page 108) states: “It’s important to note that integrating automation and data in manufacturing does not eliminate the production workforce from the process… Labor will simply look different.” In this issue, we also share a few profiles about the employees and entrepreneurs hard at work in the fastener industry. If you’re interested in sharing your story, write us at fasteners@wtwhmedia.com. We’d love to hear from you! FE

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How

data and automation

can improve production processes Victor Vance • Senior Application Engineer & Brianna McCord • Product Engineer Industrial Adhesives and Tapes 3M Although demands for production goods have trended positively over the last decade, surges in

material costs, wages, and manufacturing overhead are challenges companies must continue to face to meet these demands. The current state of production performance is primarily built on employee historical knowledge, particularly in terms of troubleshooting and problem-solving. However, this is far from an ideal approach for gaining and maintaining control over the production process. In fact, a consistent trend indicates that a firm control of production is one of the best ways to meet demands. This cannot be achieved through a reduction in labor. Historical employee knowledge and, in turn, production process control, would typically be lost — which could lead to an increase in performance variability, possible downtime, and troubleshooting time.

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Engineers programming automated, liquidadhesive dispensing equipment.

Data and automation in manufacturing As manufacturing continues to evolve toward a more advanced and connected ecosystem, a new environment is emerging. It is one in which data and automation are increasingly playing a central role. Integrating automation in the production process is a strategic and reliable alternative to reliance on labor alone. It can, to a certain extent, guarantee production process control. The use of data, including material and production data, will impact many parts of the production

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process. Material data, found in technical data sheets and similar documents, provides insight into many key automation requirements and parameters. Collecting and analyzing production data can lead to predictive manufacturing, reducing downtime and troubleshooting time. More than merely robotics, automation drives efficiencies by streamlining and optimizing processes, reducing waste and processing time, and improving quality. This frees up capital for

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An example of flexible automation at work using modular robotics.

business investment and expansion while reducing a sole dependency on labor. With automation, producers can re-deploy labor and resources to drive impact elsewhere. This requires precision control, the interface of people, data, machines, and real-time communication functionality, which must be integrated into eversmaller footprints. It must also be nimble enough to adapt to ever-changing demands. At the same time, the safety and durability of these systems are required, as harsh environments and challenging world circumstances become the norm. Automating tapes and adhesives One component of process automation in the adhesive industry is the dispensing of tapes and liquid adhesives. Such automation serves to increase quality, consistency, and repeatability, which are important for controlling processes and improving production. Relying on labor for such tasks, and especially unskilled labor, introduces variability in the process. Attracting skilled labor remains a challenge for many organizations.

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Implementing improvement tools to create different application techniques and more control into the production process is recommended to foster operational growth. Automating the application of tapes and liquid adhesives is a trend that has accelerated for manufacturing companies to remain competitive and relevant. Integrating process-assisted tooling, fixed automation, and flexible automation into the production process increases control and transfers the responsibility of dispensing from staff to the acquired machinery. Additionally, relying on data to validate and streamline decision-making supports efficiency and growth across all operations. While some markets continue to rely on labor to perform the application and dispensing of tapes and liquid adhesives through manual tools, other markets have turned to automation to offer greater efficiency and improve production performance across operations. Automation offers a spectrum of solutions, from fully automated processes across production operations to niche solutions and applications, such as www.fastenerengineering.com

a simple dispensing or bonding solution. Customers and end-users are increasingly recognizing the benefits of investing in automation to improve their production processes. Automating the dispense of tapes and liquid adhesives encompasses a broad range of equipment and technologies ranging from simple manual tools to customizable multiaxis robots. Whether integrating automation into processes to increase productivity, quality, safety, or reduce costs, customers and end-users are increasingly moving away from the use of handheld manual tools to automated equipment and data. Ultimately, the automated dispense equipment selected is based on many factors. It might relate to the level of human interaction necessary, material chemistry, cost, the volume of dispense/ output rate, the precision required, and the type of dispense. For instance, the equipment used to dispense hot-melt and polyurethane hot-melt adhesives is different than those used to dispense structural adhesives. As for the dispensing equipment, several options exist and depend on DESIGN WORLD

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The levels of automation Automation

Manual tools

Description

Factors to consider

Manual operation with simple hand tools and methods to improve the manual application process without automation.

Equipment examples

• Assembly volume: Low volume • Labor costs: Low, inexpensive, easy to hire • Quality requirements: Quality achieved manually • Budget: $

Tape: Hand tape applicator (HTA), Dauber bottle, J-roller, file cards

• Assembly volume: Low volume • Labor costs: Low, inexpensive, easy to hire • Quality requirements: Quality achieved manually • Budget: $$

Tape: Straight-line laminator, cut-to-length dispenser

Liquid adhesive: Spray adhesive applicator, handheld battery-operated applicator, handheld pneumatic applicator

Process assists

Primarily manual operation with some advanced, semiautomated tools. These mechanical or electrical tools increase the productivity or precision of the manual application process.

