Connections member newsletter

www.fmanet.org july/august 2008

FMA Sponsors Teen Race Car

Driver Brennan Palmiter
August 2008 Palmiter Combines Passion for Racing, Welding
12 FabCast--10 Steps For Increasing
The Fabricator’s Cash Flow
10 -11:30 a.m. CDT
18-19 SAIL 2008: Shipyard Applications
for Industrial Lasers
Williamsburg, VA

September 2008
9-10 The TPJ Symposium Series...
Tube & Pipe Fabricating and
Producing Conference and
Roundtable - Fabricating Track &
Producing Track
Columbus, Ohio
9-10 FabCast–Fundamentals of Press Brennan Palmiter and FMA team up to support the future of the industry.
Brake Operations
8 -10 a.m. CDT daily In an effort to fast-track the association’s
outreach efforts to students and encourage
14-16 EDTR Roundtable 2008:
young people to consider careers in
Solutions in Seattle manufacturing, the Fabricators &
Seattle, Wash. Manufacturers Association, International
16 Fundamentals of Stamping Presses (FMA), and its publication Practical
Dayton, Ohio Welding Today will sponsor 16-year-old
16-17 Coil Processing Workshop Livingood Motorsports race car driver
Brennan Palmiter of Ormond Beach, Fla.,
Alsip (Chicago), Ill.
for the 2008 racing season.
Details at fmanet.org Palmiter will play a key role in the FMA
Foundation scholarship program, which
offers scholarships to young people attending
trade schools or colleges and universities to
prepare for metal forming careers in
manufacturing. He also will speak to
students about welding and fabrication
and appear at two FMA events.
Brennan Palmiter............................. 1 As Palmiter’s primary sponsor, FMA has
its logo emblazoned on the hood of the
APPI.................................................3 race car and on his uniform. The logo for
industry awards................................ 4 Practical Welding Today, a bimonthly
magazine that provides information,
education......................................... 6 applications, and advice for welders, will
foundation ...................................... 8 appear on the car’s rear fender.
“Brennan Palmiter is a remarkable young
man who possesses passions for both
welding and racing,” said Gerald Shankel,
FMA president. “We were impressed with
Brennan’s racing record, as well as his drive
and determination to succeed both on the
track and in his studies.
“Our organization is dedicated to
engaging youth about the many career
opportunities in sheet metal fabrication and
welding, so this partnership makes perfect
sense for us,” Shankel added. “Brennan will
be instrumental in promoting our young
professionals program and in other student
outreach efforts, and we’re proud to have
him on our team.”
Palmiter is enrolled in an accelerated-
graduation program at Seabreeze High
School in Daytona Beach, Fla., that allows
him to graduate high school in just three
years. He also takes night classes in welding
technology at Daytona Beach Community
College. In May 2009, Palmiter will
graduate from both high school and junior
college with a high school diploma and a

safety award winners........................10 cont. on page 2

1
FMA Sponsors Teen Race Car
Driver Brennan Palmiter... cont.

Palmiter and FMA Communications Group Publisher Ed Youdell unite at the

Metal Matters 2008 conference in Lake Buena Vista, Fla.

vocational certificate in welding technology with four specialized welding

certifications.
Palmiter regularly speaks to youth groups about racing and, because of
his involvement in welding, discusses vocational programs and careers in
the trades.
“I’m thrilled to have FMA’s support and to have a lead sponsor that can
really be a part of the team and help contribute to victory,” said Palmiter.
“I look forward to helping FMA reach people my age about my other
love—the many exciting career opportunities in welding and fabrica-
tion.”
Palmiter began racing go-karts when he was 7 years old and later raced
in the novice class at a local track near his home. From there
he branched out to compete at go-kart dirt tracks in Florida,
eventually racing in the WKA State and National Dirt Series. From 2001
to 2004, in just over 175 starts, he scored 85 top five finishes and 17 state
and national wins.
In 2005, Palmiter moved from karting to race a T.Q. Late Model stock
car. He competed at dirt and asphalt tracks throughout north Florida and
south Georgia, scoring 12 top five finishes and one win in just 30 starts
and finishing his first season fourth in overall points.
In 2006, Palmiter raced a Limited Late Model car at New Smyrna
Speedway and earned “2006 Late Model Rookie of the Year”
honors. Last year, Palmiter ran the full season at New Smyrna
Speedway finishing second in points and making his debut with
the Goodyear Challenge Series.
Palmiter and his race car made an appearance at the Metal Matters
2008 executive summit in March at Disney’s Contemporary Resort in
Lake Buena Vista, Fla. Palmiter will be featured at FMA’s booth at the
2008 FABTECH® Intl./AWS Welding Show in Las Vegas.

