KLH Industries, Inc.

KLH - Positioning for Success

2010-10-28T14:16:00.000-07:00

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

2009-11-04T11:40:00.000-08:00

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

2009-07-17T12:28:00.000-07:00

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.

Service Spotlight: EDM Department

2009-07-09T07:10:00.000-07:00

Service Spotlight: EDM Department
Machining to your unique specifications

KLH Industries, Inc. has remained a pioneer of EDM technology for the past 21 years. Our machines in the wire EDM (WEDM) department are capable of working within +/- 0.00005” tolerances and handling parts up to 5 tons or over 2 ft tall.

In fact, according to Mitsubishi EDM, KLH houses “the tallest work piece capacity of any fully-submerged wire EDM on the market.” Submersing a part balances thermal levels within the tank, which allows for reliable accuracy and faster cutting times.

KLH’s large capacity WEDM machines are ideal for high-tolerance machining, such as: turbine disks found in the aerospace industry, MRI/X-Ray equipment in the medical industry, and gear box/brake parts for the wind energy industry. Whether prototypes, one part, or high-production runs, KLH has a WEDM machine to match your requirements, and exceed your expectations.

WIRE EDM:
• Maintains tolerances to +/-0.00005
• Taper angles to 45º with accuracy to three seconds
• Latest power supply technology (including Anti-Electrolysis)
• Auto threading and submersible
• 10 RMS or higher
• Fully production capable
• Wire diameter from 0.002” to 0.014”

MICRO HOLE EDM DRILLING:
• Performs difficult drilling tasks
• CNC programmable
• High repeat accuracy
• 0.004” to 0.125” diameter electrodes
• Drill depths 300 times the diameter
• Reduces risk of broken drills
• Reduces cost
• Eliminates costly machinery
• Full production capable

SINKER EDM:
• High repeat accuracy
• Surface finishes to 32RMS and higher
• Experience with an array of exotic materials including Carbide
• Full production capable
• C-axis capable for complex burns
• CNC programmable
• Eliminates costly machining of intricate details
• Equipped with tool-changer to maximize run time efficiency

Manufacturing Upswing Predicted for 2010

2009-07-09T07:06:00.000-07:00

Manufacturing upswing predicted for 2010
Trade association predicts moderate rebound for some industries

According to “Manufacturing upswing predicted for 2010” by Rick Barrett of the Milwaukee-Wisconsin Journal Sentinel, analysts believe the manufacturing recession may soon be bottoming out. This cautious call for optimism comes from a new report published by the Manufacturers Alliance/MAPI, a Virginia-based trade association. Even still, analysts believe a sustained rebound is still in the distance.

According to Barrett, these sentiments echo the experiences of Tim Hanley, vice chairman for Deloitte & Touche, a Milwaukee-based accounting firm.

“Most of the companies I am talking to are looking to 2010 to begin to come back. Most of the estimates of the comeback are moderate increases, but nonetheless they are increases and start to give companies a basis to build from,” Hanley said.

The government announced that in April, “orders increased 1.9%, more than four times the 0.4% increase that has been expected.”

Quality Assurance Update

2009-05-27T10:34:00.001-07:00

Service Spotlight: Quality Assurance

Where no detail is too small (almost literally)

Quality cannot be inspected into something.
For a lot of shops, a visit to the Quality Lab is usually the last step of the manufacturing process, however, it is actually the last place you'd want to find non-conformances.

If a part is manufactured out of tolerance, it can be inspected until the gages are worn through, and in the end, the part will still be out of tolerance. Therefore, the Quality Assurance systems at KLH Industries, Inc. begin long before the manufacturing of your part, project, or program begins. While creating the job routing for your project, a team of Quality Assurance personnel and project managers layout the who, what, when where & how the in-process inspection is to take place.

That does not, however, preclude the need for a quality lab outfitted with the finest equipment. Things such as; first piece inspection, verification of in-process inspection, sample inspection of internal and incoming product, gage R & R tests and 100% final inspection requirements (typically Aerospace) all demand a Quality Lab.

Within KLH's temperature and humidity-controlled Quality Lab (seen above), the phrase "splitting hairs" simply does not exist.

Whereas the idiom "splitting hairs" refers to a unnecessary, and often exaggerated attention to details, in the Quality Lab the thickness of a hair can be the difference between a correct piece and a piece of scrap.

Even still, a single strand of human hair is, on average, 0.004" thick, and would have to be split in half six times before matching the accuracy of KLH's Brown & Sharpe Global Advantage 9158 Coordinate Measuring Machine (CMM) - volumetrically accurate to 0.000035".

According to the Brown & Sharpe website, the Global Advantage system "is the most advanced package available today," as it can "handle any measurement and inspection task quickly and efficiently."

