KLH - Positioning for Success

Positioning for success, then and now

As the economy recovers, KLH is better positioned for development

For much of the early years, KLH Industries, Inc. experienced effortless growth. Riding the wave of a new, exciting technology known as Wire EDM, customer's sought out KLH for their quality and expertise. Despite being powered entirely by word of mouth, KLH was well positioned for success.

Retrospectively, KLH Industries was as lucky as it was good. Erratic, unplanned growth is often the fastest way out of an industry.

In the modern days of KLH, measuring, planning, and preparing for growth is a primary focus. Not simply the need for growth, but for the need for consistent, stable growth.

Positioning for success allowed KLH to survive a sharp economic downturn in 2009, while remaining fully operational and profitable throughout. In the midst of a historic recession, sales dropped to their lowest in six years, yet KLH was eager, willing, but certainty not waiting. KLH has been strategically increasing manufacturing output, growing personnel, and improving quality systems.

Upgrades began in April 2009, when KLH purchased a CMM vision system for non-contact inspection. Parts which cannot be inspected with probe heads, such as certain rubbers, could now be inspected with repeatable measurements within 0.0001" (with variation).

Over the next several months, every KLH employee received 80-hours of Lean training, totaling in excess of 2,300 hours. A substantial investment for a small business, however, a necessary step for future growth.

To satisfy a demand for more, larger turning projects, KLH purchased a Puma 480L (PDF) in early 2010. In addition, two new personnel were hired to keep the spindle turning.

In an effort to become both lean and green, the Waterjet department installed water filtration system to create a closed loop cutting system. The system, designed by Ebbco Inc., slashes water consumption by 2,300 gallon per day (90%), and is expected to double the life of consumables.

Another department to see significant equipment improvements, is also historically the newest department. While KLH has offered Dimensional Inspection services for years, adding a second CMM in July 2010 gives KLH enough throughput in the quality lab to avoid bottlenecks between internal and external inspections.

A year and a half of upgrades culminated in July 2010, when KLH achieved AS9100 certification (PDF). Situated with the proper staff, equipment, and manufacturing structure, KLH is ready to tackle the challenges of the aircraft and aerospace industry.

Over two decades later, customers still seek KLH for their quality and expertise. New machines with additional personnel, but still whistling an old tune, as a company well positioned for success.

Project GRILL - Cooking up Careers

Project GRILL cooks up careers

Project GRILL a sizzling success for WI high schools

Some competitors win medals, while others boast trophies. If you're a participant in Project GRILL, you eat brats.

That's because Project GRILL (Growing Readiness in Learning and Leading) challenges high school students to design, manufacture, and assemble a custom charcoal grill. The only condition is that the grills cook a dozen brats in one hour.

Teams are not alone, though, each is paired with an area manufacturing partner. As an Engineering Sponsor, KLH Industries, Inc. provided Waterjet Cutting services for the 2008-09 Kewaskum High School Project GRILL team, who unveiled their grill this past spring.

Manufacturing sponsors introduce high school students to the same software and technologies that they use everyday. Of course, these budding relationships are no coincidence.

Project Grill program stems from the initiative of manufacturing companies in 2007-08. These Sheboygan County manufacturers - including Johnsonville Sausage and Sargento Cheese - sought to familiarize students with potential careers by making manufacturing challenging, creative, and cool.

It worked.

Only a year later, the Fond du Lac Area Association of Commerce seized the opportunity to bring a regional chapter to their area.

With the support of Sheboygan County, Moraine Park Technical College, and a new batch of partnering manufacturers, the Association of Commerce launched an inaugural Project GRILL competition for the 2008-09 school year.

According to their website, Fond du Lac Area Association of Commerce President Joe Reitemeier believes programs like Project GRILL are vital to manufacturing sustainability in the area:

[Project] GRILL is one example of what this community needs to do to start solving the critical labor shortage of the future. Our recent survey showed that retirements and other factors are going to hit our county labor pool hard. We have to work together find creative ways to retain the talent in our schools and direct that talent to our business community.

As a further incentive for students in the Fond du Lac program, Project GRILL is also worth three credits at Moraine Park Technical College.

Project GRILL puts students into tactile, real-world situations full of both success and failure. Students not only assemble a grill, but also a toolbox of important manufacturing skills: teamwork, self-confidence, leadership, problem-solving, professionalism, and communication (to name a few).

Perhaps the most satisfying lesson, though, is that hard-work is rewarding. It seems only fitting then, that if you're a participant in Project GRILL, you eat brats.

For more information on the Fond du Lac area program, visit their Project GRILL homepage, or for Sheboygan County, visit ProjectGRILL.org.

KLH: Frequently Asked Questions

Frequently Asked Questions

How long has KLH Industries been in business?

KLH Industries, Inc. has been on the cutting edge of manufacturing since 1987 - over 21 years. While originally only a Wire EDM shop, continuous and stable growth has allowed KLH to double its square footage four times in the company's history. Over the past two decades, KLH has executed a commitment to excellence and improvement that turned a one-room shop into a one-stop shop.

What is your primary specialty?

Everything, honestly. KLH takes pride in being a full-service shop, capable of engineering and manufacturing a one-time prototype into a high volume finished product. Encompassing decades of experience, our staff of engineers, machinists, sales & marketing and customer service professionals provide on-time precision parts through four business units. Click on the respective links below to learn more about In-house manufacturing processes that we specialize in: EDM (Wire, Sinker and Micro Hole), Multi-Axis Machining (CNC), Waterjet Cutting and Certified Inspection Services. We also contain precision grinding, sawing, drilling and machining capabilities all in addition to a certified and measured supply chain.

So, my job won't ever leave your building? Don't you ever use outside vendors?

Occasionally, as part of KLH's measured supply chain. KLH only uses accredited vendors who maintain consistent levels of excellence in quality, delivery, and price - the same things our customer's value.

What industry markets or sectors do you serve?

We supply a variety of critical industries, including Aerospace, Defense, Energy, Medical, Aviation, Automotive and Food Processing, offering value added solutions to even the most problematic applications.

Can you accommodate rush jobs?

When our customers demand it the answer is Yes. Depending upon the part and processes, it may be possible to have same-day or next-day service.

What kind of experience do your employees have?

KLH employees are industry professionals trained in up-to-date manufacturing methodology. KLH strongly encourages its employees to invest in continuous education, both on the job and in the classroom.

What is your facility like?

Visitors to the KLH facility often describe it as "one of the cleanest, most organized shops" they've ever seen. This is, in part, due to embracing Next-Generation Manufacturing (NGM) principles, such as Lean, 6-Sigma, and 5S. KLH has recently been toured by high profile customers, magazine editors and high schools.