Simple Strategies for Meaningful Involvement

Engaging employees shouldn’t be hard. Try these ideas.

by Veronica J. Durden

Events Coordinator, PMPA

Published March 1, 2025

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There have been countless discussions about how keeping employees engaged helps reduce turnover. When employees aren’t engaged, companies often experience lower productivity, strained coworker relationships and frequent absenteeism as employees focus on finding their next place of employment.  However, the key question is: How can companies achieve this in a meaningful way? The answer is simple: Treat others the way you want to be treated.

Many companies are implementing ineffective employee engagement activities like book clubs and after-hour meetups. These activities take up employees’ personal time instead of focusing on initiatives that can be done during work hours.

In the shop, you can:

Develop your talent. Chances are, your next quality or IT expert has been there the whole time. Getting to know your team and their strengths not only strengthens the company but also benefits the employees. Take the time to know your employees individually. By making that investment, employees become more involved and give great ideas.

Focus on team building. These exercises don’t have to be done offsite, but can be scheduled during work hours. Take 20 minutes to get co-workers together. Understanding each other better helps the workflow go smoother. Investing in personality assessments such as CliftonStrengths can make all the difference.

Take suggestions. The tried-and-true suggestion box. Don’t just make it a staple in the corner collecting dust. Use it and show employees that their concerns are being taken seriously. Be sure to address any suggestions with all the employees — others may be thinking the same thing.

Make work fun. Did someone say scavenger hunt? Your crew is at work doing the mundane day in and day out. Start the day with a little fun by announcing a good old-fashioned scavenger hunt. Have employees snap a picture with their phone in front of items on the hunt, such as your mission statement or the first-aid station. Make it fun, but still educational. This can also be added to the company’s social media to show off the fun. You can get new employees just by showcasing your culture. Trust and believe — your competition is already doing it.

In the end, you don’t need to come up with elaborate ways to get your employees involved. It can be simple and shouldn’t take away from their free time. Investment is key to making your company feel like family. You’ve already made a great impression, that’s why they signed up. Now, keep them engaged and growing.

 

 

 

Author

Veronica Durden, MA, SHRM-CP is a human resources and workforce issues professional who specializes in manufacturing. Email: gro.apmp@nedrudv — Website: pmpa.org.

Bridge the Generation Skills Gap: Smooth Shift from Cam to CNC

Tajmac-USA’s Mori-Say 620TM CNC helps bridge the gap between the old and new worlds of machining, enabling performers who grew up with a smart device in their hand to interface with cam technology in a new way.

by David Wynn

Director of Technical Services, PMPA

Published March 1, 2025

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Tajmac-USA has introduced the Mori-Say 620TM CNC, the company’s next evolution of the traditional six-spindle cam machine, which is said to provide the power and speed of a cam machine with the versatility of CNC controls. 

The industry is facing a major shift with experienced operators retiring and new operators seeing our industry as dark, dirty and dangerous. This new machine helps bridge the gap between the old and new worlds of machining, enabling performers who grew up with a smart device in their hand to interface with cam technology in a new way.

The 620TM CNC reduces setup times dramatically, allowing operators to focus on high-value tasks. Operators can do what only they can do while the machines complete repetitive tasks. Combining CNC and cam reliability provides ease of use with modern controls. No longer do you have to retool an entire job to make a change. Redesign the cam with a few keystrokes introducing rapid improvements to the process.

As companies start to make the shift from cam to CNC, the Mori-Say TM620CNC makes that change more seamless than ever, providing cam quality, efficiency and stability. The machine also features Industry 4.0 support, future proofing the platform for years to come.