Not all parts, however, can be inspected via contact probes. Some parts are too small or too soft for contact measuring, and instead KLH utilizes a non-contact Tesa-Visio 300 CNC PC-DMIS Measurement System to provide accurate, repeatable measurements within 0.0001" with variation.

Both the Tesa-Visio and Brown & Sharpe CMM feature the PC-DMIS CAD++ software, which allows KLH to import and use solid model files - reducing programming time and eliminating the need for double entry.

Together, these two extraordinary inspection machines, along with the standard Quality Assurance equipment, give KLH the ability to meet your company’s most stringent quality requirements.

Quality Assurance goes beyond inspection. It permeates every aspect of the business. Documented and certified ISO 9001:2000 systems assure you that KLH will meet all your requirements.

KLH is currently accepting quotes for contract inspection services, capability studies, and/or reverse engineering. For pictures of the Quality Lab and technologies, visit the Quality Assurance photo album.

KLH Industries, Inc. Announcing Wind Power Manufacturing Capabilities

2009-05-06T13:05:00.001-07:00

KLH Industries, Inc.
Wind Power Capabilities

Manufacturing Tomorrow's Energy

Wind power is considered to be one of the country’s largest sources of new power generation. According to the American Wind Energy Association, in 2008, wind power provided 42% of all the new generating capacity added in the U.S. Just 4 years earlier wind power added only 2% of new capacity.

KLH Industries, Inc. recognizes the need for sustainability and the demand for alternative energy. KLH has been manufacturing parts and components for some of the nations top energy companies for years and have added value and eliminated waste for numerous projects around the globe.

KLH specializes in manufacturing parts to print including shafts, break components, yaw drive components, gear box parts and controller components. Capabilities allowing KLH to manufacture these parts include Multi-Axis Turning/Milling, CNC Drilling, Documented Inspection Services, Reverse Engineering, Micro Hole EDM Drilling, Waterjet Cutting, Wire EDM, CNC Sinker EDM, CMM Inspection, CNC Boring, International Business Familiarity and Prototyping.

KLH has been involved with Lean Manufacturing for years and is ISO 9001:2000 registered. For more information or to inquire about development, engineering or manufacturing of parts and/or components please contact Matt Stefanski (262) 253-4990 or by email mstefanski@klhindustries.com. KLH is now accepting RFQs for turbine parts and components.

KLH unveils Technical Research and Education Program

2009-04-16T10:57:00.000-07:00

KLH unveils TREP Program

by Matt Stefanski & Kevin Heins

In order to better assist secondary education programs and projects, KLH Industries, Inc. is proud to launch the Technical Research and Education Program (TREP).

KLH recognizes the impact secondary education research has on specialized projects and development. These research projects, engineering programs, product developments, and public service projects are often relied upon to provide tomorrow's solutions. Higher education facilities have been long standing members of some of the nation's most highly classified, complex engineering solutions.

The TREP Program is designed to further relationships with engineering colleges, technical schools, and national laboratories in order to provide valuable machined parts and engineering expertise.

The goal of the TREP Program is to provide higher education facilities with the finest parts available, while simultaneously saving valuable time and money for educational programs.
Often times, experience across multiple industry sectors turns into cost and/or time saving solutions for educational programs. KLH has routine experience with OEMs in the Aerospace, Medical, Defense, Energy, Automotive, Electronic, and Food Processing sectors. Of course, each sector has unique specifications and requirements.

For example, some Medical components have fine finishes that prevent contact inspection. Instead, KLH utilizes a non-contact Tesa Visio system - accurate to +/-0.0001" - that uses light to measure critical dimensional requirements.

KLH is fortunate to have already manufactured precision parts for colleges and universities across the nation, including:

• Purdue University
• Michigan University
• Northern Michigan University
• Milwaukee School of Engineering

As an ISO 9001:2000 registered company, KLH constantly monitors both internal and external work, ensuring that our customers receive the most precise, cost-effective, and controlled parts available.

Trust and respect are always required for a successful working relationship, and as a result, KLH is always compliant with strict confidentiality agreements.

KLH understands the importance of specialized research projects and would like to make available any/all of our capabilities to assist along the way of your next project.

Click here for more information about KLH's Technical Research and Education Program, or contact Matt Stefanski at (800) 294-8363 x 252 or mstefanski@klhindustries.com.

BotsIQ "Challenges" Students

2009-04-10T10:48:00.000-07:00

BotsIQ "challenges" students
by Kevin Heins

Using robotics education as a foundation for manufacturing careers
Student-participants of the BotsIQ Robotics Education Program might think the BotsIQ Challenge is destruction - to design and build a robot capable of denting, slashing, scratching, and gashing.

When two robots are removed of their safety restraints and unleashed inside a reinforced arena, it's certainly easy to get that impression.