Tape: X-Y table, level wound unwinders

Fixed automation

• Assembly volume: High Mostly automated operation volume, identical parts with reduced operator • Labor costs: High, interaction. A semi-custom expensive, difficult to hire process is designed to perform employees with technical one specific assembly step to knowledge improve accuracy or speed and • Quality requirements: reduce labor. Extreme precision and accuracy required • Budget: $$$

Tape: Cobots, robots, level wound unwinders

Flexible automation

• Assembly volume: An automated operation High volume with minimal to no operator • Labor costs: High, interaction, designed to perform expensive, difficult to hire more than one assembly employees with technical process or be re-purposed knowledge later. It usually incorporates • Quality requirements: multi-axis systems. Extreme precision and accuracy required • Budget: $$$$

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Liquid adhesive: Benchtop dispenser, digital shot control systems, volume metering systems, foot-pedal controls

Liquid adhesive: Roll coater, spray booth, XYZ gantry systems

Liquid adhesive: Cobots, robots, multi-axis systems

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Fastener Fair USA is the only exhibition in the U.S. dedicated to the full supply chain–distributors, mechanical and design engineers, purchasers, wholesalers, and end-users/OEMs – spanning key vertical industries. The next edition of Fastener Fair USA will be held in Cleveland, Ohio, putting the show in of one of the biggest manufacturing hubs in North America. Combining a comprehensive display of industry innovation with highly relevant education and unmatched opportunities to connect with peers and industry experts will create a trade show experience unlike any other.

NOVEMBER 8, 2021 NOVEMBER 9-10, 2021

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J o i n i n g and shape of some fillers, pigments, and dyes, these can have an abrasive effect on some of the equipment pieces the adhesive may flow through. Material data is essential to successful automation.

A process assist with a push-through laminator for tape application.

While some markets continue to rely on labor to perform the application and dispensing of tapes and liquid adhesives through manual tools, others have turned to automation to offer greater efficiency and improve production performance across operations.

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the type of adhesive and the level of automation desired. Parts can also be modified or replaced as required. A full understanding of the type of adhesive for dispensing is necessary before choosing the equipment. Material data, including information in technical and safety data sheets, provide insight into a significant number of automation requirements and parameters, particularly when it comes to liquid adhesives. Access to material data such as viscosity, density, the ratio by weight or volume, and a shear rate of the material provide vital insight for the equipment setup and appropriate dispense settings to create the desired application outcome. Knowing other material data, such as the adhesive ingredients, is important to help prevent and schedule maintenance. Depending on the size www.fastenerengineering.com

From one level to another Moving from one level of automation to another is not an easy task. It involves identifying the long-term goals and objectives of the manufacturer and the budget to purchase products, equipment, and training staff. It also involves connecting with the right material and dispense equipment suppliers, integrators, and converters. Identifying the ideal partners to work with based on the needs and objectives of the producer is a crucial element in successfully moving from one level of automation to another. Adopting a new level of automation can disrupt the current production process, so it’s important to source the audit results and insights from production operators. Collecting undocumented insights helps to identify inefficiency gaps and with choosing effective automation equipment for process improvement and optimization. When implemented correctly, automation can bring many benefits to a facility: an increase in reliability, performance, quality, and lower operating cost. Setting goals and milestones, knowing the challenges, and strategic planning are the elements that define a successful automation implementation process. It’s important to note that integrating automation and data in manufacturing does not eliminate the production workforce from the process. The human element in production allows for the addition of equipment to the process, and the programming and operating of automated dispense equipment. Labor will simply look different. Employees will no longer be dispensing and performing manual labor themselves but, rather, will be responsible for programming and operating automated dispense equipment. FE September 2021

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Six factors

to consider before choosing your next torque wrench Mark Edmunds • Product Manager • Snap-on Industrial Applying torque to a fastener might seem like an automatic or intuitive process. But choosing the correct value depends on several factors and doing so properly starts with selecting the ideal torque wrench for the job. Torque wrenches come in all shapes and sizes and are designed for specific applications. There are six key factors to consider when choosing a torque tool, including: 1. The torque requirement 2. Data, traceability, and error-proofing 3. Speed versus accuracy 4. Available power sources 5. Budget 6. Training Additionally, torque certification is available, which provides education on proper torque and tool use. Evaluating an application based on these six factors will make choosing the right tool for an assembly easier and safer.

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Did you know that some companies have begun restricting technicians from pulling more than 600-foot pounds of manual torque due to ergonomic issues? It’s important to practice safe tooling practices.

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Torque certification is taught at technical schools and community colleges across the country. American tool manufacturer, Snap-on, has developed a torque certification course that dives into three areas: theory, application of torque, corresponding safety steps, and proper hydraulic torque.

1 Torque requirements The first step in choosing the ideal tool for a project is to identify the torque range for your specific application. If most of the work involves applying up to 600 pounds of torque, a conventional manual wrench typically works. However, if the application involves heavy-duty bolting — say, with torque requirements reaching 2,000 pounds of torque or more — it’s preferable to select a tool that offers advanced technologies. Although many hand-torque wrench suppliers offer tools that can handle up to about 2,000 foot-pounds, first consider the potential safety hazards before purchase or use. Several companies have begun restricting technicians from pulling more than 600-foot pounds because of ergonomic issues. Tools, such as manual torque multipliers, offer a safer way for technicians to pull higher torque amounts by hand. Torque multipliers offer a mechanical advantage in applying torque to turn fasteners and, typically, use epicyclic or planetary