2

Lighting Retrofits 101
It is not difficult to notice today’s
obsession with all things green – hybrid
cars, wind power, renewable-energy
credits. Many publications contain an
article or two about what we should do
to reduce our energy consumption (or at
least make amends for it) and what will
happen if we don’t. As a business owner
or plant manager, you must integrate the
challenges and solutions of a long-term
environmental strategy into the cost structure and sustainability of
your business. This article is not about turning the lights off or
monitoring their use. This is about why and how lighting retrofits
can make economic sense for your business and simultaneously be
environmentally sensitive.
No discussion about lighting retrofits is complete without a simple
glossary of terms:
• Retrofit – Modify existing parts or system with a new one.
• Lumens – Unit of measure used to describe the amount of light
a bulb produces.
• Wattage – Amount of electricity consumed by a lamp or light
fixture.
For example, a 75-watt incandescent bulb produces approximately
615 lumens. A comparative 20-watt compact fluorescent light achieves
the same relative number of lumens.
Cost Drivers
The cost of electricity continues to increase. Given the continuing
demands on and constraints of the energy industry, the forecast is for
continued upward price pressure. Even a slowing U.S. economy will
not impact significantly the world’s growing demand for all energy
sources. Many businesses with locations in states that are deregulated
already have explored price reductions through competitive supply.
The next step in the process of managing costs is to develop ways to
reduce consumption. An energy-efficient lighting retrofit can be one
of the easiest and fastest ways to reduce energy consumption and,
therefore, costs. Total costs and payback periods typically are from
12 to 36 months, depending on the size of the facility, local
electricity costs, hours of operation, and the types of new lighting
products installed.
Increased Efficiencies
Some businesses switched from incandescent bulbs to fluorescent
lamps many years ago. This switch increased efficiencies –
incandescent bulbs convert only 10 percent of the energy to light, with
more than 90 percent burning off as excess heat. Depending on the
bulbs/lights used for comparison, fluorescents consume one-fifth to
one-third of the electricity conventional light bulbs consume.
According to Osram Sylvania, modern fluorescents typically have a
lifespan of between 6,000 and 15,000 hours, whereas incandescent
lamps usually are manufactured to have a lifespan of 750 to 1,000
hours. Each new generation of fluorescents creates additional savings.
For example, a conversion of T12s (older, wider lights commonly
found in older office buildings) to T8s can result in savings of 34 to
43 percent with no loss in lighting quality. Higher-efficiency T8 lamps
(including energy saving ballasts) can produce savings approaching 50
percent.
affinity partner
The lighting industry continues to make significant advances
in technology. Coupled with the ongoing dialogue regarding
conservation and increased competition, costs for the new
technologies and products continue to be driven down.
In most commercial facilities, lighting accounts for the single largest
energy expense, as much as 35 percent. A 40 percent decrease in
lighting energy can translate into a reduction of 15 percent in
electricity costs. Further cost decreases can be attained when fewer
cooling needs are factored into this equation. Since the amount of heat
the new lights produce is significantly reduced, the amount of energy
needed to cool the lighted space decreases. (This equation may change
during months when the building’s units are required to heat the
space. The greater the building’s cooling needs, the greater the
reduction from the light replacement.)
The benefits of a lighting retrofit are more than just reduced
electricity costs. Other benefits are:
• Reduced lighting maintenance costs.
• Potential tax benefits for facility upgrade.
• Better overall lighting quality.
• Decreased environmental emissions.
• Enhanced worker productivity and comfort.
Often a retrofit allows for a reduction in the number of lighting
units based on the increased light output. Coupled with the longer life
of the units, the retrofit reduces maintenance costs because there are
fewer lamps to replace, they need replacement less frequently and less
labor is needed to replace them.
The Energy Policy Act of 2005 provides a tax deduction of up to
$0.60 per sq. ft. for lighting upgrades made by Dec. 31, 2008. Very
specific standards and procedures must be met to qualify for this
deduction and the total deduction, depends on the amount of energy
saved as defined by ASHRAE 90.1-2001. A 250,000-sq.-ft.
manufacturing plant that qualifies for the maximum benefit would
receive up to a $150,000 deduction. (For more information about the
specific requirements and assistance in meeting the program
guidelines, go to www.lightingtaxdeduction.org.) In addition to the
federal deductions many states and local jurisdictions offer tax
abatements or credits for energy efficiency upgrades.
The quality of the light received is equally important as the quantity
of light, especially when safety and employee morale are considered.
The light output of lamps is measured in lumens. Newer T8s maintain
their lumen strength longer than T12s, resulting in brighter lights and
fewer maintenance changes.
Reduced energy consumption reduces the emissions of greenhouse