Following the July 2008 competition at the Washington County Fair, Journal Sentinel writer Don Behm noted that, inside the arena, the 15 pound mechanical robots seemed more like gladiators:
And spectators cheered like Romans when Up Chuck, armed with a spinning bar and built by Slinger High School students, systematically destroyed Black Widow IV, an entry from Germantown High School...Up Chuck's steel bar lifted its opponent off the arena floor as the audience of 50 or so howled approval. (click here to watch this match)

During a BotsIQ match, two robots participate in a head-to-head competition to outscore - and not necessarily destroy - each other. Students participate in an educational, engaging, and competitive environment with safety and operational limitations.

Regardless of the outcome, though, there is more to a BotsIQ competition than victory or defeat; students are able to nurture the core-principles of an advanced manufacturing career.

The true BotsIQ Challenge is not destruction at all, but construction (if not cleverly disguised). The construction of a multi-dimensional skill set, featuring mathematics, engineering, mechanics, teamwork, project management, and even public speaking.

According to the BotsIQ handout documentation, the official mission of BotsIQ is to "revitalize and promote scientific and technical education in middle schools, high schools, and post secondary institutions through robotics."

It makes perfect sense, then, that chief supporters of the Wisconsin chapter are area businesses, technical colleges, and manufacturing organizations.

BotsIQ gives students the opportunity to learn and develop apprenticeship level skills before students are age-eligible to do so. Employers are discovering that participants of the BotsIQ program are more prepared to contribute.

"I need employees with hydraulic and electronic aptitude or experience," says shop-owner Bill Gilbert, "I hired my last employee solely because he listed BotsIQ Club on his resume. He is working out great."

BotsIQ is nonprofit, national program inspired by the television series BattleBots®. The next BotsIQ Wisconsin competition will be held on April 4 at Discovery World, from 11:00 am until 6:00 pm.

The event is free to the public with discounted ($5.00) parking, and will be located inside of Discovery World's Innovation Theatre (simulcast in the Digital Theatre), a stadium-seated amphitheatre strangely reminiscent of a coliseum.

To see pictures of previous BotsIQ bots and competitions, click here.

SEO for Small Businesses

2009-04-10T10:45:00.000-07:00

Making SEO Work For Your Small Business
By Matt Stefanski

How do you know if you’re visible to others if you can’t see yourself? That’s the challenge for some of manufacturing’s smaller businesses in today’s world.

Many small businesses are attempting new marketing strategies on a daily basis. It used to be a panic to be found on the front pages of Google through whatever means possible. Companies have since enforced the ideas of Search Engine Optimization (SEO) for increasing their business’s internet brand recognition.

Let’s first define SEO. SEO simply translates to increasing and, more importantly, improving website traffic from search engines through organic search results. It looks at how and why search engines find your site and how relevant the search term is to your global content.

The recent economic scare has led some manufacturing companies to believe that additional expenditures for marketing campaigns and SEO in a downturn economy can be a waste. With the right tools and a lot of patience, however, SEO can play an important role of allowing your small business to be seen on the front pages of popular search engines just like the big players at a cost that is reasonable, considering the potential return.

Take KLH Industries, Inc. for example. KLH is a precision manufacturing company in Germantown, WI. Last summer KLH was organically listed on Google a handful of times, depending on the search term. Even though KLH does not generally have a product to sell, they have to focus on selling a service. The services they provide are not, by any means, typical. They manufacture critical parts and components for Aerospace, Medical, Energy, Automotive and Electronic equipment manufacturers. With a limited budget and facing a downturn economy, SEO became a cost effective way to put their services and capabilities in front of potential customers on a much larger scale and, for KLH, has proven to be very effective.

One important aspect that you must understand about SEO is that it does not happen overnight. If you already have a website, that’s a start but SEO primarily focuses on content. I stress the word content because that is the best way to gain search engine ranking through organic search. While writing content for your website, keep your customers in mind. Make sure the information is not too technical, simplistic or wordy. Keywords play one of the largest roles in SEO and it is up to you as to how you label your products or services so that search engines can find relevance to your site rather than your competitors.

Asking questions and evaluating answers are key measures to find which methods work for your business type but, again, don’t expect this to happen right away. Like any business model you have to put something into place, track it, test it and analyze it to determine if you have found the optimal strategy.

KLH is constantly exploring new methods and improving on current methods of SEO. Even through this downturn, KLH’s marketing team has developed effective SEO strategies that have helped increase brand recognition, lead generation and customer retention in all market sectors.
In closing, make sure that you are patient, determined and open-minded while implementing the right SEO package for your small business. Do your research and do not be afraid of failure. Remember to focus on what works for your potential customers. SEO is a continuous challenge and perfecting the strategy is only half the battle; the true challenge is maintaining effectiveness.