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gearing. So, for example, each of the stages of gearing multiplies the torque applied to a bolt. Torque multipliers are often used when larger, powered torque-controlled tools are unavailable. They’re also ideal for use in tight spaces where a longer-handled torque wrench is impractical. 2 Data, traceability, and errorproofing Capturing data is becoming essential at many worksites as a record of the performed tasks. This is particularly true in manufacturing and assembly applications, where companies want to ensure a job was completed to the exact specifications of the work order. Even in MRO and industrial torque applications, most companies require electronic documentation to reduce errors, improve accuracy, and ensure installation. Such data can also support maintenance teams and lead to greater jobsite efficiencies. For these reasons, data collection, traceability, and error-proofing capabilities are essential considerations when choosing a tool. Fortunately, www.fastenerengineering.com

electronic torque tools offer this level of functionality by providing instant data on the exact torque applied. This is something that most mechanical wrenches cannot do. To ensure installation is performed to spec, a manufacturing engineer can pre-set parameters or pre-program torque sequences to be followed in a precise order. These types of innovations significantly reduce errors, which benefits the onsite tech and a company’s bottom line. Several of today’s smart torque tools also provide advanced, digital features that help set an accurate torque target, record measurements for traceability or audit, and track specific torque history. Generally, this is done through mobile applications that can instantly store or share the data. 3 Speed versus accuracy When applying controlled amounts of torque, there’s always a tradeoff between speed and accuracy. For example, the slower you pull on a handtorque wrench, the more accurate you can be. Typically, the same holds for DESIGN WORLD

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The Snap-on ControlTech Micro Torque Wrench is an electronic torque wrench in a compact form factor for use in limitedaccess applications.

torque-controlled power tools — the faster that torque is applied, the less precision is achieved. For less critical torque applications in manufacturing and assembly, and where there’s already a large safety factor built into the overall project, a torque accuracy of +/- 15% may be acceptable. For such cases, work can be sped up using the clutch or lowtorque power impulse tools. Otherwise, electronic torque wrenches and transducerized power tools offer the highest degree of repeatability and accuracy for critical torque applications. These tools often offer visual alerts, which indicate when the user is nearing the desired torque setting, to prevent torque overshoot. Although these tools are not as fast as some torque technologies, they offer a safer balance of speed and accuracy. 4 Available power sources The available power source is also an important consideration, particularly for industries in remote locations. For example, a wind farm in a rural area may not have the proper power supply for many types of torque-controlled power tools. One important question to ask: is your available power supply electric, pneumatic, or from human muscle alone? For instance, suppose you have a pneumatic torque multiplier without access to the required airflow and pressure. The tool is essentially useless in this scenario. It’s also impractical to haul a heavy hydraulic pump up a wind tower for hydraulic wrenches. So, for those remote locations, a torque multiplier might be the ideal

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option for use with higher-torque applications. Battery-powered torque multipliers are also an excellent consideration. Identifying the worksite location and its power sources is critical for avoiding operational issues and choosing the ideal tools for the job. 5 Budget Different types of torque tools vary widely in function and application, so it’s no surprise that the cost for these tools does, too. The electronic models that offer data collection and wireless functionality (for workflow management) tend to be more costly than the lowertech mechanical options. Choosing the ideal torque tool means evaluating the project budget in relation to the steps required for a successful assembly. This should include safety and ergonomic considerations, as well as the documentation and traceability requirements. Fortunately, there are now more torque technologies available than ever before, and it’s possible to pick and choose from the many options to get what you need.

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6 Training Properly understanding the principles of torque is more involved than simply cranking down on a fastener until you hear a click or following a digital readout. Training classes and torque certification programs have become an invaluable resource for technicians to understand the proper use of torque wrenches and ensure a safe, effective, and reliable assembly. An ideal program should cover fastener options, including how to identify bolt and metal grades, how to select the right fastener for an application, and what tools will ensure a safe and secure assembly. It should also cover the application of torque, including how to use torque tools and how to make proper calibration equations and wrench adjustments. Additionally, any quality program will cover the assembly, tools, jobsite, and worker safety considerations. Torque tools are often a major investment, affecting the quality of an application and the ergonomics of a technician or contractor at work. It’s best to think strategically and do your due diligence to ensure the ideal tool choice for each project. FE

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Fastener Fair:

Connecting the global fastener community The inaugural Fastener Fair USA event took place in 2018, but

the exhibition launched more than a couple of decades ago and has found success in several countries since then. The first show started in England in 1995. It was organized by a UK socket-screw wholesaler interested in expanding his business and connecting with others in the industry. At the time, there was nothing like it. Then in 2005, the show opened in Stuttgart, Germany — where it remains the world’s largest fastener event. In 2008, Fastener Fair Budapest was launched on a trial run. In 2010, international B2B trade exhibition organizer, Mack-Brooks Group (a part of Reed Exhibitions – RX Global) acquired Fastener Fair. It’s continued the expansion trend.

