2015 77th Annual WI Regional Foundy & Expo Official Program

2015 Annual Wisconsin Regional Foundry Conference and Exposition Committee

A Message From the Conference Chair

T hank you for attending the 77th Annual Wisconsin Regional Foundry Conference and Exposition. This is the flagship event with the Wisconsin Chapter’s annual program. Proceeds from this event help to fund our

chapter’s mission supporting activities, scholarship awards and our chapter year program. Your attendance and participation in this event helps to ensure our continued success for years to come. During your time with us, please take the opportunity to visit our Exposition Hall and visit with the Vendors that continue to support our program annually with their participation. The Exposition Hall is rich with exhibits sup-ported by industry experts offering the latest technologies and services to help your foundry’s profitability and success for the future. Our Regional Planning Committee would like to thank all of the Exhibitors for participat-ing and representing a very important part of our annual event.

Our program would not be complete without an extensive gathering of industry experts, respected business professionals and govern-ment representatives delivering interesting and informative talks in our sessions and banquet events. Our committee extends sincere appreciation to these speakers that took time from their full schedules to support our program and to provide knowledge to our at-tendees. This year’s event, as with previous years, was developed through the efforts of the many that participated as part of our Regional Planning Committee. This committee consists of members spanning the Wisconsin, Northeastern Wisconsin and Stateline Chapters of the American Foundry Society. I would like thank all of the volunteers that spent hours of their personal time to help define, de-velop and coordinate the program that you are experiencing today. A special thank you to our Chapter Coordinator, Cindy Yang. Cindy coordinates the attendee and vendor registration process, manages the project timeline, printed materials and the extensive marketing efforts. Thank you to all for helping to make our event a success. Once again, thank you for attending our 77th Annual Wisconsin Regional Foundry Conference and Exposition. We invite you to provide feedback on your experience and suggestions for continued improvement. Please stop by the registration booth, and let us know how we are doing. Eric Lovejoy, Joy-Mark, Inc. Wisconsin Chapter AFS Regional Conference Chairman Wisconsin Chapter AFS Vice President

Cory Ashburn, Metalcasting Product Manager, AMCOL Metalcasting

Wayne Carr, Operations Manager, Olson Aluminum Castings

Jim Dallas, Sales/Project Manager, Keller, Inc.

George Forish, Jr., President, Precision Pattern Co., Inc.

Nick Gerrits, Vice President of Sales, Carpenter Brothers, Inc.

Dave Jablonski, Foundry Team Leader, Badger Mining Corporation

Leonard Lamb, Technical Director, Motor Castings Company

John Lewensky, Sales Manager, Pure Power Technologies

Eric Lovejoy, President, Joy-Mark, Inc.

Georgia Mayer, Strategic Buyer, Signicast Corporation

Paul Ostrenga, Operations Manager, Rexnord/Falk

Robert Priefer, General Foreman, Rexnord/Falk

Adel Rahman, Vice President of Operations, Kuttner, N.A.

Doug Sawyer, Vice President, Universal Welding & Engineering, Inc.

Paul Schumacher, District Manager, Refractory & Insulation Supply

Mark Villanova, Manufacturing Engineer, Grede, LLC.

Rick Yrigoyen, Regional Sales Manager, Foundry Products, Inc.

A special thank you to our conference exposition committee for their hard work and dedication!

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OFFICERS

President Mr. Adel Rahman, Vice President of Operations, Kuttner, N.A.

Vice President Mr. Eric Lovejoy, President, Joy-Mark, Inc.

Secretary Mr. Doug Sawyer, Vice President, Universal Welding & Engineering, Inc.

Treasurer Mr. Mark Villanova, Manufacturing Engineer, Grede, LLC.

Immediate Past President Mr. John Lewensky, Sales Manager, Pure Power Technologies, Inc.

DIRECTORS

2015: Mr. Cory Ashburn, Metalcasting Product Manager, AMCOL Metalcasting Mr. George Forish, Jr., President, Precision Pattern Co., Inc. Mr. Robert Priefer, General Forman, Falk/Rexnord

2016: Ms. Georgia Mayer, Strategic Buyer, Signicast Corporation Mr. Paul Ostrenga, Operations Manager, Falk/Rexnord Mr. Rick Yrigoyen, Regional Sales Manager, Foundry Products, Inc.

2017: Mr. Jim Dallas, Sales/Project Manager, Keller, Inc. Mr. Dave Jablonski, Foundry Team Leader, Badger Mining Corporation Mr. Leonard Lamb, Technical Director, Motor Castings Company

A s the President of the Wisconsin Chapter, American Foundry Society, I welcome all members, speakers, exhibitors, guests, and friends to our 77th Annual Wisconsin Regional Foundry Conference and Exposi-

tion. The Wisconsin’s Regional has always been and continues to be the largest AFS Regional in this country. It is a tradition for the Wisconsin Chapter to set the bar with respect to advancing technology and operations of all cast metals and providing a forum for metalcasters to interact. With this Regional trade show, it remains our intention to continue to provide you with a quality venue that will encourage: networking, camaraderie, educa-tion, and information transfer between the technical speakers, the vendors and the customers.

