SHORT COURSE 1
Monday, October 22 – 8:30 am until 3:30 pm

Lean: A Business Process
Instructor: Karl H. Schultz, Schultz Associates
6.5-hour course

Lean Business as opposed to lean manufacturing encompasses all facets of a manufacturing business. The process covers the beginning of when an order is placed to the end of the billing collection. It also encompasses the support functions such as product engineering, finance, materials management, human resources, etc.

Lean is not new. Successful manufacturers have been improving their business operations continuously since their beginning. However, for several decades, we have seen some Japanese manufacturers carry lean to significant business levels. Some western manufacturers have adapted the lean tools, techniques, and process to their business while achieving outstanding competitive results. The hallmarks of lean are teamwork, communication, efficient use of resources, and continuous improvement.

Participants will receive an overall briefing of a lean business. They will learn what a lean business is, how they can adapt it to their business, the implementation challenges, and what results might be achieved. Focus will be on electric motor manufacturing.

Short course will cover what is a lean business, the background of the Toyota Production System, the continuous improvement building blocks such as cellular/flow, quality at the source, visual management, teams, plant layout, pull/kanban, batch resolution, value stream mapping, 5S’s, standardize work, Total Quality Management, and Total Predictive Maintenance.

The short course will also discuss the cultural changes that must be addressed, and the potential results.

A Glider Exercise will be conducted. The purpose of the exercise is to experience and examine role and behavior changes that can occur when processes are improved or altered. The group is divided into two teams. One team is directed to be autocratic, inflexible and traditionalist. The other team will be experimental, team oriented, and progressive. There are two different rounds. The resulting outcome will demonstrate many of the lean business processes. Schultz Associates has the documents to conduct the Glider Exercise.

Several videos demonstrating lean manufacturing tools and techniques will be presented.

Each attendee will receive a workbook.

Who should attend:
Heads of business, department managers of all disciplines, high to medium level individuals, and “champions” of lean.

Instructor Biography:
Karl Schultz currently is the President, Schultz Associates, specializing in manufacturing and technical management consulting. He has had nearly 20 years in the electric motor, gear, and drive business and 40 years in general industry.

He is an experienced “hands on” manufacturing manager who has had both line and staff positions implementing lean/world class manufacturing processes. He has also developed and implemented white-collar productivity and quality processes along with teaching technical organizational dynamics at General Electric. His career has focused on in plant/operations management and manufacturing engineering at some of the premier companies such as General Electric, Emerson Electric, Chrysler, and Cincinnati Milacron. He also has extensive experience particularly in Europe, Asia, and Mexico.

Karl holds a BSME from Western Michigan University. He is a member of the “Electrical Manufacturing and Coil Winding Association” and a past member of the “Small Motor and Motion Association” (SMMA). He has been a senior member of the “Society of Manufacturing Engineers” (SME) and a member of the “Society of Automotive Engineers” (SAE) once serving as Vice Chairman of the Highway Vehicle Manufacturing Engineering Committee. He has been a contributor to technical journals and a speaker at industry conferences. He has received numerous awards such as Best Industry Award (General Signal) and Most Valuable Player Award (BMI), and others. He is an adjunct instructor at the Oregon Institute of Technology.

SHORT COURSE 3
Monday, October 22 – 8:30 am until 4:30 pm

Polymer Chemistry for Engineers
Instructor: James V. Masi, PhD – Professor Emeritus, Western New England College, Research Professor, University of Southern Maine
6-hour course

Who should attend?
The purpose of this course is to introduce polymers/plastics to a broad cross section of engineers and technologists who have a need to gain, improve, or refresh their knowledge of polymers/plastics. This course is intended for technologists, engineering technologists, and professionals in the plastics industry, engineers, and engineering managers. The course stresses the fundamentals of materials and processing, with examples attendant to each topical section. Demonstration labs will be given on site and by animated applets.

Course Description:

The course will be presented by means of demonstration, PowerPoint slides, experiment (real and virtual), and parts display. Each participant will be given software, PDF files of the presentation (hard copy as well), links to key websites, and samples of small parts made of various polymers fabricated by different processes (to be handed out on completion of course). Ample time will be allowed for Q&A.

