2. F-32XL Hot Brass Forging Machine
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1 TRAMEC SLOAN owes its history to entrepreneurial Americans who believed that manufacturing quality products with great service provides an exceptional value to the industry. Every day, the people of Tramec Sloan live by these beliefs established by our founders. Timeline: 1986 Hebco Products is formed by Hank and Joyce Hessey as a manufactured steel brake lines Transcraft Trailer and Miller Trailer purchase air brake hose assemblies, due to supply issues Hebco begins manufacturing of air brake hose assemblies, using all purchased components Brass cost spikes 50 plus percent. Hebco purchases first two screw machines to produce air brake hose ends/ to remain competitive Hebco builds air brake business, notable customers Trailmobile, Fruehauf, Monon Trailer, Strict, Transcraft, Great Dane, and others Hank and Joy Hessey sold business to MascoTech Hebco grows over 300%, profits increase over 700% Masco Tech sold Hebco Products to Qualitor Crawford Machine Inc. is formed by Hank, Joyce, Brad, and Kevin Hessey along with 5 other minor shareholders. Main Products, air brake hose assemblies and terminal bolts CMI s #1 and #4 largest customers goes bankrupt. (Trailmobile Monon Trailer) 2002 we survive CMI began our aftermarket brass fitting program, 40 components manufactured in house CMI purchases 22 screw machines at auction in an addition to the 21 we currently housed CMI survives the recession making a small profit Purchase first Hydromat Purchased three additional Hydromats, and two Gov Ro shape machines CMI Merges with Tramec LLC Tramec Sloan Galion produces a record 48 million fittings and purchases a record 7.25 million pounds of brass TS invests in technology. Neotechman forging is added to Galion One of only 4 companies in America to have this technology. (Anderson Fittings, Parker Hannifin, and Conbraco) TS increases investment on technology based equipment. BTB is purchased TS increases investment on technology with addition of IFP parts washing system.
2 1. QUALITY The quality department performs inspection on approximately 3 million parts produced in our machining area each month The quality department performs testing representative of approximately 200,000 hose assemblies each month There are 7 total associates working in the quality department The quality department has approximately 140 years of collective experience in the quality profession Some of the equipment utilized for the inspections are listed below o Digital and dial calipers o Vernier depth micrometers o Digital drop indicators o Vernier pitch micrometers o Vernier bore micrometers o Pin gages o Thread plug gages o NPTF thread rings o NPTF thread plug gages o Oasis optical measurement system o Digital height gages o Profilometer surface roughness measurement o o Vernier and digital micrometers Vernier and digital blade micrometers The machining equipment holds tolerances as low as.006 (6 thousandths of an inch) NOTE: A piece of paper is.005 thick Tramec Sloan maintains a certificate of registration to ISO 9001 at current specifications, currently 2015 version 2. F-32XL Hot Brass Forging Machine The hot brass forging machine was installed August This machine traveled all the way from Girona, Spain. Its manufacture is NEOTECMAN, S.L. This machine takes brass rod and forges it into shapes like 90 degree elbows and tee shaped fittings. This machine can use brass rod up to 14 foot long! That s about 2000 parts per hour. This machine runs at about degrees Fahrenheit when running, and the parts are at about degrees Fahrenheit when they exit the machine. Only 4 companies in America to have this technology. 3. MACHINING The machining department at Tramec Sloan consists of 60 plus employees from Management, Supervision, Scheduling, Tool Room, Maintenance, Leads, Set-up Operators, machine operators, Parts washers, and Material handlers. We have an average of 75 machining stations that consists of ACME, Davenport, CNC, Rotary Transfers, Hydromats, Secondary, parts washing, Forging, and high speed machining (BTB). The Tramec Sloan machining division focusses primarily on brass fittings with a range of 90,000 LBS 180,000 LBS of brass rod a week with an average of 3 million fittings produced a month. The average fitting is produced in less than 10 seconds. FUN FACTS The Kingsbury machine The company s history began with the founding of a sewing machine, clothes wringer manufacturing and Repair Company in 1875 by a local man named David Piper. Ten years later he welcomed young James S. Wilkins, Jr. into the business. Together they formed the Triumph Wringer Company that within a few years began to manufacture cast iron toys, including a toy wringer originally produced as a promotional item. ACME Machine By 1980, Acme-Cleveland had become one of the largest machine tool manufacturers in the United States, with net sales of $405 million. Oldest to newest equipment at Tramec Sloan in production 1. Davenport ACME Neotecman BTB IFP washing system- 2017
3 4. TOOLING The Tool Room is an integral part of the machining department at Tramec Sloan Galion. The machine people: setup, lead, operator, etc. are our initial customers. We control and manage the perishable tooling used in the production of our brass and steel parts, as well as the packets of documents that go out to the machine(s)with each set-up, including the part print, tool prints, lay-out sheet, and quality check sheets. A typical screw machine set-up includes the following tools Spot drill Two through drills Step drill 2 or 3 form tools Trepan tool (pronounced trapan ) Thread rolls Recess tool Cut off tool We sharpen tools, modify existing tools as necessary, work with machine people to trouble shoot machining issues, maintain inventory levels, and work in tool design with outside tool makers with whom we work to grow and maintain strong working relationships. Some of our main customer tools include: Step Drills Trepan Tools Hollow Mills (used in the Hydromat and BTB machines) Dovetail Form Tools