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| AdobeStock

Fastener Fair • Cleveland, OH • November 8-10, 2021

“We call it geo-cloning, where we take an event that works in one city or country and include it in another,” shares Bob Chiricosta, event director with RX Global. “Currently, there are eight Fastener Fairs around the world.” Aside from in the USA, this includes Germany, France, Italy, India (in Mumbai and New Delhi), Turkey, and Mexico. Chiricosta is a chemical engineer turned marketing expert, turned event DESIGN WORLD

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director. He’s been with Mack-Brooks and then RX Global for 11 years but began work specific to the Fastener Fair when it launched in Mexico. “Then, we wanted to bring what we offered in Mexico, which was a great success, to America,” he says. “And we knew that we wanted it to be located in the eastern part of the U.S., partially because there was already another annual West Coast event in Las Vegas. www.fastenerengineering.com

Mark your calendars! After missing a year due to the pandemic, Fastener Fair USA is returning to Cleveland, November 8th to 10th. Be sure to register early at fastenerfairusa.com.

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Fastening 101 will return to the Fastener Fair this year. Presented by the nonprofit Fastener Training Institute (FTI), the intensive program provides a thorough understanding of the fastener industry including products, applications, industries, and more. According to FTI, it’s fit for anyone in the industry interested in broadening their fastener knowledge — and attendees will discover much more than the basics.

Connecting digitally Fastener Fair CONNECT is a new digital business platform, scheduled for November 17th and 18th, 2021. Fastener Fair Stuttgart, Italy, Mexico, India, and the USA and Fastener are joining forces, unifying the Fastener Fair communities around the world, and providing a unique, global networking event for the industry. “We’ve wanted to make better use of the fact that we have a global fastener community that can connect, share, learn, and grow together,” says Bob Chiricosta, event director with RX Global, organizer of the Fastener Fairs. “The fastener industry is worldwide and it’s enormous. We believe we have an opportunity and a responsibility to bring it together.” The digital event will offer conference sessions, virtual product showcases, and interactive networking opportunities. “Fastener Fair CONNECT will provide exhibitors with a digital platform for attendees to present products, equipment, and technologies to a targeted global audience,” he says. “It will be a unique, notto-be-missed experience, with more details to be released soon.”

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But mostly because it’s that where a tremendous amount of fastener companies are based…in the Midwest and Southeast.” The 2018 show was launched in Cleveland, followed by Detroit in 2019. “We received a wonderful response to the event, which grew considerably after just one year,” says Chiricosta. “Interestingly, the two cities between Cleveland and Detroit also attracted different audiences. You primarily get the executives attending in Cleveland and the automotive engineers in Detroit, which is great. And then 2020 happened and, unfortunately, we had to cancel the show last year.” The Fastener Fair is ready to return to Cleveland later this year, at the Huntington Convention Center. The conference is set for November 8th and the expo hall on November 9th and 10th. “Ohio is one of the states where fasteners are a big deal, so it makes sense to return to Cleveland, where there’s a bit of a hub of fastener-related business,” he says. “And we’re so looking forward to connecting and reconnecting with everyone in the industry — and so is everyone else, I’m sure. Fasteners is such a tight-knit industry and people are ready to get out again.” Granted, the pandemic means there will be greater security measures in place and fewer international exhibitors and attendees. “It’s an evolving process and we’re keeping up with all of the latest developments to ensure a safe event. We’re also keeping everything at the convention center this year to avoid transporting people on busses to different locations. For example, the last time in Cleveland, we hosted the event party at the Rock & Roll Hall of Fame,” he says.

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The Fastener Fair is currently tallying a survey that asks its U.S. attendees what new city they would like to see the event take place in the future. Expect the show to return to Detroit in 2022 and after that, it may be up to you.

In Detroit, it was at GM’s impressive global headquarters. This is one of the features Chiricosta attributes to the success of the Fastener Fair. “Let’s just say, we know how to throw a party,” he laughs. “Fastener Fair is much more about networking than other shows, which suits the industry. The fastener community in the U.S. is very much alive and thriving, and they enjoy getting together, connecting, and sharing news and accomplishments. I think this is particularly true and important this year.” Another feature that sets the Fastener Fair apart is that it’s not scarce in relation to its list of invitees. Rather, the show is open to the entire fastener manufacturing and supply chain. “Often end-users are not welcome at such events, but we encourage the full value chain to attend. It opens up dialogues and the useful exchange of information,” he explains. “Truth be told, manufacturers do want to speak with the Ford engineer who’s looking to spec some bolt for a vehicle set to launch three years from now or to

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the aerospace engineer looking for updated rivets for a plane.” Chiricosta says manufacturers are typically respectful and well-aware of their distributor relationships. To reaffirm and strengthen the manufacturersupplier bond, the Fair organizers also suggest that manufacturers place a sign in their booth that lists the distributors at the show that offer their products. “Fastener Fair is also unique because of its worldwide exposure,” adds Chiricosta. “The shows are held in multiple countries because fasteners are made all over the globe. We truly represent that.” Typically, this means the fastener community in America can learn firsthand about fastener innovations in Germany or India or Taiwan, for instance. “Can you believe that about onethird of the exhibitors at each one of Fastener Fair events around the world come from Asia? Granted, that won’t happen this year in the U.S., given the pandemic, but I find it incredible that we’ve been able to continually connect www.fastenerengineering.com

an industry on such a global level.” It’s also a good way to share ideas, learn, and potentially collaborate on certain projects. Chiricosta says many of such manufacturers specialize in one type of fastener and they’re looking for specific innovations or international distributors. “I think the Fastener Fair offers an excellent opportunity to bring the fastener world together, no matter which event of ours you attend,” he says. “I’m extremely proud of the events that we offer to support the fastener industry and am excited to kick things off in Cleveland this November. I hope to see you there.” FE