Dr. James V. Masi received his B.S. in Physics from Fairfield University, the M.S. in Physics from Long Island U., and the Ph.D. in Materials Science from the Univ. of Delaware. He has over 45 years experience in industry and academia and has worked and researched in solid state devices, liquid crystals, corrosion, semiconductors, luminescence, energy devices, electromagnetics, dental materials, and other areas of materials science. He joined Western New England College in 1980 and is presently professor emeritus of Electrical Engineering and Bioengineering. He was Exec. Dir of The Northeast Center for Telecom. Technologies (NSF Center of Excellence) from 1997-2001. He is presently a research professor at the University of Southern Maine. He is retired and is a consultant in JM Design consultants. He holds over 60 patents, has authored over 140 articles and papers, and has authored 3 books and 3 videotapes. He is a member of the IEEE, ASME, ASM, SPIE, ECS, AVS, AAPT, and is a fellow of the AIMBE.

Ray Zabinski

Shannon Kelly

SHORT COURSE 4
Introduction to Resins and Varnishes
Instructors: Ray Zabinski and Shannon Kelly of Von Roll USA, Inc.
Monday, October 22 – 1:30 pm until 3:30 pm
Tuesday, October 23 –1:30 pm until 3:30 pm

Abstract:
The focus of this course is to present a basic understanding of resin and varnish materials for motor and generator applications. The fundamental differences of various types resins will be covered, including their function and typical use for both low and high voltage applications. Recommended typical resin testing will also be presented including accelerated aging, UL requirements and tank maintenance.

Who Should Attend: This course would appeal to both technical and non-technical personnel who require a fundamental working knowledge of resins. This would include marketing and sales managers, including senior managers and product managers and other non-engineers who need to understand the basics of resin materials. Entry-level engineers with limited experience with resins and varnishes for the motor/generator industry would also be interested.

Instructor Biographies:
Ray Zabinski is an industrial chemist for Von Roll USA, Inc. He has worked primarily in R&D throughout his 27 year career in various areas including resin and varnish synthesis and development, UV curable materials development and various materials applications . Ray has taught several courses on insulating materials for EIC conferences and has been a NEMA representative in their resins division.

Shannon Kelly is a Product Development Chemist for Von Roll USA, Inc. She has a B.S. degree in chemistry from Renssalaer Polytechnic Institute, Troy NY. Shannon has worked for Von Roll for over 10 years in various positions including Varnish and Resins R&D, manufacturing and Quality Control. Shannon is well versed in the various aspects of resin testing and UL procedures.

Dr. Nancy Frost

Kevin Alewine

Hal Miller

Ray Zabinski

SHORT COURSE 5
Introduction to Electrical Insulation for Non-Engineers
Instructors: Dr. Nancy Frost, Kevin Alewine, Hal Miller and Ray Zabinski of Von Roll USA, Inc.
Monday, October 22 – 8:00 am until 10:00 am
Tuesday, October 23 – 8:00 am until 10:00 am
Wednesday, October 24 – 8:00 am until 10:00 am

Abstract:
The focus of this course is the basic aspects of insulation materials for the novice. The fundamental aspects of insulation materials will be covered, including how to select materials and how to test performance.

The course covers the properties of the various types of insulation, with an emphasis on materials used in commercial and industrial products, ranging from low to high voltage (over 2300 V) and up to high temperature (> 180oC) applications. We will also review the major test methods and standards used in selecting and qualifying insulation systems. Also covered in the course is an introduction to electricity at the basic and introductory level as well as insulation materials and the areas where they are utilized (transformers, motors, generators).

Who Should Attend:
This course would appeal to both technical and non-technical personnel who require a fundamental working knowledge of electrical insulation materials and systems. This would include marketing and sales managers, including senior managers and product managers and other non-engineers who need to understand the basics of electrical insulation systems. Entry level engineers with limited experience in insulation materials would also be interested in this course.

Instructor Biographies:
Kevin Alewine, Applications Engineer with Von Roll Isola USA, has been involved in resin and varnish sales, applications and marketing for more than 20 years. Kevin is heavily involved in insulating liquids training and applications support work at Von Roll. Kevin has organized or participated in several workshops and seminars in the industry.

Nancy Frost, Ph.D. joined Von Roll Isola USA in 2002 as a Dielectrics Engineer and UL Liaison. Nancy’s education includes a B.S. in Chemistry and M.S. & PhD in Electrical Engineering. She has published technical papers in conferences regularly for the past 10 years and has given over 30 presentations on insulation materials. She is also very active in the IEEE Standards Working Groups and the IEEE Dielectrics and Electrical Insulation Society.