 

Author

David Wynn is the PMPA Director of Technical Services with over 20 years of experience in the areas of manufacturing, quality, ownership, IT and economics. Email David

 

How’s the Water? From Business As Usual to VUCA to BANI

Do we even have the words to describe and/or make sense of how business circumstances have changed?

by Miles Free III

Director of Industry Affairs, PMPA

Published March 1, 2025

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One of my favorite ideas to think about is David Foster Wallace’s famous “This is Water” commencement speech. In the speech, he talks about a couple of young fish swimming one way, and a slightly larger fish swimming past them in the other direction. The larger fish says, “Morning boys, how’s the water?” The two younger fish ask themselves, “What the hell is water?”

To the fish, water is the most important aspect of their very existence — it supports them, provides them thermal and respiratory resources, as well as total environment for their activity. From outside, it is easy to make fun of the fish’s lack of understanding the water. They take it for granted.

Business As Usual

In business, we start out as those younger fish in David Foster Wallace’s story. As new hires, we just try our best to deal with “business as usual.” We try to learn the tasks that need to get done, we figure out the best way to do those tasks with the tools given to us, and eventually we start to learn some other context stuff about our job, our customers and business. How’s the water? It’s fine once we figure out our place in it. Business as usual.

In the fish metaphor, “business as usual” is our “water,” and we are the fish. Business as usual is our all-too-obvious environment, support system, policies and procedures, assignments, tools and other available resources. We just take these all for granted.

Volatility, Uncertainty, Complexity, Ambiguity (VUCA)
But the water can change. Perhaps a rainstorm carries more run-off into the stream, making it murky, difficult to navigate and hard to keep oriented. The fish have to put their noses down and swim as hard as possible just to stay in one place. Storms can impact the quality and conditions of the water, and in our business, one storm that can change our “water” is called VUCA.
Volatility, Uncertainty, Complexity, and Ambiguity (VUCA) is the storm that changes conditions in our stream, clouds our vision, destroys our confidence, establishes variable behaviors to cues and confuses our certainty.

Volatility. Just think of prices of inputs. As consumers, we think of gasoline prices as volatile. So are materials and other energy prices.

Uncertainty. We have given our best price on that quote that we need to keep our shop full, but is it attractive enough to win the order? Did other competitors take a loss on their offers just to fill their shops, too?

Complexity. An old hand from 20 years ago would certainly be overwhelmed at the complexity of the parts and conformance requirements that the parts of today have. Not to mention supply chains and combinations of the different ways our materials might be produced.
Ambiguity. Here’s a line from a standard that I had to argue with many customers years ago: “Grades 5 and 5.2 bolts, screws and studs shall be heat treated (fully austenitized), oil or water quenched, at option of manufacturer…”

Despite the very clear “shall be heat treated (fully austenitized)” phrasing, I had many companies arguing that the heat treat was “option of the manufacturer” and that they wanted to purchase material to the mechanical properties specified by buying heavy drafted, not heat treated, cold drawn materials. And that is in a very common, agency-issued national consensus standard.

When circumstances change — at our suppliers, our customers, in the markets or in global transportation systems — our “water” quickly changes from the clarity of business as usual to the murky and almost opaque VUCA variety. How’s the water where you work?

Brittle, Anxious, Nonlinear, Incomprehensible (BANI)
Today, many of us yearn nostalgic for the good old days of VUCA. Business as usual is a luxury too distant to remember. In today’s “water”, Brittle, Anxious, Nonlinear, and Incomprehensible (BANI) describe the conditions in which we and our colleagues (our fellow fish) must work.

Brittle. Might best describe the reaction of some employees to losing their accustomed work-from-anywhere flexibility as they are mandated to return to office. Ask Amazon how that is working out. Or Tupperware — which recently filed for bankruptcy protection due to its failure to adopt an online sales model despite its in-home direct sales model failing to sustain company finances.

Anxious. Anxiety is almost certainly the result of the ambiguity and uncertainty of the prior VUCA model, but now it describes us as performers rather than our environment. With ever present uncertainty — whether unavailability of needed materials, late deliveries, late or delayed payments or customers suddenly ghosting our salespeople — anxiety is a common characteristic of almost everyone with a job with responsibilities that depend on others. And it is also a direct result of the nonlinearity of responses to events in our “water.”