Last year, we had great success with our first-time tryout of the student casting competition. This year, we have taken that success, built on it, and expanded this competition to include more educational institutions, and more students. This was done in line with our mission statement “to promote education and build relationships between the educational and business communities, to strengthen and promote our metalcasting industry today and for the future.” Please encourage and support these students; after all, the students are the new blood that our industry needs to sustain its long term existence. Kindly allow me in this message to take a minute to thank those that have worked tirelessly to make this Regional a reality. Let me start by thanking the organizing committee that put together a program that will surely ensure the quality show that we all are accus-tomed to expect from the Wisconsin chapters. A special thank you note goes to Dr. Eckhart Grohmann for his continuous support in donating gifts to our technical speakers the “Man At Work” books. A thank you note also goes to George Forish, Jr. (Precision Pat-tern Co., Inc.), for his handling, finishing, and mounting the plaques that are also being given to the speakers. No message should be written without a special thank you note to the Arrangement Committee, spearheaded by Mike Cortez (Precision Pattern Co., Inc.). Last but certainly not least – a very special “Thank You” to all of our exhibitors, keynote speakers, technical speakers, the sponsors and the participating academic institutions. On behalf of the Chapter’s officers and directors, I hope you find the 77th Annual Wisconsin Regional Conference and Exposition informative, interactive, and interesting. Welcome, and enjoy the show! Adel Rahman, Kuttner N.A. Wisconsin AFS Chapter President

2014-2015 Wisconsin Chapter Officers and Directors

A Message from the Wisconsin Chapter President

Regional Conference Agenda & Information

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Wednesday, February 11, 2015 Registration: 2:30 p.m. Exposition Hours: 3:00-6:00 p.m. Reception with Vendors: 5:00-6:00 p.m. Conference Banquet 6:15 p.m. Featuring Kick-Off Dinner Speaker: Mr. Rich Meeusen, Chairman, CEO & President of Badger Meter, Inc.

Thursday, February 12, 2015

Registration: 7:30 a.m. Technical Sessions: 8:30 a.m.-4:45 p.m. Exposition Hours: 8:00 a.m.-5:00 p.m. Lunch with Vendors: 11:45 a.m.-1:00 p.m. Lt. Governor Rebecca Kleefisch Visit: 1:00-2:00 p.m. Networking with Vendors: 4:00-5:00 p.m. Awards Banquet: 5:30 p.m. Featuring Dinner Speaker: Mr. Gary Gigante, President & CEO of Waupaca Foundry

Friday, February 13, 2015 Registration: 8:00 a.m. Technical Sessions: 8:30-11:30 a.m. NO EXPOSITION HOURS

Lost and Found The lost and found is located at the AFS Wisconsin Registration Desk in the hotel lobby.

Conference Badges Required AFS Wisconsin Chapter requires that all attendees wear their conference name badges at all times during the conference hours. Badges must be worn in all sessions and in the exhibit hall. The badges not only indicate that you are fully registered for the confer-ence but also serve as a courtesy to other registrants. If you need a replacement name badge, please go to the registration table locat-ed in the lobby of the hotel. Thank you.

Exhibits Exposition exhibits are located in the Concorde Ballroom; be sure to visit all exhibitors, and see the latest new products, learn about new technology, and gain insight into new services. The Student Casting Competition, along with Foundry in a Box will be located in the Sabre Ballroom.

Dietary Needs Please inform the staff at the registration desk if you require any special dietary necessities.

Recycling of Name Badges Help us recycle! Please note that if you no longer need your name badge, please return them to the registration table.

Speaker and Exhibitor Evaluations A reminder to complete the speaker evaluations handed out at the technical sessions. Your feedback helps us to plan for next year’s conference Exhibitors, please be sure to complete your evaluations, and return them to the registration desk. Company Tours Interested attendees who would like to participate in the company tours listed on page 12, please stop by the registration desk for directions.

Conference Information and Reminders

Regional Conference Agenda & Information

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Conference Exhibition Map

Meet Your Keynote Speakers

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Richard A. (Rich) Meeusen is the Chairman, President and Chief Executive Officer of Badger Meter, Inc., a Milwaukee, Wisconsin-based company that is listed on the New York Stock Exchange. Meeusen joined Badger Meter in 1995 as vice president-finance. He was elected president and Chief Executive Officer in 2002 and chairman in 2004. Prior to joining Badger Meter, Meeusen served as Vice President of Finance and Treasurer of Zenith Sintered Products, Inc., in Germantown, Wisconsin, and in the audit division of the Milwaukee office of Arthur Andersen & Co. Meeusen received a BBA degree in accounting from the University of Wisconsin-Whitewater in 1976 and an

MBA degree from the Kellogg Graduate School of Management at Northwestern University in 1995. He is a Certified Public Ac-countant (CPA). He has received numerous awards including the BizTimes 2013 Community Leader of he Year award, the 2010 Business Leader of the Year Award from the Harvard Business School Club of Wisconsin, the 2010 Communicator of the Year Award from the Public Relations Society of America - Wisconsin Chapter and many more. Meeusen and his wife Maribeth live in Pewaukee, Wisconsin. They have two grown children, Matt and Julie.

Featuring Wednesday Night Dinner Keynote:

Gary Gigante is the President and Chief Executive Officer of Waupaca Foundry, Inc. He attended the University of Wisconsin-Madison where he earned his Bachelor’s of Science Degree in Metallurgical Engineering in 1978. He began his career in 1978 at Waukesha Foundry as a metallurgist. In 1981, he accepted the position of metal-lurgist at Waupaca Foundry, Inc., and went on to hold several other positions with the company, including Plant Manager, and Vice President of Operations. He was named President and COO of ThyssenKrupp Waupaca in 2004, and assumed this current position as Pres-ident and CEO of the company in 2007.

A member of AFS since 1979, Gary has also been active in FEF where he has served as a trustee at large, and an AFS Director Class of 2013-2017. Gary and his Wife, Jeanine, currently reside in Waupaca, WI.

Featuring Thursday Night Dinner Keynote:

Rebecca Kleefisch, a former small business owner and news reporter, serves as Wisconsin’s 44th Lieutenant Governor. She was elected Wisconsin’s Lieutenant Governor on November 2, 2010. Widely credited for coining the phrase, "Wisconsin is Open for Business," Rebecca played a key role from day one in business growth and retention for Wisconsin – cold-calling Illinois businesses that, in turn, relocated to Wisconsin, and nimbly responding to businesses looking for support. Rebecca serves as Wisconsin’s "Jobs Ambassador" and spearheads the Governor’s Small Business Summits and Tax Reform Roundtables. She chaired the Governor’s Sub-Cabinet on Workforce Investment, which developed the "Wisconsin Working" plan to connect the unemployed to jobs, encourage the hiring of veterans, and address

Wisconsin’s graying manufacturing workforce.