gases. That’s an added benefit that doesn’t change your bottom line
but can impact your sustainability quotient.
Examples
EXIT Sign
A compact fluorescent lamp replacement
uses 25 percent less energy of the standard
incandescent; an LED EXIT sign uses less than
10 percent. This is a very simple example of the
differences in lighting technologies and how they
translate to savings.
cont. on page 11
3
FMA, TPA Seek Applicants for Industry Awards
Awards Program Honors Industry Success Stories.
FMA and TPA are seeking applicants for two industry awards. The The company also is an active member of its local community. It
FABRICATOR’s Industry Award 2009, presented by FMA, and TPJ’s contributes to several philanthropic activities, hosts open houses
Industry Award 2009, presented by TPA, are open to individuals or and plant tours, and offers an internship program with local
companies in the metal forming and fabricating industry or the tube vocational-technical schools. In addition, the Eastern Connecticut
and pipe fabricating and producing industry who have successfully Chamber of Commerce named Rob Marelli 2006 Entrepreneur
improved operations, attained business growth, and contributed to of the Year.
both the local and industry communities. About Lincoln Industries.
“Manufacturing has been the backbone of America, and we feel Lincoln Industries, formerly Lincoln Plating, has grown from a
it’s appropriate to honor the heroes of the industry by paying tribute small job shop in 1952 to a first-class manufacturing company for
to those individual leaders or companies that display innovation and the heavy truck, power sports, automotive and agriculture
determination to succeed,” said Gerald Shankel, president and industries. The company has been named to the Great Places to
CEO of FMA. Work® list for medium-sized companies for four consecutive years,
Winners will be recognized on the cover of the February 2009 issue an award presented to companies in America that develop successful
of The FABRICATOR®, and the cover of the January/February 2009 organizations with highly productive and satisfied people.
issue of TPJ-The Tube & Pipe Journal®, respectively, and will be The company also is known for its award-winning wellness
featured in a high-profile article in the respective issue. program, and was recognized in 2007 with an American
To apply, visit the FMA Web site at fmanet.org/IndustryAward. The Heart Association Platinum Award for being a Start! Fit-Friendly
application deadline is Sept. 5, 2008 at 5 p.m. E-mail completed workplace.
applications to randym@thefabricator.com. Each winner will be Through considerable research and development, the company
selected by an awards committee consisting of staff and members of designed an internal ceramic coating system that protects chrome
the FMA and TPA respectively, and will be honored at a 2009 FMA exhaust stacks from the high heat generated from the diesel
conference. Winners will be notified by Sept. 30, 2008. Please contact particulate filters need to meet the 2007 EPA regulation. At the
Randy Myers at 815-227-8255 for more information. time of development, no other supplier was able to provide exhaust
tubes which were chrome plated externally and ceramic coated
Meet the 2008 Winners internally in a high volume application.
Seconn Fabrication, a leading sheet metal fabricator based in Lincoln Industries is a sponsor of the “Dream It Do It”
Waterford, Conn., received The FABRICATOR’s Industry Award campaign that helps young people identify their passion and
2008 presented by FMA. Lincoln Industries, an engineering, provides them tools to find careers in manufacturing. The
assembly, packaging and logistics management company based in company also conducts frequent plant tours for elementary, high
Lincoln, Neb., received the TPJ – Tube and Pipe Journal Industry school and college classes, and supports numerous community
Award 2008 presented by TPA. activities and charities.
“This new award is designed to recognize those individual leaders
and companies that display innovation and determination to succeed,”
said Gerald Shankel, president and CEO of FMA, of which TPA is
a technology affiliate. “Manufacturing is the backbone of America
and we’re proud to honor Seconn and Lincoln as an industry success
story.”
Danny Forster, host of Extreme Engineering on the Discovery
Channel, presented the awards to Rob Marelli, president & CEO of
Seconn Fabrication, and Hank Orne, President of Lincoln Industries,
in a special ceremony on March 13 during the Metal Matters 2008
conference.
About Seconn Fabrication
Seconn Fabrication, a leading sheet metal fabricator based in
Waterford, Conn., has received The FABRICATOR’s Industry
Award 2008 presented by the Fabricators and Manufacturers
Association, International (FMA). The new FMA award is bestowed
upon an individual or company within the metal forming and
fabricating industry that has successfully improved operations,
attained business growth and contributed to both the local and
industry communities.
Established just four years ago, Seconn Fabrication has grown FMA President and CEO Gerald Shankel, “Build it Bigger” host
from a team of five employees in a 5,000-square foot facility to 66 Danny Forester, TPJ – Tube and Pipe Journal Industry Award 2008
employees in a custom-designed 35,000-square foot manufacturing winners Bill Hancock and Hank Orne from Lincoln Industries,
showcase. Gross annual sales have grown from $500,000 to more Editor Eric Lundin, and FMA Communications Publisher, Ed Youdell.
than $9 million.
4
 The FABRICATOR®'s
Industry Award 2009
presented by FMA