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From home experiments to U.S. manufacturing

How Craftech found success Michelle Froese • Editor

It’s perhaps of little surprise that Barbara Gerard became CEO of Craftech Industries, Inc.,

a U.S. high-tech manufacturer of standard and custom parts and fasteners. Her father started the company in 1967, and fasteners were a big part of her childhood. “I remember I was in fourth grade when one of my classmates told me that my dad bought two robots,” she shares. “I didn’t believe it at first. I ran home after school and, sure enough, there were two big machines in the basement of our barn.” Gerard grew up on a farm near Castleton, New York. These “robots” were machines for manufacturing parts. “I would love to go to the barn and read all of the manufacturing books my dad had and even play around with the machinery,” she says. “He originally managed a small fastener company in Castleton and became very intrigued with the different materials used for these parts, so he started experimenting.” Gerard says she would help him sort parts on the kitchen table — and would find evidence of her dad’s experiments in interesting places. “For example, I’d go into the freezer for bread or something and there would be frozen bars of nylon or another material that my dad would test to see how well it would resist the cold,” she says. “At one point, a neighbor also started an injection-molding company in Chatham, and my father thought it was the future of fasteners.” Additionally, a nearby General Electric manufacturing in Pittsfield, Massachusetts was developing plastics. “All of this led to my dad opening Craftech. He didn’t have a lot of money, but he knew the business,” she says.

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With DIRAK-SNAP-Technology, it’s possible to create high-strength connections without the use of tools. Watch an assembly video at https:// tinyurl.com/DIRAKsnap.

An example of the PEEK customized plastic parts from Craftech, Inc. In many ways, Gerard’s dad was ahead of his time. Stainless steel was a commonly used material for fasteners but, over time or in harsh conditions, it’s subject to corrosion and rust. However, materials such as nylon or plastic (used by Craftech to this day) offer several benefits, including anti-corrosion qualities and longevity in critical applications. “At the time, nylon was big because it doesn’t conduct electricity if used in electronics,” says Gerard. Eventually, her dad moved his business from Chatham to Stockport, New York. “By then, he began making parts in Delrin and PVC, DESIGN WORLD

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and then Teflon came along.” Despite helping her father out when she was younger, Gerard never planned a career at Craftech. In her early 20s, she went to Manhattan and worked in publishing for a while with Bantam Books. “Books, publishing, writing…that was my dream. But I soon realized how tough it was to earn a living in that industry,” she says. Gerard also got married and eventually ran a small business with her husband, providing high-gloss lacquer for furniture designer, Karl Springer. “Honestly, this was one of the best www.fastenerengineering.com

decisions I made if only to learn about the hard knocks of business life. There’s a fine line between knowing when to keep going and when to quit. I learned valuable lessons.” Sadly, Gerard’s father passed in 1985. Her brother ran the business for a while but then Gerard and her husband, Skip Gerard (currently, the president of Craftech), took it over. “For a while, I wanted a life of my own, and what my dad did seemed mundane. But then, his business began to become more interesting to me as technologies developed and the semiconductor industry grew,” she says. “It’s fascinating, really. Without certain kinds of materials, such as PEEK plastics, September 2021

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Fastening + Joining

Assured Splice Quality for Assured System Performance When engineered systems rely on the performance of every input and output, every wire and splice counts. That is why, from automatic self-calibration to real-time indication of splice quality, the Branson™ GMX-W1 Ultrasonic Wire Splicer assures repeatability in your assembly operations. Touchscreen programming, multiple welding modes, and anti-side-splicing design support error-free production, while real-time monitoring, data collection, and statistical analysis prove splice quality and assure traceability. Learn more at: Emerson.com/Branson

we couldn’t do much with semiconductors. The photoresist process would destroy any metal parts. Titanium is one of the strongest metals on earth, and the acids would eat right into it.” PEEK (or polyetheretherketone) is a type of plastic that offers high-performance engineering and versatility. The material has an extremely stable chemical structure that’s rare to find in other plastics, making it ideal for use in fasteners in several applications and industries. “Right now, PEEK is the flavor of the year, but there are always advances and this will likely morph into another material soon. It’s so interesting to watch the new developments.” Although Gerard gained interest in the family business, taking over Craftech proved challenging at first. “The company was in debt at the time, so we spent a few years shoring it up, buying new equipment, and putting in ISO 9,000 and 9,001,” she says. These are the International Organization for Standardization or ISO’s quality management standards. “It was important to us to guarantee our customers as much efficiency and accuracy as possible.” This value system has worked well for the business. Craftech went from 10 employees when the Gerard’s took over the company to more than 60 today. Its diverse manufacturing capabilities include injection molding, mold building, screw machining, and CNC machining — which are now all performed in-house at the company’s Hudson-based plant. “If I could make one suggestion, it would be that more engineers approach us directly when looking for parts or to solve problems. Often there’s a middleman and sometimes the communication link gets broken down,” says Gerard. “We have so much experience to share that working one-on-one with engineers is welcomed and sometimes necessary for critical projects.” Craftech serves a variety of industries including aerospace, automotive, chemical, medical, electronics, semiconductor, marine, telecommunications, and others. It can provide standard and custom parts that are traceable and manufactured from low to highvolume runs. “We’ve been quite successful, and I give my husband a lot of credit for that. He’s a very creative engineer. I have an MBA in finance and I run the finance part of our business,” says Gerard. “But I also contribute to our online blog, so I still get to write. And I don’t think this industry shares enough information so it’s important for me to provide that insight.” FE

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Several grades of PEEK fasteners are available commercially, depending on the application.