Rebecca is a colon cancer survivor, a member of the NRA, and a graduate of the University of Wisconsin-Madison. She is the mother

of two daughters, Ella and Violet. She lives in Oconomowoc with her husband, State Representative Joel Kleefisch.

Featuring Thursday Afternoon Keynote:

Regional Conference Schedule Wednesday, February 11, 2015

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Time: Session | Location

3:00 p.m. Exposition Kick-Off | CONCORDE BALLROOM

6:15 p.m. Wednesday Night Kick-Off Dinner | VOYAGER BALLROOM Topic: “Challenges Facing Today’s Manufacturing Companies: Talent, Resources and Regulations.” Featured Wednesday Night Speaker: Mr. Rich Meeusen, Chairman, CEO and President of Badger Meter, Inc. Join us as we gain insight into the many challenges facing Wisconsin manufacturers in today’s environment. Chair: Mr. George Forish, Jr., Precision Pattern, Inc. Co-Chair: Mr. Eric Lovejoy, Joy-Mark, Inc.

THANK YOU TO OUR WEDNESDAY NIGHT DINNER SUPPORTER:

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Alfred Spada is Editor/Publisher of Modern Casting and Metal Casting Design & Purchas-ing magazines and AFS Director of Marketing, Communications and Public Relations. Spada is a graduate of Northwestern Univ. and has an MBA from the Univ. of Colorado. Spada entered the metalcasting industry in 1997 as an editor for Modern Casting. His previous experience was in journalism and

communications as an editor for Pro Football Weekly magazine. Spada has spent his 15 plus years in metalcasting visiting metal-casting facilities across the globe and writing about the industry from both a technical and management perspective. In addition to his role with AFS and its magazines, Spada serves as Publisher for the International Journal of Metalcasting and has edited two books on metalcasting—the Iron Casting Engi-neering Handbook and Metal Casting Design & Purchasing. Spada regularly speaks to both metalcasters and casting buyers about the present and future of the global metalcasting industry, casting applications and casting design. Spada has a wife, Beth, and three daughters, Alyssa, Abigail and Audrey.

Nick Fox is the Manager at Galesburg Cast-ings, Inc, a 60 employee Ductile Iron Found-ry. He has 20 years’ experience working his way from the core machine to managing the overall operation. Nick has presented numerous technical pa-pers and presentations at Metal Casting Con-gress, strongly involved in the Engineering Division of the AFS Technical Committees

and is currently the Chairman of the Institute.

Attendees! Be Sure to Visit and Network With All

of Our Exhibitors !

Kick-Off Keynote Speakers

Robertson Ryan & Associates,

the insurance provider to the

Wisconsin Chapter.

Matt Cruise 414.283.4212

www.robertsonryan.com

Regional Conference Schedule Thursday, February 12, 2015

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8:30-9:45 a.m. General Kick-Off Keynote Speaker | AVIATION THEATRE

Topic: Developing the Future Leaders of Metalcasting Speakers: Al Spada, Director of Marketing & Publisher, AFS National This presentation will discuss current outreach and education initiatives at AFS aimed toward developing the future leaders of our industry. These initiatives include the Future Leaders of Metalcasting group and our Found-ry-in-a-Box program. We must engage future leaders early and often, showing the opportunities available through metalcasting. Then, once we engage them, we must continue to develop their potential.

Topic: The Future of Education and Training in the Foundry Speakers: Nick Fox, Chairman, The Institute & Galesburg Castings Will review the changes made to The Institute and how our $1 Million Pledge is working for the industry. We have created some exceptional courses with new content designed by professional designers. The material, the presentation of the material and the instructors are committed all meeting this centuries level of educational re-quirements. We have committed ourselves to provide the best education to the industry and continue to develop and provide state of the art training services. Chair: Mr. Wayne Carr, Olson Aluminum Co-Chair: Mr. Rudi Jansen, Grede - Browntown

10:00-11:15 a.m. Education - Cast Metals Roundtable| AVIATION THEATRE

Topic: Focus on Energy Speaker: Mr. Robert Peaslee, President, Manitowoc Grey Iron Foundry Rob will be leading this panel as it discusses energy saving opportunities in foundries. Topic: Wisconsin’s Strategic Energy Management (SEM) Leaders Program from Focus on Energy Speaker: Mr. Tim Dantoin, Sr. Engineer, Leidos Engineering Solutions Focus on Energy created the Wisconsin SEM Leaders Program to help the state's largest industrial energy users create a sustainable program for effective energy management by integrating energy considerations into organi-zational decision-making. SEM Leaders do this by improving operational procedures, administrative practices and individual behaviors affecting energy use. The program isn’t for everyone. Participation is limited to com-panies demonstrating a commitment and readiness to improve their energy performance. Topic: Focus on Energy Emerging Technology and Energy Efficiency Finance Programs Speaker: Mr. Tim Konicek, Director, CleanTech Partners, Inc. The Focus on Energy Emerging Technology Program actively finds, evaluates and promotes the deployment of emerging energy efficiency technologies in Wisconsin. We will review the program and discuss how we can work with Wisconsin foundries and metal casters. A second topic will be to describe how Focus on Energy can provide financing for energy efficiency projects in Wisconsin for either emerging technologies or best practices. Chair: Mr. Rick Yrigoyen, Foundry Products, Inc. Co-Chair: Steve Lewallen, Wisconsin Cast Metals Association

10:00-11:15 a.m. Engineering | CONCOURSE 1

Topic: Sand, Clay and Mulling Technology - Update Speaker: Mr. Jim Furness, President, Furness Newburge, Inc. Jim will provide an update on the recent developed mull to energy concept, and share how it relates to clay/sand reclamation to benefit foundries. Jim will be receiving the Scientific Merit Award at the Metal Casting Congress in April. Chair: Mr. Eric Lovejoy, Joy-Mark, Inc. Co-Chair: Mr. Doug Sawyer, Universal Welding & Engineering, Inc.