Picture Yourself as the 2009 FABRICATOR

Industry Award Winner
Think you have what it takes to be the winner of The winner will receive:
The FABRICATOR's Industry Award? Apply today at 1. Photo cover of the February 2009 issue of
www.fmanet.org/industryaward. Award entries must be The FABRICATOR.
received by Sept. 5, 2008, at 5 p.m.
2. High-profile editorial feature in the respective issue.
The award is open to any individual or any company 3. Award to be presented at a 2009 FMA conference.
within the metal forming and fabricating industry who
has successfully improved operations, attained business
growth, and contributes to both the local and industry
communities.
Certified Education Centers FMA Training at the
The Fabricators & Manufacturers Association, Intl., is striving to
build relationships between companies and their local colleges. We Convenience of Your Own Desk
understand the importance of creating that “pipeline” to breathe life
back into America’s industries. E-learning is rapidly growing as the education delivery format of
The following institutions have been recognized by the FMA to choice. Like no other training form, e-learning promises to provide a
have exemplary programs, facilities, and instruction. FMA’s CECs are single experience that accommodates different thinking and learning
engaged in a mission to interest today’s youth in pursuing careers in styles. FMA will soon have some of its most popular seminars available
the metal forming industry. As an educational institution, they are as on-demand modules students can complete at their own pace.
welcomed into the FMA family and offered free training by industry Interaction still remains a vital ingredient to learning, so FMA also
professionals, curriculum support, assistance in securing equipment, offers one-hour presentations that engage attendees. FMA FabCast
and a place on our website and publications. programs are Webcasts, a technology in which live presentations are
provided on a platform over the Internet for viewing, with audio from
Kirkwood Community College your telephone. FabCasts offer outstanding advantages over traditional
Cedar Rapids, IA instruction because they are:
www.kirkwood.cc.ia.us • Convenient - Participate in an FMA FabCast program from your
Moraine Park Technical College own desk or in a conference room. There is no need to be away
West Bend, WI from the office! There are three simple steps: log on, call in, and
www.morainepark.edu interact!
Rock Valley College • Comprehensive - FabCast programs are packed with vital in-
Rockford, IL dustry information. Learn how to implement business processes,
www.rockvalleycollege.edu develop staff, and receive information on the latest technologies.
• Cost-effective - Only $99 for FMA and TPA members! No
British Columbia Institute of Technology
travel expense is incurred since you don’t even need to leave your
Burnaby, BC, CAN
desk. Included in the fees are presentation materials provided for
www.bcit.ca
handouts and future reference. The number of staff who view the
Minuteman Regional Technical High School FabCast programs is unlimited. Simply register one person from
Lexington, MA your office and set up the computer in a conference room with a
www.minuteman.org speaker phone; everyone may receive the same information at the
College of DuPage same time.
Glen Ellyn, IL Upcoming FabCast topics include:
http://www.cod.edu/ Bringing Lean Manufacturing to Your
Press Brakes by Design -
Kalamazoo Valley Community College
July 16, 2008
Kalamazoo, MI
10 Steps for Increasing the Fabricator’s Cash Flow - Aug. 12, 2008
http://www.kvcc.edu/
Budgets and Metrics in the Fab Shop: They Need Not Be ‘Four-Letter’
Louisiana Technical College Words’ - Oct. 21, 2008
Greater Acadiana, LA
http://www.greateracadianaregion.net All programs are from 10 – 11:30 a.m. CDT. See the full calendar
at fmanet.org/FabCasts/FMA-FabCasts-Calendar.cfm.
Renton Technical College
Renton, WA Want to suggest a topic for future FabCast programs? Interested in
http://www.rtc.edu/ presenting? We encourage you to keep us informed of your
Lincoln Educational Services educational needs. Contact Jacob Peterson at jacobp@fmanet.org or
Grand Prairie, TX 815-227-8209 for more details.
http://www.lincolnedu.com/
Illinois Central College
East Peoria, IL
http://www.icc.edu/
Thomas Nelson Community College
Hampton, VA
http://www.tncc.edu/
Manufacturing Technology Academy
Traverse Bay, MI
http://www.mta.tc
If you believe your local college merits recognition with its work
in the community and is preparing students for success in the metal
forming industries, please contact the Fabricators & Manufacturers
Association, Intl., to recommend the college as a Certified Education
Center! E-mail info@fmanet.org or call 888-394-4362.