Nonlinearity. This one is really easy to spot. Just look at the demands by customers for compensation far beyond the actual damages should a product or service fail to conform perfectly to the order requirements. With escalating penalty clauses, and threats of legal consequences, a failure to provide any aspect of a product could result in legal damages thousands of times beyond that of the affected part cost. It may even endanger the company’s continued existence. Anxiety is high when our people and organizations face the nonlinearity of our customers. Oh, and what if ocean shipping is delayed because the critical items that you must have to fulfill the contract are significantly delayed or unavailable? Or a mill closes?
Who can predict the costs of these high-impact scenarios?

Incomprehensible. There are many, many areas where the world can seem incomprehensible to our colleagues and organizations. For me, the rate of change of the rate of change is shockingly high. It seems like every day some new thing becomes a mandatory part of the environment. For me personally, the day that I am writing this, I learned how to print on the office printer directly from my cell phone. It never stops. No time to catch our breath, the next wave is already breaking above our heads. What will be the consequences of the election on our shops and businesses? How can we even start to know?

Better Together.
One of the ways that can help us remain effective, whether our particular water is business as usual, VUCA or BANI, is to effectively associate with our peers. At PMPA, we call this “Better Together.” PMPA and its participating members provide sensemaking on technical, operational, quality, financial, regulatory, safety and government affairs matters. PMPA members are not just willing but eager to weigh in on a way to solve that problem that is intractable in your shop. We provide monthly benchmarking for sales, lead times, profitability and employment prospects as well as hours worked and overtime.

Archimedes bragged that give him but a place to stand, and he could move the earth. I don’t think that fish can use levers, (sorry, Achimedes) but giving our members a solid footing when they face BANI, VUCA or just plain business as usual — through PMPA ListServe Communities, reports, staff consultations or expert training and networking at our local and national meetings — can surely take away the pain of surprises as well as the ignorance of unawareness.

 

 

Author

Miles Free III is the PMPA Director of Industry Affairs with over 50 years of experience in the areas of manufacturing, quality and steelmaking. Miles’ podcast is at pmpa.org/podcast. Email Miles

 

 

 

 

 

 

The ITR Economics quarterly forecast report gives us insight into eight industries that are the primary drivers of our shops’ success. The ability to consistently look into the future with actionable data gives us a competitive edge.  The reason that PMPA members closely follow the ITR Quarterly forecast report is that the ITR process of analysis clarifies and makes patterns clear that the news cycle seems to miss.  Cut through what the financial media is telling you about the economy and use the ITR report to get at the heart of what affects your shop.  Check out in this month’s PMPA February 2025 Economic Report from ITR Economics.

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The Institute for Trend Research (ITR) quarterly reports focus on major areas of economic growth and decline in key market segments for the Precision Machined Products Industry. They are provided to PMPA members as part of the association’s overall business intelligence program and are used as a management tool to help PMPA members plan for what lies ahead and which markets they should focus on in a complex manufacturing environment. 

The Lost Art of Mastery

There is value to honing and mastering a craft. But it takes time and experience.

by David Wynn

Director of Technical Services, PMPA

Published February 1, 2025

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I recently went down a rabbit hole watching various craftsman videos. Individuals carrying on traditions of long-lost trades. Things like Japanese long bows, wooden soup ladles, hand cut wooden shingles and hand-woven rope. All these steps take years to perfect. A person must dedicate large portions of their life mastering the techniques in every step of the process. From selecting the right raw material to final assembly, each area has multiple steps to learn. A person dedicates time and mental energy to learning how to recognize what is a conforming or non-conforming part. An intimate relationship between a person’s being and their craft develops. It becomes difficult to discern one from another. I think now about our current society. We live our life with a “drive through” mentality. It seems like we want it now. When I look at sports, I see a different story. Parents will tell their children to put in the time. Learn the basics and build up skills over time. Children are learning mastery of a craft. It is this attitude that we should bring to our work when we become adults.