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10:00-11:15 a.m. Ferrous | CONCOURSE 2

Topic: Operation of a Rear-Slagging Cupola Speaker: Mr. Jeremy Mowry, Melting Engineer, American Cast Iron Pipe While front-slagging cupolas are the mainstay in North American iron melting, a few rear-slagging cupolas have endured the test of time. In this talk, the advantages and disadvantages of separating iron and slag inside the cu-pola will be discussed. This includes well design, refractory, tapping, operation, draining, and maintenance. Chair: Mr. Adel Rahman, Kuttner, NA Co-Chair: Mr. Doug Dearey, Maynard Steel Company

10:00-11:15 a.m. Non-Ferrous | CONCOURSE 3

Topic: Shakeout and Recent Developments in Binder Systems for Aluminum Applications Speaker: Matthew Hartman, Cold Box Product Manager, ASK Chemicals This presentation will be a discussion of the primary cold box binder systems and their impact on shakeout in aluminum castings. Recent advances in technology for improved shakeout performance will be presented. In additional, parameters that can affect shakeout and the optimization of these parameters will also be discussed. Chair: Mr. David Jablonski, Badger Mining Corporation Co-Chair: Ms. Ruth Mack, Loeb-Lorman Metals, Inc.

11:30 a.m. - 1:00 p.m.

LUNCH WITH VENDORS | CONCORDE BALLROOM & VOYAGER BA LLROOM

2:15-3:30 p.m. Value Added Services Roundtable Part I | AVIATION THEATRE

Topic: Options for Outsourcing Your Cleaning Room Operation Speaker: Greg Kovacs, Plant Manager, A&E Cleaning and Grinding Advantages of having an outsourced “2” Cleaning room. Services available to your company in the Milwaukee Area, and the ease of access to our facility. Topic: Local Flexible Manufacturing Networks That Compete in a Global Environment Speaker: Robert Mazur, Global Castings Buyer, AAA Sales and Engineering, Inc. Companies that produce competing product lines link up in order to achieve the lowest cost, best delivery and quality for each item produced. Customer Orders are directed to member (Tier 1) of the FMN whom has the highest value added, allowing each company to increase their competitive advantage in the market place. The final result is the entire FMN increases its capacity and profitability to provide products of excellent value for their customers. Topic: Heat Treating Principles for Steel and Iron Castings Speakers: Chuck Hartwig, Metallurgist & Tim Komar, Quality Manager, ThermTech This presentation will discuss heat treating principles of steel and iron castings. A review of important consider-ations from the customer’s perspective for the successful processing of iron and steel castings. Chair: Mr. John Lewensky, Pure Power Technologies, Inc. Co-Chair: Mr. Eric Lovejoy, Joy-Mark, Inc.

1:00-2:00 p.m. Special Conference & Expo Extra | VOYAGER ROOM

Topic: Manufacturing in Wisconsin Speaker: Lt. Governor Rebecca Kleefisch Chair: Mr. Adel Rahman, Kuttner, NA Co-Chair: Mr. Eric Lovejoy, Joy-Mark, Inc.

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2:15-3:30 p.m. Environmental | CONCOURSE 1

Topic: Risk Assessment and Beneficial Use of Spent Foundry Sands Speaker: Paul Turpin, Sr. Project Manager, TRC Companies This talk will discuss the U.S. Environmental Protection Agency’s (EPA’s) released of the long-awaited Risk Assessment of Spent Foundry Sands in Soil-Related Applications. This risk assessment evaluated the beneficial use of silica-based foundry sand produced by iron, steel, and aluminum metalcasting operations in manufactured soils, soil-less potting media, or road base. Based on studies conducted by the U.S. Department of Agriculture (USDA), and the application of highly conservative screening techniques and risk screening models, this docu-ment concluded that there is no evidence that these specified uses of foundry sand could pose significant risks to human health or the environment. Topics will include AFS’s role in the assessment, how the risk assessment was performed, the applicability of the approval, and how this assessment should promote the increased beneficial use of foundry sands in Wisconsin and elsewhere. Chair: Mr. Adel Rahman, Kuttner, N.A Co-Chair: Mr. Doug Sawyer, Universal Welding & Engineering, Inc.

2:15-3:30 p.m. General | CONCOURSE 2

Topic: Sand Cores and Molds-Costs and Possibilities Speaker: Don Covert, Solution Provider/Technical Sales, Humtown Products Don will be providing an overview of what sand cores really cost, insight into todays technology, and provide us an understanding in prototype with reduced capital expenditure. Chair: Mr. Cory Ashburn, AMCOL Metalcasting Co-Chair: Mr. Carey Chapman, Unimin

2:15-3:30 p.m. Non-Ferrous | CONCOURSE 3

Topic: Increasing Efficacy of Aluminum Operations Through Proper Flux Selection Speaker: David Youngblood, President & CEO, Basic Resources, Inc. By combining proper methodology on the front end with advantageous product choices, flux can significantly improve aluminum operations through improved efficiency, flexibility, and cost savings. Chair: Mr. Paul Schumacher, Refractory & Insulation Supply, Inc. Co-Chair: Mr. David Jablonski, Badger Mining Corporation

3:45-5:00 p.m. Value Added Services Roundtable Part II | AVIATION THEATRE

Company Tours A&E, and AAASE If you are interested, please stop by the registration desk for directions. Please note that you will need to provide your own transportation to and from the tours. AAA Sales & Engineering A&E Cleaning and Grinding, Inc. 1120 W. Northbranch Drive 1000 W. Pelton Drive Oak Creek, WI 53154 Oak Creek, WI 53154 (414) 764-2700 (414)766-1180 Chair: Mr. John Lewensky, Pure Power Technologies, Inc. Co-Chair: Mr. Eric Lovejoy, Joy-Mark, Inc.


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Exhibitors! We value your feedback! Remember to turn in your evaluation forms!