6
ALAW Laser Conference
2008—Celebrating 16 Years of
Education in Lasers!
In its 16th year, ALAW 2008 continues to be the premier North
American industrial laser industry event. Over 200 attendees convened
in Plymouth (Detroit), Mich., during the week of May 12th to hear
from the automotive industry and suppliers during the Automotive
and Body-in-White Tracks, and to learn from the popular case
studies presented by job shop and OEMs during the Fabricators Track.
Automotive manufacturers and Tier 1 and 2 suppliers from the global
automotive industry delivered presentations on laser processing for
automotive components; diode, fiber, and disk laser applications for
welding and cutting; and how lasers are being used worldwide in the
automotive industry.
In addition to the presentations, attendees visited 25 vendor
exhibits, which included a body-in-white frame (Ford Focus®)
displayed by the Tailored Steel Product Alliance (TSPA),
pictured below.
Attendees were also invited to network during two open houses
hosted by Fraunhofer and TRUMPF Laser, as well as a reception
hosted by IPG Photonics. New this year to ALAW was a golf outing,
with 20 players. The golfers enjoyed a sunny day on the beautiful
Luke and Matthew courses at the Inn at St. John’s.
In summary, ALAW encompasses state-of-the-art laser processes for
manufacturers and job shops, as well as automotive manufacturers and
their suppliers. For manufacturing and job shop facilities, this
conference offers a fundamental understanding of laser technology,
current applications, and practical solutions to problems.
Save the dates for next year!
The ALAW Laser Conference is scheduled May 11-14, 2009,
at the Inn at St. John’s Conference Center, Plymouth, Mich.
Visit alawlaser.org or contact Jen Christian at jen@alawlaser.org
for more details.
Hands-On Fundamentals of
Tube and Pipe Fabricating
Attendees got up close and personal with machines at TPA’s
Fundamentals of Tube and Pipe Fabricating session June 4.
T-DRILL Industries Inc. in Norcross, Ga., opened its doors to
host 15 attendees for the program that featured five industry
experts who had the opportunity to enhance their presentations
with equipment demonstrations.
John Hodges of T-DRILL kicked the program off by highlighting
various cutting and end finishing processes. A lively discussion gave
attendees the opportunity to explore the advantages and disadvantages
of methods they currently use while also learning about alternatives.
Hodges then took attendees to T-DRILL’s shop floor to demonstrate
the processes.
Greg Miller of Tubular Solutions Inc. and Eric Stange of Tools for
Bending Inc. covered tube bending and bending tooling. There are
many factors involved in selecting and implementing tube bending
solutions and the process can be difficult. Miller used case studies to
enhance attendee’s ability to successfully coordinate a tube fabrication
project from start to finish.
Stange went on to describe the interaction of tooling during the
bending process, explaining how features, design considerations, and
techniques affect the process. Maruka USA provided the tube bender
for use during the demonstrations.
Walter Sperko of Sperko Engineering Inc. provided attendees
excellent insight on common welding processes used for welding tube
and discussed special situations, such as welded coated steels, welding
fumes, and the basics of OSHA.
To finish the day, Robert Dean of Aristo Machines Inc. brought in
various parts for attendees to view, helping them identify basic tube
end forming methods. He explored the advantages and disadvantages
of various methods and gave attendees sources to gain more insight
and information on each method.
Attendees were able to interact with each instructor as well as with
each other, network to get specific questions answered, and receive
solutions to their individual challenges.
If you missed this program or are looking for other tube and pipe
sessions, don’t miss TPA’s upcoming Tube & Pipe Fabricating and
Producing Conference and Roundtable September 9-10 at the Hyatt
on Capitol Square in Columbus, Ohio.
This dual-track program will feature six sessions and two interactive
roundtable discussions for each technology–fabricating and
producing. Don’t miss this conference! For more information go to
tpatube.org and click on Education.
Charles Parham of
Maruka USA
demonstrates tube
bending processes to
attendees Tony Altman
and Toby Allen.
7
Main Steel’s Tribute Gift Expresses Founder’s Attitude
Thomas Andrew Mallan, founder of
Main Steel Polishing Co., inspired employees
and friends with his positive outlook.
When toll processing powerhouse Main Steel Polishing Co. lost its
revered founder, Thomas Mallan, to a long illness last summer, they
wanted to give him a memorial tribute of consequence.
“Instead of flowers, the company wanted to do something lasting,
something that had an impact,” said CEO Tom Connell.
So Connell put out the word and 22 employees, associates, and
friends contributed. Over the next several months, the company
presented the Fabricators & Manufacturers Association Foundation
with a total of $7,500 to benefit its scholarship fund.
Connell, who started working with Mallan in 1977 and joined his
company in 1981, added, “As well as our originator and chairman of
the board, Tom was my best friend. Over the years I watched him strive
not only to succeed, but to raise the standard in metal processing as
well. Now some young person preparing for a role in the industry will
be helped toward the goal. I know Tom would have liked that.”
And, Connell added, if we were looking for an inspiring example of
cheerful perseverance, we’d find it in Linda Mallan. Throughout her
husband’s difficult final years, she never flagged, taking the two of them
on trips to Alaska and Europe despite the challenges travel posed.
“As long as they had a wheelchair and oxygen, she kept him
experiencing all life had to offer,” Connell said. “She didn’t believe
in sitting at home.”
When thanked for her generosity to the Foundation, Linda said,
“I’m delighted we’re able to make a difference. Tom always valued
education, although he never finished college. He started at the
University of Massachusetts, but after a year-and-a-half, his father died
and he had to quit. So he was self-taught, and luckily, he was intuitive
and had a mechanical mind, and he was able to go far with that.”
Far, indeed. Although his company started with just one sheet
polisher, Tom’s leadership and forward thinking moved Main Steel
from a single location to the company’s position today as the largest
independent toll processor in North America, with 10 facilities. In
2006, the company celebrated its 50th anniversary.
Linda continued, “Tom really valued practical education, and it
seems like that isn’t taught much anymore. Manufacturing is an
important part of our economy, but every kid wants to be a