G. Harold “Hal” Miller, Materials & Processes Consultant, Von Roll USA Inc. and Von Roll, M Tec Division has been involved in Product & Applications Development for insulation systems from low voltage through high voltage rotating machines since 1969. Hal has been active ASTM, NEMA and IEEE Rotating Machines and Dielectrics Insulation Society activities and has been a regular instructor and contributor to EIC conferences for most of his career.

Ray Zabinski is an industrial chemist for Von Roll USA, Inc. He has worked primarily in R&D throughout his 27 year career in various areas including resin and varnish synthesis and development, UV curable materials development and various materials applications . Ray has taught several courses on insulating materials for EIC conferences and has been a NEMA representative in their resins division.

TUTORIAL 1
Monday, October 22 – 8:30 am until 11:45 am

Understanding Induction Motor Performance – Why Settle for Speed Torque Curves
Director: Prof. Donald Skaar- San Diego State University (emeritus)

Description:
This tutorial will present methods by which one may thoroughly and quite-accurately assess the performance characteristics of single-phase or balanced multi-phase induction motors under running conditions without the use of a computer or a scientific calculator.  The methods include a graphical and an analytical approach; the graphical method will be emphasized because of its simplicity and insightfulness.  The mathematical complexity of either method is limited only to taking the square root of two squared numbers – and hence may be performed using the simplest of calculators [attendees will be provided with a 99-cent calculator for use in working out example problems]. Because of the hands-on approach of the tutorial, the enrollment must be limited to the first fifteen registrants.

Who Should Attend:
Any technically-oriented person who has an interest in assessing the performance of induction motors under normal running conditions and who has a fundamental grasp of the concept of impedance should find the material easy to grasp.  It would be beneficial if attendees were also familiar with the concepts of efficiency, slip, torque and synchronous speed.

TUTORIAL 2
Monday, October 22 – 1:00 pm until 4:00 pm

Product Development for Electrical Manufacturing Devices
Director: Jim Marshall

Description:
The path from product concept to the customer’s hands is a long and perilous journey that can impact the success or failure of your product. This program will discuss the necessary steps, commonly known as tollgates, at each stage of development, from product concept through a completed manufactured product, to assure successful completion of that journey while avoiding pitfalls along the way.
 
Successful product development is a long-term process that must be embedded into the culture of your company.  Each team that “touches” the product—design, engineering, production, marketing, etc.—must understand and commit to creating a product that will delight the customer. Therefore, we will begin with the “Fuzzy Front End.”  This is the crucial first step in the process, which greatly enhances your ability to deliver a product that meets the customer’s requirements long before the product is actually developed. Then we will walk through each of the various tollgates in the development process to look at best practices and barriers to success.  These tollgates include:
1. Finalizing Customer Requirements
2. Concept Development
3. Detailed Layout & Design
4. Production Tooling Design
5. Pilot Lot Approval
6. Approve Product for Distribution
 
Who Should Attend:
Product developers and manufacturers of commercial products, including marketing, design
engineering, manufacturing engineering, quality, purchasing and accounting professionals who have a role in new products, will benefit from this program.

Biographies
Jim Marshall is president of J. W. Marshall Inc., a consulting firm specializing in advanced manufacturing engineering, particularly in the area of consumer products. Jim’s expertise includes, product design, tooling design, plant and production layouts and other areas of automation.
 
Jim started his career at Black & Decker working in motor development, testing and later motor manufacturing engineering. He went on to establish and managed a new motor manufacturing operation for an appliance manufacturer.
 
Jim began his own consulting business in 1972. Since that time he has consulted with companies throughout the United States and internationally from Hong Kong to Stuttgart. Over his career he has received over 20 design and process patents relating mostly to motors, transformers, power tools, fuel reformers and fuel cells.  
 
Jim graduated from Bliss Electrical Engineering School. He is a life member of the Institute of Electrical and Electronics Engineers (IEEE), a member of the Electrical Manufacturing and Coil Winding Association (EMCWA) and a past member of the Small Motor Manufacturing Association (SMMA). He directed the first Short Courses for the Coil Winding Association on the Automated Manufacturing of Armatures and the Automated Manufacturing of Fields.