AFS Wisconsin Chapter Committees “C’mon - Get Involved!”

The lifeblood of our chapter flows through the active involve-ment of its members who give their time and talent to help the chapter fulfill its mission. Our chapter operates through the collective leadership and participation of many members, in-cluding the officers, board of directors and committee leaders and members. We have nearly 500 individuals who are mem-bers of this great chapter, yet the number who actively partici-pate in chapter operations is just a fraction of that number. Why not get involved? Make a commitment and join a committee today! Ask yourself “what can I offer my colleagues?” Are you skilled on the technical side? Do you have your finger on the pulse of the most pressing issues facing the foundry industry? Then get involved with one of the technical committees and have an in-fluence on what gets presented at future monthly meetings or the next Regional Conference. Are you an ambassador for the metalcasting industry, full of enthusiasm about all things foundry? Do you like mentoring young people about our industry? Maybe you’d like to contrib-ute to the outreach activities of the Education committee through the amazing Foundry-in-a-Box initiative. Make sure to visit the Foundry-in-a-Box booth at the Sabre Ballroom to learn more about this wonderful program. Do you enjoy the social or networking side of things? Perhaps you’d like to join the Membership committee or the committees that organize and run the Christmas party, Golf Outing and Old Timers. Or maybe you just like being involved and would be happy to help out a little. All of the committees can use help. Pick the one that appeals to you and let somebody know you want to be included. Your chapter needs your energy and ideas. Why not join a committee today! “C’mon – Get Involved!” Submitted by the ad hoc Alignment Committee * Cory Ashburn, Adel Rahman, Doug Sawyer, Rick Yrigoyen * The Wisconsin Chapter recently initiated a review of the ex-isting committee structure by forming an ad hoc “Alignment Committee.” This group is developing recommendations to streamline our committee structure and improve participation levels. Please let us know if you have some ideas on this sub-ject.


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3:45-5:00 p.m. Safety | CONCOURSE 1

Topic: Your Foundry: Safer Than An Aircraft Carrier? Speaker: Mark Mehling, Management Advisor, The Foundry Marketer The same methods that revolutionized safety in air travel can be applied in a foundry. This proven system has no inspections or fines. And embraces the most dangerous (and often overlooked) part off the plant- the people! In this presentation, learn how you can save workdays, lives, and money with a pro-active, predictive, easily imple-mented approach. Whether you are the CEO worried about your people, the Safety person with day-to-day ac-countability, or even CFO looking to reduce medical costs, you will get answers in this fast moving and informa-tive presentation by an experienced safety expert. If you are looking for a better answer than just gloves, glasses, and OSHA, you MUST attend this presentation. Chair: Mr. Doug Sawyer, Universal Welding & Engineering, Inc. Co-Chair: Mr. George Forish, Jr., Precision Pattern Co., Inc.

3:45-5:00 p.m. Ferrous | CONCOURSE 2

Topic: High Ductile Iron Developments Speaker: Greg Miskinis, Director of Research and Process Development, Waupaca Foundry Automotive Original Equipment Manufacturers (OEMs) are continuously seeking and developing thinner wall and light weight components to meet strict fuel efficiency requirements in the market. High strength and high ductility ductile iron has been developed by optimized chemistry and process control. Using high performance ductile iron and CAE simulation technology to create precise actual bench testing conditions, it was shown that the high strength ductile iron was a viable option to achieve 5-20% of weight reduction in safety critical part ap-plications. Chair: Mr. Adel Rahman, Kuttner, N.A. Co-Chair: Mr. Doug Dearey, Maynard Steel Casting Co.

3:45-5:00 p.m. Non-Ferrous | CONCOURSE 3

Topic: Combustible Dust and Explosion Protection Speaker: Jim Axt, Engineered Systems Support, Summit Filtration Technology, LLC. We will cover combustible dust standards, National Emphasis Program, OSHA, NFPA and Chemical Safety Board Reviews along with Process Hazard Analysis (PHA) guidance. We will also look at applicability, feasibil-ity, identification of risks and mitigation strategies and options, and how to avoid becoming a statistic. Chair: Mr. Nick Gerrits, Carpenter Brothers, Inc. Co-Chair: Mr. Roy Pickhard, Milwaukee Valve Company

The AFS Wisconsin Chapter, along with AFS Northeastern Wisconsin Chapter and the AFS Stateline Chapter would like to thank Woodland/Alloy Castings, Inc. and Precision Pattern

Co., Inc. for casting and finishing the award plaques.

Woodland/Alloy Castings


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5:30 p.m. AWARDS BANQUET | VOYAGER BALLROOM

Topic: Staying True to Your Strategy Featured Thursday Night Speaker: Mr. Gary Gigante, President and CEO of Waupaca Foundry, Inc. After experiencing the Great Recession and the sale of the company twice in the past five years, it is conceivable that Waupaca Foundry’s overall business strategy could be challenged. However, remaining laser focused and setting priorities has been paramount in navigating tough and changing times. This talk will expose some of the challenges, the impact on the company’s priorities, and its commitment to its mission and vision. Chair: Mr. Adel Rahman, Kuttner, N.A. Co-Chair: Mr. Eric Lovejoy, Joy-Mark, Inc. Casting Competition and Scholarship Awards Ceremony to follow.