stockbroker. Well, without manufacturing—without farming, or
roofing, or mining, or plumbing—there’s nowhere for stockbrokers
to do their thing, is there?”
She makes a good point. Research shows that as baby boomers in the
skilled work force retire, they are not being replaced—at least not in
the numbers U.S. industry requires. (For a white paper on the coming
work force crisis, go to http://www.fmanet.org/White-Paper-Request.
cfm.) In response to this shortage, the Fabricators & Manufacturers
Association Foundation is heavily involved in interesting today’s youths
in manufacturing careers and furthering their studies.
8
“The FMA Foundation was a good fit for us, because its mission
is in line with Tom’s interests,” Linda concluded. “He was really
enthused about machinery. We had a boat, and he loved that boat—
but not because he could fish off the back of it. It was because of
its mechanics!”
Similarly minded students—146 to be exact—sent scholarship
applications to the FMA Foundation this spring. Two of them will
begin classes in engineering or another manufacturing-related course
of study in the fall compliments of Main Steel’s generous tribute gift.
Watch these pages for a follow-up story on the scholarship
recipients. Discover the many ways to include the FMA
Foundation in your charitable giving plans at fma-foundation.org
or call 888-394-4362.
FMA Foundation’s New Staffer
at Your Service
Meet Nathan Ruby,
FMA Foundation’s new
Major Gifts Manager.
Nathan’s background makes him uniquely qualified to guide donors
through the steps of making a truly fulfilling corporate or individual
gift to the FMA Foundation—and to do so in a way that brings value
to the donor and is transformational to the metal fabrication industry.
Nathan earned a B.S. degree in History from Bradley University
before working for Lutheran Brotherhood and several nonprofit
organizations—including Lutheran Senior Ministries, Evangelical
Lutheran Church in America Foundation, and Home Sweet Home
Ministries—in the areas of development and planned giving.
Nathan lives in Dunlap, Ill., with his wife and three children. Please
contact him at nathanr@fmanet.org or 309-360-4983 for assistance
with your charitable gift to the Foundation—and be a hero in your
industry! The FMA Foundation introduces youth to manufacturing
careers through grants to help fund manufacturing summer camps for
middle-schoolers across North America. To students enrolled in
engineering and other manufacturing-related schooling at trade
schools, colleges, and universities, the Foundation awards scholarships
of up to $5,000 per year. More at fma-foundation.org.
Q: I need the names of tube producers in Central or South America who can make
tubing that can be used in the food and beverage industries. Can you help me?
A: Yes. There are several ways to find tube producers throughout
the world. The first place to look is our own Who’s Who on
fmanet.org. Anyone can search for association members who produce
tubes of various sizes and material. A quick search for stainless steel
tube producers found 17 companies, but none of them are in Central
or South America.
Another search on the Tube and Pipe Producers Buyers’ Guide on
thefabricator.com yielded 37 manufacturers of stainless steel
tubing. None of these companies, however, is in the geographic area
that you mentioned.
Next a search on a software package that the library purchased,
Simdex Steel Tube Manufacturers Worldwide Guide, was searched
by application. Searches also can be done by geographic area
(see Figure 1).
This search produced five companies, one in Argentina, three in
Brazil, and one in Mexico. I will send you contact information and a
brief description of each company’s capabilities.
Figure 1
RAC receives many requests like this one. To help answer these
questions, the library utilizes the Simdex database. It includes over
1,200 tube and pipe manufacturers from more than 90 countries,
and it is searchable by application, size, shape, material,
manufacturing process, and company name.
The database is just one of many research sources the Research
Center can use to answer members’ requests. Members can contact
the Research Center by calling 815-399-8700 or e-mailing
researchassistance@fmanet.org.
As a member, you have access to the largest and most extensive library devoted to
the metal forming and fabricating industry—a benefit reserved exclusively for
members. FMA’s Research Assistance Center is the most efficient source for the
information you need to optimize your operation. Advantage and AdvantagePlus
Members enjoy unlimited FREE research, while Basic Members receive one hour
of FREE research assistance per month. Get your research questions answered
when you call the Research Assistance Center at 1-815-399-8700 or
e-mail researchassistance@fmanet.org.
9
Safety Award Winners Finding Skilled Employees Has Just Gotten Easier
Finding skilled employees is one of the top concerns in the
Congratulations to the following Advantage and industry. To address this problem, FMA encourages you to use its
AdvantagePlus member companies that made safety a Job Board to help simplify the hiring process.
priority in 2007! Some recent enhancements include:
• All jobs posted directly through FMA’s site will go to the top
Most Improved Merit Award of the list and have an FMA logo next to their ad for greater
Welfab Inc. Anderson & Dahlen Inc.
visibility.
N. Billerica, MA Ramsey, MN
• Job seekers now can search by keyword, location, or job type.
Note to job posters: Use key-words within your job posting
Honor Award Clarion Metals
that job seekers would type in the search.
AK Tube LLC Covington, GA
Columbus, IN Visit fmanet.org/JobBoard to post jobs today.
Main Steel Polishing Co. Inc.
B. Walter & Company Inc. Dallas, TX Exclusive Member Access to Safety.BLR.com
Wabash, IN FMA is pleased to announce a new Advantage-level member
Mayflower Vehicle Systems benefit that allows access to more than 90 safety-related
FMT Inc. Inc. subject areas offered at Safety.BLR.com. The site includes
Findlay, OH Shadyside, OH customizable and downloadable training tools (in English and
Spanish), regulatory analyses, daily regulatory updates,
Great Lakes Contracting Inc. Wichita Steel Fabricators best-practice case studies, safety e-newsletters, and articles
Milwaukee, WI Wichita, KS written by BLR’s staff of safety professionals.
“The site is an excellent tool for our safety committee,” said
Main Steel Polishing Co. Inc. Honorable Mention Nora Eberl, human resource officer at Buffalo, N.Y-based Eberl
Tinton Falls, NJ Main Steel Polishing Co. Inc. Iron Works, Inc. We have printed posters to post in our plant
Commerce, CA and distributed the safety newsletters to employees. It’s a great
resource and timesaver.”
Main Steel Polishing Co.
Inc.— To check out this benefit, log on to Members Only at fmanet.org
Manokin Street Read a sample from safety.BLR.com below.
Baltimore, MD