We will spend between one-quarter and one-third of our life at work. We should pick a craft we love. Why do we feel we do not have to put years of work learning our way up through a company? Why do we feel entitled to start at the top at work? Why are we so offended when someone asks us to sweep the floor and wash parts? I remember when I started out that was all I got to do. Later, I was moved to secondaries, slowly moving my way up to setups. It was better this way. I learned every step of the process. I knew who the internal customers were. When I was washing parts, I did not want to receive a pan full of bar ends and chips. So as an operator, I kept that stuff out.

I think society has forgotten mastery of the craft. We no longer plan on three-to-five-year apprenticeships to build our knowledge for our career. There are pockets of this still — in the medical field, for instance. A surgeon must commit to a one-to-three-year fellowship after medical school, a time spent with a senior surgeon to hone your craft. It is a time of mastery, putting all that a doctor learned in school into practice.

As shop owners and managers — and as parents to the next generation — we must sell the importance of mastery better. We need to explain to the younger generation it is not demeaning to learn a craft. On the contrary, it is the ultimate job security. We have masters in our shops and they are valued. Most of the time, we keep them working part time after they retire. I was always told no matter what you do, do it at your best. If you are going to sweep the floor, then strive to be the best floor sweeper ever. We have a notion that certain types of work are demeaning. They are not! All tasks work together to make our shops run like well-oiled machines. Would you run your car without the oil? Pride in our work is essential to mastery. A level of never being satisfied.

The master is always striving to do it better the next time. Masters become masters not because of what they know, as much as it is that they know there is always more to learn.

To the next generation: Do not be afraid to take the path of mastery. Just like coming to a new team in freshman year, you must start at the bottom. Work your way to the top and prove yourself. Do whatever someone asks of you and do it well. Do not just do it well, do it best. If you want to find your way up a ladder, find the tasks no one wants to do and jump on those. Volunteer to do the tough work. Those who do what no one else does get noticed. You will also find that tough work teaches you lessons that will enhance your capabilities through your whole career. Put in time and effort and you will go far. We need you in this industry. The work pays very well and is rewarding, but the price for admission is your commitment. If you love it, then commit to it, and you will be rewarded with a distinguished career for which you will want to spend a third of your life.

 

Author

David Wynn is the PMPA Director of Technical Services with over 20 years of experience in the areas of manufacturing, quality, ownership, IT and economics. Email David

 

PMPA Craftsman Cribsheet #136: ISO Material Groups: Cast Iron

Published February 1, 2025

By David Wynn, Technical Services Manager, PMPA

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Cast irons are divided into three main grades for machining. Within those categories, they can be broken down into subgroups of ferritic and pearlitic cast iron. Ferritic cast irons are more ductile and have higher dimensional stability in higher temperatures. Pearlitic cast iron has a higher resistance to fretting corrosion. Fretting corrosion occurs in air when surfaces rub under oscillation, rotation or vibration under load. Pearlitic cast irons also have higher hardness and higher mechanical properties.

Some cast irons can be heat-treated to martensitic with higher hardness values. Hardness numbers in the chart are approximate ranges. Machinability varies widely in each category because cast irons of each type can vary widely in ductility and mechanical properties. The less ductile the material, the better the chip will break. There is little industry standard on the naming of the categories from insert manufacturers. Below approximates the categories and ranges.

Find the specific grade of cast iron in a reference manual to get surface feet per minute (sfm) with high strength steel (HSS). Multiply the HSS number by 2-2.5 and it will provide a reference point for what sfm you should use with carbide. The sfm guidelines given based on material groups above can vary widely, which can be seen in the machinability range.