THANK YOU TO OUR THURSDAY NIGHT DINNER SUPPORTERS:

Scholarship Winners George J. Barker Memorial Scholarship George J. Barker Memorial Scholarships support graduate level educational efforts, including direct student scholarships, in arts and sciences beneficial to the cast metal industry, particularly within the Wisconsin Chapter AFS membership area. Final evaluation and selection of grant recipients are made through an interview process conducted by the George J. Barker Memori-al Research Foundation Interview and Evaluation Committee. This Committee conducts interviews of each candidate either in person or via telephone. The Committee uses a cascade of criteria in considering applications. The maximum award could be as much as $5,000.00 although many factors such as funds availability, the number of qualified applicants, the needs of the individual applicants and certain screening criteria all can affect the sizes of the individual awards. Please reference details about the George Barker Me-morial Scholarships at the Wisconsin Chapter (wisconsinafs.org) or FEF (fefinc.org) web sites. Recipient: Peter Kim, Virginia Tech The FEF Past Presidents’ Scholarship Fund Made possible through your support, The Wisconsin AFS Chapter is grateful and honored to continue its long standing tradition of “distributing Chapter funds to traditional and non-traditional education programs…that help promote education in the sciences, arts and crafts relating to the metalcasting industry.” The chapter donations made directly to the Foundry Educational Foundation and the George Barker Memorial Fund are distributed by their respective Board of Directors. Recipients: Nicholas Barningham (UW-Platteville), Nicholas Bouska (Northern Iowa), Nick Fleischfresser (UW-Platteville), Jake Johnson (Northern Iowa), William McKone (UW-Platteville), Rylee Moder (UW-Madison), Mary O’Brien (Purdue Lay-feyette), Kyle Patterson (Northern Iowa), Nathan Peplinski (UW-Platteville), Alex Rasch (UW-Platteville), Brant Wilterdink (UW-Platteville) The AFS Wisconsin Chapter Scholarship Fund The purpose of this fund is to (1) establish or finance scholarship and/or incentives and awards, (2) to financially assist AFS Mem-bers’ children, and/or young people interested in a career in the metalcasting industry, and (3) to enhance the workforce of the com-panies within the Wisconsin Chapter of AFS. For more information, please visit www.wisconsinafs.org. Recipient: Christine Schilling, Cardinal Stritch University

Regional Conference Schedule Friday, February 13, 2015

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8:30-9:45 a.m. General | AVIATION THEATRE

Topic: Making Manufacturing More Environmentally Sustainable: Good For the Planet, Good for Your Bottom Line Speakers: John Jozwowski, Cast Iron Manufacturing, & Nathan Nissen, Sr. Environmental Health & Safety Pro-gram Manager-Sustainability, Kohler Company Kohler Co. manufactures plumbing products and industrial castings at its cast iron foundry in Kohler, Wis. The company produces grey, enamel and ductile iron products. Kohler has a long history of environmental stewardship and has implemented significant changes to make its manufacturing processes and overall operations more envi-ronmentally friendly. This discussion will focus on recent changes to make the company’s cast iron operations more sustainable and decrease its environmental footprint by reducing greenhouse gas emissions, conserving water and increasing waste recycling. Chair: Mr. Eric Lovejoy, Joy-Mark, Inc. Co-Chair: Mr. George Forish, Jr., Precision Pattern Co., Inc.


Topic: Tips for Successful Application of Casting Simulation to Nonferrous Castings Speaker: David Schmidt, Vice President, Finite Solutions, Inc. Dave will provide several case studies of simulations of various nonferrous castings to illustrate how to get the most accurate results possible. Discussion will include model and process setups, analysis of simulation results and techniques for creating efficient gating and riser designs. Chair: Mr. David Jablonski, Badger Mining Corporation Co-Chair: Mr. Roy Pickhard, Milwaukee Valve Company


Topic: “Sand Reclamation Overview” - Reclaimed Sand That Performs Well As - Or Better Than - New Sand. Speaker: David Silsby, Director of Sales, Simpson Technologies Corporation This presentation will review the basic reclamation process flow and the different reclamation options available to today’s foundries. Chair: Mr. Tom Gaeding, Carpenter Brothers, Inc. Co-Chair: Mr. Dick Haun, Accuride Wheel End Solutions/Gunite Corp.

8:30-9:45 a.m. Safety | CONCOURSE 3

Topic: Foundry Insurance and Risk Management Issues Speaker: John Mares, Foundry Risk Consultant, Marsh & McLennan Agency Foundry Insurance and Risk Management issues including: Workers Compensation, Property, and Liability Cover ages. What is the total impact of an injury to an employee? What is the effect on your Workers coverage? What is the effect on your Workers’ Compensation Experience Mod? What does the claim end up costing the foundry client? What other Risk exposures are unique to foundries and how can they be addressed? Chair: Mr. Cory Ashburn, AMCOL Metalcasting Co-Chair: Mr. Doug Sawyer, Universal Welding & Engineering, Inc.

NO EXHIBITION HALL - TECHNICAL SESSIONS ONLY

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Regional Conference Schedule Friday, February 13, 2015

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10:00-11:15 a.m. Ferrous | AVIATION

Topic: Use of Lower Magnesium Alloys for Ductile Treatment Speaker: Ken Copi, Field Account Manager, Elkem Materials, Inc. A discussion of why lower Mg treatment alloys provide higher and more consistent Mg recovery, reduced slag and ladle buildups, and several other benefits. Several case studies are included. Chair: Mr. Eric Lovejoy, Joy-Mark, Inc. Co-Chair: Mr. George Forish, Jr., Precision Pattern Co., Inc.

10:00-11:15 a.m. Marketing | CONCOURSE 1

Topic: Foundries Are Going Broke...Could Yours Be Next? Speaker: Mark Mehling, Management Advisor, The Foundry Marketer This presentation, delivered at the 117th Metalcasting Congress, is an overview of the study of 23 closed found-ries. 7 Myths and 7 Numbers were identified as key elements in the bankruptcies. You will learn how the same methods used for defect analysis on the plant floor can be applied to the biggest threat to a business-revenue and sales defects. If you are troubled by cheap foreign competition, only have ‘buy on price’ customers, and believe that lowering prices is the only way to get more business, this presentation is a MUST ATTEND to begin the journey to long term higher profits and stability. Chair: Mr. Adel Rahman, Kuttner, N.A. Co-Chair: Mr. Doug Dearey, Maynard Steel Co.