HEX SOCKET SET SCREWS SOCKET, FLAT & BUTTON HEAD CAP SCREWS SQUARE HEAD SET SCREWS SHOULDER BOLTS HEX & TORX KEYS ZINC PLATED SOCKETS SPECIALS, STANDARDS & SECONDARIES

300 North Klick St., Hampshire, IL 60140 630.800.6377 / Sales@SetkoFasteners.com

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Designing peace of mind Michelle Froese • Editor

Ask 80-year-old Dieter Ramsauer about his childhood and he’s likely to tell you about the bicycle he assembled when he was six years old from scrap parts he found around his neighborhood. In fact, he loved building things out of nothing — and still does. After the second world war, there were many piles of discarded objects in his hometown of Velbert, Germany, which he loved to assemble, disassemble, and re-assemble into something new. It’s perhaps no surprise that years later he founded Dieter Ramsauer Konstruktionselemente GmbH in 1991. Konstruktionselemente roughly translates to “construction elements.” The Germanbased company, now simply known as DIRAK, supplies innovative fitting components for industrial enclosures. What began in a small office building with just a few employees has grown into a global supplier to dozens of distributors, with multiple locations worldwide (including in the U.S., China, Singapore, India, the Middle East, and others). “Dieter is a fascinating person,” shares Gregory Breads, CEO of DIRAK. “He’s a toolmaker by trade and initially went through an apprenticeship, which is quite common in Germany, where he still lives today. There, he learned all about design and manufacturing but it’s really an innate talent for him. He’s a tinkerer of sorts who enjoys experimenting with different ideas and creating new things.”

Dieter Ramsauer, the founder of DIRAK.

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With DIRAK-SNAP-Technology, it’s possible to create high-strength connections without the use of tools. Watch an assembly video at tinyurl.com/DIRAKsnap.

Case-in-point: He built half-adozen harpsichords — just for fun. “Apparently, these are concert-level instruments, too,” says Breads. “Dieter is the quintessential engineer-type of designer, who puts his ideas into action.” He also designed a line of golf clubs just because he saw room for improvements. Early in his career, Dieter worked as a sales engineer, which helped him gain perspective on the sheet metal industry and better understand what customers wanted. This resulted in a modular quarter-turn and a rod latch system, which he designed and patented in the late ’60s. A quarter-turn serves as a simple and cost-effective way to keep lids, cabinets, or small doors closed. A rod latch is a connection system used DESIGN WORLD

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for multi-point latching requirements on larger doors. Later, Dieter would improve on the rod latch so that it could be mounted outside of a seal in the bending area of a switch cabinet to allow for greater open cabinet space. “Essentially, Dieter would spend his days in sales and evenings working on new projects. This not only led to new designs but also to new standards for industrial hardware that he would patent and license to the company,” says Breads. Many of these patents have since become industry standards. After gaining valuable experience, Dieter eventually ventured out on his own and started DIRAK. “Our classic quarter-turn is the ideal www.fastenerengineering.com

example of what’s now an industry standard. It’s a simple concept of a housing, insert, and locking cam. However, Dieter took the basic idea of a lock and standardized the three parts, so that they could easily be swapped out with other versions. This allows a single cutout in the sheet metal to accept a variety of housing styles which, in turn, accepts a variety of inserts and locking cams,” explains Breads. This means nearly any kind of locking actuation will work with the quarter-turn, whether that’s a screwdriver or a specialized tool. “Today, we also have hundreds of patents, thanks to Dieter,” he adds. “Our current claim to fame is something we call DIRAK-SNAP-Technology or DST. In the sheet metal hardware world, September 2021

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Fastening + Joining

Karl-Heinz Overhamm, Global Managing Director (left) and Gregory Breads, CEO of DIRAK, Inc. (right).

generally, attachments are made by either using threaded inserts such as nuts and bolts or by welding. There are pros and cons to each technique, depending on the application. But Dieter had the idea of creating an attachment process that requires no tools.” This is how DST was developed. Products with DST slide directly through a panel cutout and snap into position, ensuring a strong and secure connection — without the help of tools. According to Breads, the swinghandle was the first example of a product that could be installed without a single piece of additional hardware. And yes, Dieter can also be credited for its design. A swinghandle lies flush against a panel or enclosure when latched and then pulls out to an open position. “Now, we’ve taken the DST concept and applied it across our entire product range. And this innovation is what truly sets us apart in the industry. Sure, we can supply the industry-standard hardware for enclosures but we’re continually upgrading and inventing new ideas and raising the standards, too.” DIRAK currently offers a catalog of more than 5,000 different standard products but its strength is in its design capabilities. Among the many