Thread Rolls Did you know? With an average of 8-10 tools per set up, we can have upwards of tools on the floor at any given time. TOOLING (CONTINUED) With some tools we get over 120,000 hits before needing sharpened Typically, the tolerance on precision tooling is 10% of the tolerance on the part o If the tolerance on a part is.005 (thickness of a piece of paper) then the tolerance on the tool will typically be.0005 (five tenths), or ½ of a one thousand In addition to tooling aspect, the tool room also covers purchasing and machine repair. We not only control the perishable tools, but we also do purchasing area quotes, orders, receiving and dispensing of all the materials needed to produce parts in our plant, maintain our machines and equipment, keep our plant clean, and protect all associates. These items would include things such as: Oils and lubricants Machine/ Equipment repair parts Tooling/ Non-Perishable Factory supplies Safety supplies o We have at least 35 different styles/sizes of gloves for various tasks around the plant The tool room machine repair side has multiple high use repair parts. This side covers all of the screw machine end of the plant s production machines. They range from tiny set screws and o-rings for the CJ Winter heads to the large gears and even conveyers for the machines. The tool room is a vital part of keeping our production running so we can all make good parts. Good parts make everyone happy in many ways. 5. PARTS WASHING The IFP KP 200 Parts Washer is the newest piece of equipment in the building. It was installed in July Sold by Gosiger out of Dayton, Ohio; this machine originates from Venice, Italy where its manufacture, Industrial Finishing Plants is located. This parts washer washes under vacuum conditions in an alcohol based solvent. This makes it capable of washing both brass and steel parts. The machine can wash up to 400 pounds of product every 15 minutes. This is faster than all 3 of our old washers combined. The new washer also cleans and protects the parts better. This machine uses less electricity, water, and consumables. 6. ROTARY TRANSFER MACHINING CENTER (BTB) Manufactured by the BTB Transfer Spa (Bovezzo, Italy) and installed in January 2017, the BTB machine is a high speed machine capable of producing up to 900 parts per hour. It uses 8 work holding stations on a rotary table with 13 CNC controlled machining units, and a vision system with robot for part loading. This equipment allows the BTB to machine forged or slug parts from 3 different directions simultaneously. The BTB is capable of producing straight, 90 degree elbow, and tee shaped parts.
4 7. BRASS SUPPORT AND HAND ASSEMBLY Brass Fittings For Nylon Tube Assembly Produce Fitting to ship direct and supply Tramec-Sloan warehouse in Holland, MI Produce bulkhead fittings to supply hose production in Galion and Iola, KS. Order sizes from 10 piece to 20,000 Produce as many as 1,250,000 fittings per month 1/4 3/8 & 1/2 Nylon tube fittings Over 5 million components used per month in production Thread Seal Operation Per customer requirements majority of our fitting are thread sealed Up to 500,000 thread sealed BRASS SUPPORT AND HAND ASSEMBLY (CONTINUED) NTA INSERT PROCESS Press in a steel tube insert using a machine or hand insert press. Most common sizes are 1/4, 3/8, 1/2 and 5/8 Each machine is capable of running up to 10,000 pcs. per shift NTA NUT & SLEEVE SPINNING OPERATION Hand operation using spinner to assemble nuts and sleeve to fittings Most common sizes are 1/4, 3/8, 1/2 and 5/8 Each machine is capable of running up to 10,000 pcs. per shift. BRASS SUPPORT AND HAND ASSEMBLY (CONTINUED) TERMINAL BOLT ASSEMBLY T-Bolt machines used to assemble lock washers and jam nuts to the terminal bolt body Parts leave the assembly machine packed and labeled for Customer shipment. Reusable Hose Fitting Assembly Hand assembly using air spinners to build fittings. 3/8 and 1/2 hose fittings to be used to assembly hoses without the use of special equipment.
5 8. SHIPPING/ RECEIVING The shipping/ receiving department here at Tramec Sloan-Galion plant runs like a welloiled machine. Covering over 6,000 customers, we are always on the move. The shipping/ receiving department is made up of about 10 hard-working employees that cover 5 different areas. Bagging, boxing, pulling, and packing parts are just a few of the many ways we get shipments prepped and ready to go. With new orders coming in everyday, our same day shipping and 100% on time delivery goals are a challenge that we can proudly say we achieve. Hundreds of skids come and go throughout the week. It is a challenge keeping up with all of the moving product, but challenges are always accepted by this department and conquered to the best of everyone s abilities. In fact, for the month of September; the Galion division had no shipping errors. That s pretty good odds with over 5,000 pages of orders printed for this month. The Galion plant provides over 1000 different part numbers to the market place. We ship around 1 million parts a month. That s a shipment weight of about 160,000LBS. Thank you for visiting out plant, and enjoy the carnival! 9. AIR BRAKE HOSE SUPPORT AND ASSEMBLY Assemble Air Brake Hoses For Large and Small Trailer Manufacturers Assemble hoses per Customer orders Order sizes from 1 piece to 8,000 Produce as many as 165,000 hoses per month 1/4 3/8 & 1/2 hose diameter Over 6 million feet of hose used per year - Enough hose to cover the distance from Galion, OH to Key West FL 1 st Operation - HOSE CUT Cut hose to correct length per order Maintain product for each assembly line AIR BRAKE HOSE (CONTINUED) 2nd Operation - First Crimp Crimp on the specific fitting for the order Label the hose with the Customer part number and traceability information 3rd Operation - Second Crimp Crimp on the specific fitting for the order Verify the correct components on both ends Last Operation - Inspect & Package Quality Inspection of each hose assembly Package to Customers specifications and ready for shipment.
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