Topic: 3D Technology and 3D Printing of Sand Molds Speaker: Steve Murray, SME Additive Manufacturing Certified, Hoosier Pattern What is 3-D Printing? Why use 3-D printing in your foundry: What you need to know about 3-D Sand Printing before you start, additive manufacturing ( 3-D sand printing ) can add to a foundries bottom line. Chair: Mr. Nick Gerrits, Carpenter Brothers, Inc. Co-Chair: Mr. Greg Payleitner, Sharp Refractories, Inc.


Topic: Measuring Shrink by Thermal Analysis Speaker: David Sparkman, President, MeltLab Systems, Inc. New research in thermal analysis is showing subtle differences in iron that reveal micro and macro shrinkage, as well as cracking and gas holes. This goes well beyond the traditional thermal analysis or the usual intelligent systems approach and can actually see void formation as a reduction in the normal stresses that form mostly in ductile iron and in many aluminum alloys. Chair: Mr. George Forish, Jr., Precision Pattern Co., Inc. Co-Chair: Mr. Rick Yrigoyen, Foundry Products, Inc.

REMINDER!

DON’T FORGET TO TURN IN YOUR SPEAKER EVALUATION FOR MS!

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BOOTH #213

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FOUNDRY IN A BOX

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The Wisconsin AFS Chapter has taken an assertive approach to promote the foundry industry to local schools and surrounding com-munities though the Foundry In a Box program. The Foundry-in-a-Box is an educational tool that consists of a microwave oven melt-er, flasks, patterns, reusable sand and related tools and equipment. It is highly portable and requires no special facilities in order to be used. Our Chapter's volunteers have been successful in educating all levels of interest including middle school, high school, and colleges students. Without educating young talent, the industry will not be able to remain competitive. By educating our young peo-ple and communities on the importance of the metalcasting industry, we will ensure more people choose metalcasting as a career path. It also encourages communities to recognize and support the value of our industry. Without cultivating new talent, the industry will not be able to remain competitive in today’s global manufacturing environment. AFS chapters, groups, teachers and even parents can draw upon this web page to spotlight the metalcasting industry and have fun while doing it! Our Chapter's Education Committee will continue to focus on the education, mentoring, and recruitment of young talent. Thank you, Rick Yrigoyen, Foundry Products, Inc. Wisconsin AFS Director 2016 Wisconsin AFS Education Committee Chair

We welcome donations to support the mission of Foundry in a Box.

Stop in at the Sabre Ballrooom and come experience Foundry in a Box first hand!

We invite you to come and cast the Wisconsin Chapter AFS medallion!

Thank you to Precision Pattern Co., Inc. and Markcraft Co. for making the AFS Wisconsin Chapter pattern and finishing the medallion.

AFS Wisconsin Regional Invitational Casting Competition

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Under the guidance and help of the AFS National Directors, the Wisconsin Regional Conference is pleased to include the “Student Casting Contest Competition” a traditional event in its annual program. This feature of the 77th Wisconsin Regional Foundry Conference is a great opportunity to promote educa-tion and build relationships between the academic and business communities. A team of students from each of the invited Student Chapters have worked together in designing, manufacturing and presenting a casting which can be seen in the Sabre Ballroom. These entries will be on display during the Conference exhibition hours. Please take the time to view and interact with the participating students. The University of Wisconsin-Platteville set the bar high in winning the “AFS Region 5 National Directors’ Casting Contest” at the 76th Wisconsin Regional Conference. This year, it is expected that the competition will be challenging as Michigan Tech, Muskegon Community College, Northern Iowa, Purdue University Lafayette, University of Wisconsin Madison, University of Wisconsin Platteville and Western Michigan University compete for the coveted honor of winning first place. Judging based on benefits delivered to the casting customer, use of the casting process’ unique capabilities, quality and workmanship will be conducted by industry experts. Awards will be presented at the Thursday Night Banquet.

Please support the future workers of our great industry and stop in at the Sabre Ballroom to view the castings.

John Lewensky, Pure Power Technologies, Inc. Wisconsin AFS Chapter Past-President

Individuals

George Forish, Jr., Precision Pattern Equipment Co., Inc., Dennis Hageman, Missouri Refractories, Frank Headington, Neenah Foundry Co., Rich Hoster, Smith & Richardson, Inc., John Lewensky, Pure Power Technologies, Inc.,

Robert Peaslee, Manitowoc Grey Iron

Competing Universities Thank You for Your Support and Donations!

AFS Wisconsin, along with AFS Stateline, and AFS Northeastern Chapters would like to thank the companies, along with the individuals listed below for their support and donations towards the Student Casting Competition.

Companies

Judges include: Al Spada - AFS National, Greg Miskinis - Waupaca Foundry and Steve Robison - AFS National

AWARDS

1st Place: $2,500

2nd Place: $1,000

3rd Place: $500

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For more information, please visit www.afsinc.org

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American Foundry Society

Upcoming Events

Northeastern Wisconsin Chapter: February 14, 2015 | Annual Valentine’s Dance Holiday Inn Neenah River Walk | Neenah | WI March 2, 2015 | Annual Student Night Best Western Bridgewood Hotel | Neenah | WI April 6, 2015 | Non-Ferrous Focused Program Best Western Bridgewood Hotel | Neenah | WI May 7, 2015 | Foundry Tour & Dinner Tour: Arrowcast, Inc. | Dinner: The Gathering For more information on these events, please contact: Brian Powell, Waupaca Foundry by email: [email protected] Stateline Chapter March 10, 2015 | Monthly Meeting “What employers can do to hire and retain new talent” Ted J. Schorn, V.P of Quality & Technology, Enkei America Butterfly Supper Club | Beloit | WI April 28, 2015 | Scholarship Night/Joint Meeting with UW-P Butterfly Supper Club | Beloit | WI June 12, 2015 | Annual Golf Outing Timber Pointe Golf Course | Poplar Grove, IL For more information on these events, please contact Wayne Carr, Olson Aluminum, by email: [email protected] Wisconsin Chapter March 16, 2015 | Monthly Meeting “ERISA Compliance” Jeff Sewell, Regional Sales Director Total Administrative Services Corporation (TASC) May 18, 2015 | Old Timers’ Dinner Event 1st Annual Spoon, Cup and Saucer Competition “The History of Wisconsin” John Gurda, Milwaukee Historian and Writer For more information on these events, please contact the AFS Chapter Office at [email protected]

We look forward to seeing you at these events!