Wendell Leimbach is a director in the MWD Consulting group of RSM McGladrey.  Wendell is an engineer and consultant with more than 40 years of manufacturing engineering and business management experience.  Wendell has helped his clients improve their positions relative to world-class companies in the areas of advanced manufacturing, product design, process innovation, machine development, materials management and project management.  In addition, he has helped numerous clients streamline operations, reduce costs and improve profits through a variety of cost containment and waste elimination techniques.  This range of experience allows Wendell to provide a strong best practices approach to middle-market and large manufacturers and wholesale distributors.
 
Wendell’s experience includes leading the MLE Consulting Group at American Express Tax and Business Services for seven years.  For 16 years, Wendell was a partner in two consulting firms that he co-created and, for17 years he held various responsible positions with Black & Decker, including as director of factory automation.
 
Wendell holds a Bachelor of Science degree in Mechanical Engineering and a Master of Administrative Sciences degree from the Johns Hopkins University in Baltimore, Maryland.  He is a member of the Tau Beta Pi fraternity.  He has held the Certified Manufacturing Engineer designation and is active with the Society of Manufacturing Engineers (SME) and the American Production and Inventory Control Society (APICS).   He is past president and member of the Board of Directors of the Engineering Society of Baltimore.
 
As a faculty associate of the Johns Hopkins University School of Continuing Studies for 17 years, he has taught graduate level courses on contemporary operations management issues. In addition, he has lectured and published articles in various professional, trade and business publications.

Michael O’Banion is vice president, engineering of Kamal International. Mike has more than 32 years experience designing power tools as director of engineering for Black & Decker/DeWalt and for a short time with AEG Power Tools, and Johnson & Johnson Ethicon Endosergery, a supplier of endoscopic medical instruments. During this time, Mike accumulated 96 US Patents issued, numerous International Patents and currently has several Patents Pending.
 
While with Black & Decker/DeWalt, Mike was involved with the development of woodworking tools including, miter saws, table saws, routers, sanders, planers, and jointers. He has also designed all type of drills, screwguns, and vacuum cleaners.
 
Recent projects include an automatic indexing screwdriver, a unique power driver for the US Navy, antiterrorist barriers for Homeland Security, line voltage thermostats, and an innovative new line of flashlights. Mike has also served as expert witness and given depositions for injury litigation and trade secret infringement cases.
 
Mike has a BSME from Tri-State University and numerous courses toward an MBA.

Mark Winkeler

Ron Goetter

TUTORIAL 3
Monday, October 22 – 1:00 pm until 3:30 pm

Electrical Insulation Chemistries and Applications for Motors and Transformers
Directors: Mark Winkeler and Ron Goetter

Description:
This tutorial will cover basic chemistry classes used in the electrical insulation industry. A survey of these chemistries will then be reviewed outlining Advantages and Disadvantages of each chemistry.
The next section will cover application techniques that have been used successfully in various markets. These can then be tied to chemistries to determine fitness for use as a complete package based on the application requirements.
The last section will divide the electrical insulation industry into market segments where value drivers will be used to discuss very specific recommendations based on the requirements of that market segment.

Who Should Attend:
Anyone who has an interest or need to learn more about the chemistry and application options available for the electrical insulation industry. This may include materials engineers, buyers, strategic planners, electrical engineers and plant managers. This tutorial is designed to be an introduction to those new to the industry and a refresher to those with years of experience.

Biographies:

Mark Winkeler is the Manager of Technical Services at ELANTAS PDG (formerly The P.D. George Company). He has been with the company since 1982 and is responsible for the technical services group at ELANTAS PDG. The group’s activities include customer support, agency testing and prototype processing.  Mark works closely with R&D and Sales to develop innovations to assist the electrical industry. Mr. Winkeler received a BS in Physics from Southern Illinois University in Edwardsville in 1981 and Masters in Business Administration in 2006. He serves as chairman of ASTM Subcommittee D9.01, member UL STP for UL1446, and chairman of NEMA RE-6 Resin Technical Subcommittee. He has authored papers on various electrical insulation topics that have been presented at the EEIC and EMCWA conferences.

Ron Goetter is the Director of Research and Development for Secondary Insulation and Electronic and Engineering Materials at ELANTAS PDG. Ron has been in the industry with ELANTAS PDG for 17 years in a variety of product service and research positions. He has authored a number of papers and made presentations at trade conferences over the last 6 years. Ron graduated from Southern Illinois University- Edwardsville with a Masters degree in Organic Chemistry. He has also taken a number of courses through California Institute of Technology’s Industrial Relations Center focusing on product development, technology and competitive intelligence.