 

 

 

 

Author

David Wynn

David Wynn, MBA, is the PMPA Technical Services Manager with over 20 years of experience in the areas of manufacturing, quality, ownership, IT and economics. Email: gro.apmp@nnywd — Website: pmpa.org.

What Does the Future Hold for Leaded Steels?

12L14 and other leaded steels are no longer melted in the U.S.

by Miles Free III

Director of Industry Affairs, PMPA

Published February 1, 2025

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My 50-plus-year career in steelmaking and manufacturing took me to employment at mills and meltshops in four different states, four different melt shops and authority over quality at 10 steel mills — both hot and cold finished. Leaded steel was a product of these plants.

In addition to the aforementioned plants, our cold finished mills often sourced leaded steel hot roll bars from Inland Steel or Bethlehem Steel. We cleaned, cold drew and straightened these bars, selling millions of pounds for hose fittings, carburetor and fuel line parts and many other automotive and non-automotive applications. Leaded steels provided machining shops with economies of production through increased tool life, increased speed, increased production rates and superior as-machined surface finish. Leaded steels were the optimum input for the screw machining industry in those days.

While leaded steels were often the most important product for our sales throughout the 1980s and 1990s, there were also enhanced grades: LedAX from Inland Steel and Beth Led B from Bethlehem Steel. Their higher price (mostly due to higher yield loss at the hot mill during rolling) could be justified when trying to hold difficult tolerances, finishes or cutting the finest threads. Despite the abundance of choices, the market was filled with rumors about the upcoming banning of lead, by customers, the Europeans or the EPA. A host of substitute materials — some containing bismuth, selenium, tellurium and even tin, were developed and brought to market. My counsel to our company’s customers — many of whom were PMPA multispindle screw machine shops making hose fittings for automotive and fluid power applications — was to not get too upset by all of these rumors. Leaded steels were plentiful in the market and would remain so despite all of the angst in the marketplace.

My final steel manufacturing employer, Republic, had two EPA permits to melt lead: one at Lorain, Ohio’s Basic Oxygen Furnace, and Continuous Caster (formerly U.S. Steel, where I was lab supervisor) and one at the Canton Electric Furnace Meltshop and Cast Roll (formerly Republic). I have been bullish on leaded steels as an appropriate and readily available input for our industry throughout my career.

Until the Lorain works (which had been integrated into the Bartech/ Republic Steel operations) were destroyed by a series of catastrophes starting with a cold weather fish-kill event. The fish clogged the cooling water intakes — crippling the blast furnaces. Without hot metal from the blast furnaces, there could be no steelmaking at the BOF/ Continuous Caster. An Electric Arc furnace was constructed to restore steelmaking at Lorain. A fire, just days before the scheduled start-up, made that construction a total loss. All steelmaking was destroyed at Lorain, which had one of the two valid EPA permits for melting leaded steel here in the U.S.

The Republic Canton Plant was owned by a Mexican firm, Grupo Simec. They shut down all of the Republic non- Mexican steel operations last summer when they moved all orders to their newer plant in Tlaxcala, Mexico (bit.ly/PMPA-PM0225a). The Republic Canton Meltshop had the second EPA permit for melting leaded steels.

All 12L14 and other leaded-grade special bar quality (SQB) bars that I know of in our shops are imported as hot rolled bars for cold drawing by U.S. or Canadian cold finishers from European sources — Germany and Great Britain being the primary countries of origin to my knowledge. There are supposed to be some changes in the British Steel Industry as they try to wean themselves off of Blast Furnace BOF production (Port Talbot) for “carbon/climate reasons,” which I expect could take the Brits out of the 12L14 game for more than a couple of years (bit.ly/PMPA-PM0225b).

Currently, the U.S. has tariffs imposed on steel bars coming in from overseas under Section 232. According to the U.S. International Trade Commission, the tariffs increased the average prices of steel and aluminum by 2.4% and 1.6%, respectively, disproportionately hurting “downstream” industries that use steel and aluminum in their production processes. Despite no domestic source of leaded steels, our imports of leaded steel are still covered by the tariff “to protect” domestic industry.