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industries the company serves, it supplies to several essential sectors including telecommunications, power infrastructure, water utilities, and the medical sector. “We offer a hygiene line of products, for example, that includes extremely high-grade, heavily polished stainless steel, combined with silicone seals that are specifically designed for highly sterile environments,” says Breads. These products can be used in medical equipment, at research facilities, and in the food and drug market. They’ve been in high demand throughout the COVID-19 pandemic. “We also carry captive fasteners, which I think are quite brilliant,” he says. Captive fasteners provide a permanent hold within a housing or assembly, preventing loss or damage to its fastening components because of a loose or broken part. “Basically, traditional captive screws are secured to one panel and can then be screwed to a second one,” explains Breads. “So, this means that even if unscrewed from that second panel, the captive screws cannot be removed from the first panel.” This is important in any enclosure that has a motor or moving parts inside, where it’s critical that the parts do not fall out or, for safety reasons, that someone cannot reach into the www.fastenerengineering.com

equipment and injure their hand. “Due to their design, captive screws require specialized equipment to secure them to the first panel. However, our captive fasteners use DST and do not require any tools at all,” he says. Captive fasteners are often used in medical devices or machine enclosures. “Peace of mind is so important to us at DIRAK,” he adds. “In fact, it’s so important that it’s become a part of our mission statement as we go through a bit of rebranding in the U.S.” Breads says DIRAK has a set of global values but, as CEO, he wanted to redefine the North American branch to include its own value system. “We wanted to build the culture of the company from the inside, and not just from the outside,” he says. Last year, Breads sent out a survey to his team and received a similar response from nearly every department. “About 80% of the respondents said providing peace of mind is something we do best at DIRAK,” he says. “So, for instance, our Sales Team said we take the burden of hardware design off of our customers to provide peace of mind. While Customer Service mentioned that we’re continually working to not only meet but improve delivery deadlines to provide peace of mind. Others noted that we offer free health insurance premiums to our employees, providing DESIGN WORLD

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peace of mind to them as well.” He adds: “These ‘peace of mind’ comments stood out to me, so that’s become our new purpose statement and I’m quite proud of it.” The company put together a video on its new mission statement (which you can view at tinyurl.com/DIRAKmission). What’s clear is just how strong and supportive of a team Dieter has built at DIRAK. “Through German engineering and quality to customer service, we take a personal approach with our customers. It’s so important to show we care,” says Breads. “Even Dieter continues to work at our headquarters office nearly every day…or, if he’s not there, chances are he’s busy visiting a customer. He’s quite an inspiration.” FE A captive fastener.

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By Michelle Froese • Editor

Setting goals

and ﬁnding balance with Fasteners Direct Caia Baker is a list-maker. Like many of us, she has a to-do list but perhaps more importantly, she has a list of goals that she routinely sets — and accomplishes. In under two weeks, she’s crossed off six of her 14 goals for this month alone. “I have a whiteboard in my office where I write out the goals that I need to get done. And this list is completely separate from my to-do list,” she shares. “It’s important to me that I’m continually learning and evolving. I never want to become fully comfortable in the space I’m in because…well, there’s always room for growth.” Baker’s office is in Fasteners Direct’s Webster, New York facility, a wholesale fastener supplier to the manufacturing, industrial, automotive, and construction sectors. She’s currently the company’s VP of Procurement, a role she helped develop — based on one of her goals to keep evolving. Caia Baker, VP of Procurement with Fasteners Direct.

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In 2018, Fasteners Direct expanded its warehouse, which now provides more than 50,000 square feet of space.

“I began with Fasteners Direct in June of 2013 as a purchasing agent, which was a big shift for me,” she says. “Before that, I was a project manager for a Fortune 500 company where there was close to zero work-life balance, and I became unhappy. I come from a big, close-knit family that I rarely got to see, so shortly after my dad passed away, I knew it was time for a change.” Baker was at an airport, awaiting a delayed flight when she decided to polish off her resume, and officially begin the job hunt for something new. Fasteners were the furthest thing from her mind but, not long afterward, she noticed a LinkedIn post for a position with Fasteners Direct. “It was three o’clock in the morning when I noticed the post, and I just thought…why not?”

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Two days after sending her application, Baker was called in for an interview. “I have to say, one of the best parts about working here is that it’s literally like a family environment.” Fasteners Direct is a family-owned business that was founded in the early ’90s by Herb Parr, the father of seven sons, who was concerned with providing future jobs for his family. Today, four of his sons own the company and continue to grow it. In 2018, they expanded the warehouse to provide more than 50,000 square feet of space for their stock. “It’s been such a supportive place to work and challenge myself,” she says. “When I expressed interest in other

www.fastenerengineering.com

areas of the business, after a year or so of being here, Gary Parr [the current CEO of Fasteners Direct] offered to have a couple of brainstorming sessions with me to redefine my role. He wanted to bring in the knowledge I had from my project management days, implement, and build on it.” Baker says it was empowering to be listened to, acknowledged, and given the opportunity to grow her position. “At first, there was a learning curve as I was new to the fastener industry. And too often there’s a stigma with being a woman, especially in a maledominated sector,” she says. “But I never felt that here. I always feel heard and like an important part of this company.” This has allowed Baker the freedom

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Fastening + Joining “It’s important to me that I’m continually learning and evolving. I never want to become fully comfortable in the space I’m in because… well, there’s always room for growth.” — Caia Baker

to explore different options and set new goals for herself — and the company. For example, to better organize and streamline the workflow, she was able to research and implement a digital platform. “It allowed us to move from a more manual system for orders, which we called ‘the yellow list’ because we used yellow sheets of paper to track the orders so you couldn’t miss them, to an electronic system,” she explains. “After a trial period, we purchased a license for Smartsheet for more efficient work management.” Smartsheet is a software program that lets employees collaborate, manage, and report on work (and fastener orders) in real-time. Baker says she had the office trained on it in under two weeks. She adds that Fasteners Direct is continually supporting new ideas for better business practices and customer service. The company is also dedicated to supporting local manufacturers and the community.