Main Steel Polishing Co.

Inc.—
Boyle Street
Baltimore, MD Safety Pros Share Ideas for Observing National Safety Month
Members of the Safety Forum at Safety.BLR.
McAbee Construction Inc.
com have been sharing ideas for fun programs and
Tuscaloosa, AL
activities they can conduct during National Safety
Month, which the National Safety Council observed
Nisshin Automotive Tubing in June.
LLC
Versailles, KY The discussion thread on National Safety Month
has become one of the most active since BLR
launched the Safety Forum in March.
Nova Group Inc.
Napa, CA One safety professional’s company held a different
safety-related contest for each week of the month. In
one week, the company held a contest in which em-
Welfab Inc. ployees had to find hidden safety items in a picture.
N. Billerica, MA The company hired an artist to create the picture.
The company also held an electronic scavenger hunt
in which employees had to find the answers to safety
questions on the Internet.
Another company used scratch tickets as a fun
way to prompt workers to think about safety.
The tickets contained safety-related questions and
employees had to scratch off the correct answer. If
they answered correctly, they became eligible for a
drawing and could win an instant prize.
One forum member suggested safety jeopardy or
safety poker as possibilities. Another member said
he tried safety poker last year but that it wasn’t a
good fit for his organization because of its size (700
employees).
Another contributor to the forum created an
activity in which employees separated into teams to
investigate a mock accident scene. The teams had to
determine what caused the injury and describe how
it could have been prevented.
This article and many more can be found at
Safety.BLR.com. For more ideas, visit the Safety
Forum and the National Safety Month Resource
Center.