The re-election of Donald Trump has ensured that tariffs will be a major policy in the new administration. So now that we are forced to purchase leaded steels overseas, because there is no domestic melt source, we will be forced to pay even higher prices due to cost off shipping, current tariffs and expected new additional tariffs. If our domestic cold finishers can find leaded hot roll to cold draw for our shops.

So, I am no longer as bullish about the prospects for leaded steel availability in the United States. To the best of my knowledge, we have lost all domestic melt capacity for leaded steels. Great Britain is closing their leaded steel producing operations for at least a year. And importing leaded steel — regardless of supplier or country of origin — will result in much higher costs due to transportation, ongoing and increasing tariffs. We have yet to see how proposed Carbon Border Adjustments, or “Carbon Taxes,” will impact the market or availability.

If there was a hope, it would be that under the new administration, U.S. steelmakers might find an opportunity to apply for a permit to produce leaded steel bars for machining. Quite unlikely. So, I would advise all of us, as precision machining shops and purchasers of precision machined components, to start researching to develop process modifications and investigate available steel grades, new tools and coatings that we can adopt to deliver similar performance and economics as our traditional leaded steels continue to decline in availability and application, while increasing in price.

 

 

 

Author

Miles Free III is the PMPA Director of Industry Affairs with over 50 years of experience in the areas of manufacturing, quality and steelmaking. Miles’ podcast is at pmpa.org/podcast. Email Miles

 

Hiring A New Generation — Generation Z

Be prepared and understand what many don’t know about Gen Z.

by Veronica J. Durden

Events Coordinator, PMPA

Published February 1, 2025

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Most people are aware of the differences between workforce generations and the stereotypes that come with each. Generation Z is the newest generation entering the workforce, and they might be unlike anything you’ve seen before.

Perceptions Versus Reality
Online and social media often mock Gen Z for their fashion, speech, eating habits and sensitivities. However, they will be valuable assets to both the team and the company. This generation brings a fresh perspective and innovative ideas that can drive your company forward.

Preparing for Gen Z Employees

  • Loyalty: They may not automatically be loyal; companies will need to earn Gen Z’s loyalty by showing interest in their professional development. Building a strong relationship with Gen Z employees involves understanding their career goals and providing opportunities for growth and advancement.
  • Salary: According to Forbes, salary is a significant factor for Gen Z when choosing where to work. They are willing to sacrifice personal time to achieve financial stability, having witnessed the 2008 recession’s impact on families. Offering competitive salaries and benefits can attract and retain these employees.
  • Education and Experience: According to O.C. Tanner, members of Gen Z will have more degrees but less experience. They are eager to make a change and establish themselves in their organizations. They value growth and professional development and understand the importance of technology, potentially helping with social media. Providing mentorship and training programs can help bridge the experience gap and integrate them into the company culture.

Job Hopping
An important factor to remember is that job hopping is common among Generation Z. According to ResumeLab, 83% consider themselves job hoppers, leaving jobs for reasons like wages, company culture, work-life balance and meaningful job growth. This generation is not afraid to seek out new opportunities that better align with their values and career aspirations. Companies need to focus on creating a positive work environment and offering clear career progression paths to retain these employees.

Welcoming Gen Z
Generation Z will bring new perspectives to the workplace. Be open-minded and receptive to their ideas.

They seek not just a paycheck but a workplace with a culture that complements their lifestyle, such as flexible hours, environmental friendliness and diversity. Embracing these values can lead to a more dynamic and inclusive work environment. Ultimately, all generations share the same goals: stability, capability and the opportunity to flourish in an organization. Is your organization ready?

 

 

 

Author

Veronica Durden, MA, SHRM-CP is a human resources and workforce issues professional who specializes in manufacturing. Email: gro.apmp@nedrudv — Website: pmpa.org.