“We were deemed essential during the pandemic and were fortunate enough to remain open. We even partnered with a customer of ours to make face shields,” shares Baker. “We had separate stations set up and this meant we were able to provide local jobs to people who had just lost theirs because of COVID-19.” As for one of her personal goals, Baker recently joined Women in the Fastener Industry (WIFI), a non-profit organization that provides opportunities, education, and mentorship for women in fastening. “There are some awesome women working in this industry and it’s just nice to have that sisterhood to fall back on,” she says. “I also like the networking aspect and having contacts who are supportive and will either just listen or help out because they ‘get it’ and also work in the industry.” So, what’s Baker’s favorite part of her job now that she’s at a family company with a work-life balance? “It’s tough to narrow it down to one thing, but I think it’s mainly the connections with my vendors and coworkers. I enjoy building relationships that feel more like friendships. We’ll talk about fasteners or sometimes just family things…like about my daughter, you know.” Fasteners Direct allowed Baker a four-day workweek since having her first child in June of 2020, just so she could spend more time with her family. “It’s been such a shift working here compared to what I was used to and, especially, with my daughter. But I’m so grateful,” she says. “My grandmother always told me…just be yourself, Caia. Avoid being your own representative because that’s false. Just be your kind, open, bubbly, smart self. And I get to do that here, every day.” FE

Fasteners Direct offers custom-produced kits to meet required specifications, as well as a vendor-managed inventory program. This provides customers with access to a hands-free ordering system to manage and maintain inventory.

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FASTENER FASTENER DESIGN WORLD

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Selecting the Optimal Washer Flat: Generally used for load disbursement Tab/Lock: Designed to effectively lock an assembly into place Finishing: Often found on consumer products Wave: For obtaining loads when the load is static or the working range is small Belleville: Delivers the highest load capacity of all the spring washers Fender: Distributes a load evenly across a large surface area Shim Stacks: Ideal for simple AND complex applications

Boker’s Inc. 3104 Snelling Avenue Minneapolis, MN 55406-1937 Phone: 612-729-9365 TOLL-FREE: 800-927-4377 (in the US & Canada)

bokers.com

Structural Adhesives for Specialty Trucks and Trailers Many truck and trailer manufacturers are making the switch to adhesives instead of traditional welding and fastening. Lowering fuel cost, wind drag, and weight has become an important component in manufacturing specialty vehicles. Several trial applications have been performed, and results have shown that the bond of structural adhesives are stronger and more reliable. Ellsworth Adhesives offers a variety of acrylic, epoxy, and urethane structural adhesives. Structural adhesives can be used to configure work truck equipment, trailer assembly, and aftermarket upfitting. Applications can range from panel bonding for trailers, installation of tool boxes in construction trucks, shelf hanging for delivery vehicles, plumbing equipment for firetrucks, to electrical components in utility vehicles.

Ellsworth Adhesives Ellsworth.com (877) 454-9224

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Branson GMX-W1 Ultrasonic Wire Splicer from Emerson Blends Performance, Ergonomics The Branson GMX-W1 Ultrasonic Wire Splicer from Emerson delivers precise and repeatable splicing of non-ferrous wires for in-line or pig-tail configurations. The lightweight, compact design of the GMX-W1 splicer makes it ideal for use as a portable unit for wire harness in-line assembly boards. The user-friendly design of the GMX-W1 splicer features a 22” touchscreen HMI, whose touch-keyboard and drag-and-drop program editor make it simple to create, edit, and recall different production recipes for splices, sequences, and harnesses. The screen also accesses the unit’s multiple welding control modes and offers flexibility for configuring production- and quality- monitoring solutions. The actuator unit of the GMX-W1 splicer is also userfriendly with an illuminated weld area, and a patented vertical stacking feature in the welding head.

Emerson Automation Solutions www.Emerson.com/Branson

SET SCREWS • HEX KEYS • SHOULDER BOLTS • NYLON TIP • SOCKET CAP SCREWS • STAINLESS • METRIC / INCH • ZINC PLATED SOCKETS • SHORT ARM HEX KEYS • 6-LOBE SOCKETS • BUTTON HEAD CAP SCREW • DOWEL PINS • IMPORT / USA • BRASS TIP • STANDARDS / SEMI-STANDARDS • SQUARE HEAD SET SCREWS • HEX JAM SCREWS • LONG ARM HEX KEYS • NYLON PATCH • LOW HEADS 6-LOBE (TORX) KEYS • BUTTON FLANGE CAP SCREWS

Please visit us at www.SetkoFasteners.com

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Setko Fasteners & Distribution 300 N. Klick St. Unit A • Hampshire, IL 60140 Sales@SetkoFasteners.com setkofasteners.com (630) 800-6377

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