10
Lighting Retrofits 101 cont.
Upgrade of Production Floor, Warehouse Lighting Fixtures
The size of the entire complex was 245,000
sq. ft. The goals were to maintain the existing
amount of light, reduce energy consumption,
and achieve a tax deduction. Existing
annual energy costs were almost $340,000.
No changes were made to the height of the
lights. The entire retrofit cost was $240,000.
The amount of light per lamp increased by
almost 100 percent, meaning that each lamp
produced more light per unit of energy it consumed. At an average
electricity cost of $0.085 per kilowatt-hour, total annual energy
savings equaled $128,000, or 38 percent. Additionally, the company
met the tax deduction standards and therefore received the maximum
$0.60 per sq. ft. This resulted in a deduction of $147,000.
Where to Go From Here?
How do you know if you should explore a lighting retrofit? First,
determine the last time the lights were upgraded. If it’s been longer
than seven years, there is a good chance that new technology can offer
significant savings. Then, determine the number of hours per day the
lights are on in your facility. Multiply that number by 250 (for a five
day operation) or 365 for a full-time operation. This defines your
“burning hours”. Facilities with annual burn hours of 3,000 or more
are likely retrofit candidates. Determine what lighting fixtures and
lamps you currently have.
The next step is to conduct a lighting audit. The cost for this service
ranges from free to 3.5 cents per sq. ft. Often the lighting auditor will
build this cost into the entire project if you decide to move forward.
Local electricians are often versed in lighting audits and retrofits, but
you might want to speak to a lighting expert. Most lighting
manufacturers – General Electric, Philips, Sylvania – have experts
on staff to help you make some determinations. Some local electric
utilities help customers reduce usage and can provide information
regarding lighting. (For a list of and information about manufacturers,
distributors, designers, and service firms that participate in the lighting
industry, go to lighting.com.)
As business owners and managers, we have the responsibility to all
of our constituencies – employees, owners, customers – to be
cost-efficient, productive, and a sustainable part of the community.
Energy-efficient lighting systems can help us achieve these goals.
Kathy Kiernan is senior vice president with Affiliated Power
Purchasers Intl (APPI). APPI is the endorsed energy consultant for
FMA and TPA. For more information on APPI, visit appienergy.com.
11
Connections
member newsletter
july/august 2008

Connections Staff
Editor
Kimberly Pollard
kimp@fmanet.org
Contributing Writers
D’Ann Hamilton, Dena Mattausch
Member Services & Research Director
Nancy Olson
Membership Operations &
Customer Service Manager
Jill Klug
Graphic Designer
Sarah Currie

Contact us
Customer service: 888-394-4362 or
815-399-8775
Fax: 815-381-1371
FMA e-mail: info@fmanet.org
FMA Website: www.fmanet.org
TPA e-mail: info@tpatube.org
TPA Website: www.tpatube.org
FMA Connections is
published bimonthly by:
Fabricators & Manufacturers Associa-
tion, International®
Tube & Pipe Association, International®
833 Featherstone Rd.
Rockford, IL 61107-6302 USA