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If Not, See What Benefits You’re Missing!

♦ Networking opportunities through membership in the chapter nearest you is included with your AFS membership at no additional charge. Chapter meetings provide the forum for exchange of ideas and information with your peers.

♦ Career development through more than 100 CMI courses and special AFS conferences furnish you with continuing education opportunities.

♦ Practical and timely information to keep you current on metalcasting technology, management and government af-fairs issue through Modern Casting.

♦ Access to the latest in metalcasting equipment, process, supplies and services at CastExpo, held every third year in conjunction with Casting Congress.

♦ In-depth information to keep you up-to-date, provided through current books, videotapes, transactions and research reports, discounted to AFS members only.

♦ Library services, providing all types of metalcasting information from the AFS Library through the Retrieval Service and Metalcasting Abstract Service, discounted to AFS members only.

♦ Improved operations through management and technical software programs available to members at significant dis-counts.

♦ Proactive leadership and industry representation in the political arena, providing a voice for all metalcasters through the AFS Washington Office.

♦ Peer Recognition through involvement in AFS management and technical committee accomplishments.

For more information please visit www.wisconsinafs.org

ARE YOU A MEMBER OF THE AMERICAN FOUNDRY WISCONSIN CHAPTER?

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The Wisconsin Chapter of the American

Foundry Society, in cooperation with the

AFS - Stateline and the Northeastern

Wisconsin Chapter, would like to thank all

of the speakers, exhibitors, attendees, along

with the regional conference planning

committee for making this event a

great success!

Booth #200 Booth #106

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BOOTH #300

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The 78th Annual Wisconsin Regional Foundry Conference and Exposition

SAVE THE DATE

Mark Your Calendars for Next Year’s Regional!

February 10-12, 2016

Secure your space now! Stop by the registration booth to learn more!

BOOTH #418

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Visit us at Booth #216

EXHIBITORS MAP

Entrance

Entrance

Entrance

100 102 104 106 108 110 112 114 118

101 103 105 107 109 111 113 115 117 119

200 202 204 206 208 210 212 214 216 218

201 203 205 207 209 211 213 215 217 219

300 302 304 306 308 310 312 314 316 318

301 303 305 307 309 311 313 315 317 319

400 402 404 406 408 410 412 414 416 418

401 403 405 415 417 419

Concorde Ballroom - Exposition

502 501 500

503

504

Ent

ranc

e

505

506

Sabre Ballroom - Student Competition

507 508

CONCORDE BALLROOM

Booth Company

1 102 ABP Induction

2 414 AFS National

3 416 AFS National

4 412 AFS WI Chapter Membership

5 218 Ajax Tocco Magnethermic

6 309 Albarrie Environmental Services

7 201 AMCOL Metalcasting/MTI

8 311 Anderson Laboratories, Inc.

9 204 ASK Chemicals

10 206 ASK Chemicals

11 117 B&L Information Systems

12 100 Badger Mining Corporation

13 304 Blast Cleaning Technologies

14 107 Busch Precision

15 109 Busch Precision

16 300 Carpenter Brothers, Inc.

17 108 Carrier Vibrating Equipment

18 203 Daubert Cromwell

19 401 Disa

20 114 EC&S

21 405 EMSCO, Inc.

22 404 ETA Engineering

23 318 ExONe

24 205 Expert Cores of Wisconsin

25 307 Fairmount Santrol

26 118 Finite Solutions

27 406 FLASH

28 113 Focus on Energy

29 310 Foseco

30 312 Foseco

31 211 Guardian Software Systems

32 104 H.A. International

33 112 HASTINGS air energy control inc

34 209 Hickman Williams & Company

35 418 Humtown Products

36 212 Hunter Foundry Machinery

37 200 Inductotherm Corp

38 408 Industrial Associates/Bronco Blast Equip.

39 419 J.B. DeVenne, Inc.

40 219 John Maye Associates of Wisconsin, Inc.

41 301 Joy-Mark, Inc.

42 314 Kloster-Redford/Carver Dependable

43 119 KUTTNER, N.A.

44 217 LaempeReich

45 402 LECO Corporation

46 400 Loeb-Lorman Metals, Inc.

47 115 Marshall W. Nelson & Associates

48 214 MeltLab Systems

49 106 Metal Parts & Equipment Company

50 315 Miller Compressing/Alter Trading

51 316 Milwaukee Chaplet, Inc.

52 208 Modern Equipment Company

53 302 OmniSource

54 202 Perfect Patterns, Inc.

55 216 Pillar Induction

56 207 Refractory & Insulation Supply

Booth Company

58 210 Rice Industries

59 103 Roberts Sinto Corporation

60 306 S&B Industrial Minerals

61 305 Schust Engineering, Inc.

62 110 Spectro Analytical Instruments

63 101 Summit Foundry Systems, Inc.

64 215 Team Industrial Services, Inc.

65 313 ThermTech

66 308 Thermtronix Corporation

67 105 Tinker Omega Manufacturing

68 303 Unimin Corporation

69 213 Universal Welding & Eng.,, Inc.

70 403 Wheelabrator

71 111 WCMA

72 505 Foundry Educational Foundation

73 506 Foundry in a Box

74 508 Michigan Tech

75 507 Muskegon Community College

76 504 Purdue University-Lafayette

SABRE BALLROOM

77 503 University of Northern Iowa

78 502 UW-Madison

79 501 UW-Platteville

80 500 Western Michigan University

Booth Company

57 319 Refractory Services, Inc.

Documents

2015 77th Annual WI Regional Foundy & Expo Official Program