Inside CIM this month. Metal Cutting: Metrology. Tooling: Cutting Composites. Fabricating: Welding. July 2013 Vol. 27 No. 4.

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1 Inside CIM this month Metal Cutting: Metrology Tooling: Cutting Composites Fabricating: Welding July 2013 Vol. 27 No. 4

2 FABRICATING Lise Baker is general manager of Champ Industries, which supplies stainless steel components and assembly for Magikist car wash units.

, five-employee company in 1992 and expanded it to 55,000 sq. ft. and 60 employees in only six years.

3 FABRICATING By Sue Roberts, Associate Editor Lise Baker, general manager of Champ Industries, Winnipeg, Man., entered the world of metal fabricating at the urging of David Bridges, then owner and her stepfather. He had purchased a small, 5,000-sq.-ft., five-employee company in 1992 and expanded it to 55,000 sq. ft. and 60 employees in only six years. The company was rapidly growing and I was asked to help manage, said Baker, whose nursing background is augmented by management experience. I joined the company in Baker focuses on accessing the skills of the company s workforce. Employees contribute to decisions that move the company forward. It s not my style to micromanage. I ask what I can do to help get a job done and give the employees the autonomy to do what is needed. Our employees determine how to do a job and make it their own. Glass Washers to Components In 1967 a teenage Bridges was hired by industrial glass washer manufacturer Paul Moore Co., also in Winnipeg. By 1988 Champion Industries had purchased the company and Bridges had taken the lead as general manager. It was a big step for him, said Baker, but he had a keen sense of fabrication. He did a lot of soul-searching and reflection and took the step to ownership. Renaming the company Champ Industries wasn t a shortening of the previous name, it was a loving nod to Bridge s favorite childhood dog. A paw print is tucked inside the letter p in the company logo. There was one problem with manufacturing quality glass washers: The equipment would be 25 or 30 years old and still running well. New product orders were not increasing, but Bridges recognized the opportunities available to help other companies meet their metal fabrication needs. Diversification began, and the risk paid off. Bridges used his contacts to develop relationships with local OEMs and became skilled at developing component parts for other customers. By 1998 Champ had outgrown the original shop and moved to a 30,000-sq.-ft. facility at its current location. Two years later, an expansion to 55,000 sq. ft. nearly doubled the company size. As need for capacity grew, more people, equipment, and shifts were added. Steady Growth From New Technology The key thing that helped my stepfather develop his business A stainless Champ logo graces the conference table where employees meet for production planning. extremely quickly was the purchase of a laser cutting machine. Prior to that shears, punches, and saws did the majority of the work. Now nearly everything Delivering Champ Industries produces components on both sides of the border Car Washers, Fuel Tanks, and More

FABRICATING Feeding the Need for Welders Thirty percent of Champ employees are CWB-certified welders. The company has 20 GMAW and 10 GTAW stations. starts at a laser.

TRUMPF TruLaser 7000 tube laser with automation. A lot of our work for current customers required tube processing.

And it diversified our business. With the tube laser there were new processes that we could implement in order to reduce waste, improve operational efficiency, and reduce costs.

4 FABRICATING Feeding the Need for Welders Thirty percent of Champ employees are CWB-certified welders. The company has 20 GMAW and 10 GTAW stations. starts at a laser. It s much faster with greater precision and accuracy, Baker said. The first flat laser was quickly joined by three others, along with CNC brakes. A recent addition is a 20-ft. TRUMPF TruLaser 7000 tube laser with automation. A lot of our work for current customers required tube processing. We thought the tube laser would help us do the work quicker, become more competitive, and allow us to reduce our costs and extend the savings to our customers, said Baker. And it diversified our business. With the tube laser there were new processes that we could implement in order to reduce waste, improve operational efficiency, and reduce costs. We were able to help many Good, experienced welders are needed to meet the production needs of Champ Industries. However, the company knows that the experience needs to begin with good training. Based on this principle, our welding supervisor and production manager has been involved with two local welding programs as part of the Advisory Committee to share his experience and narrow the gap between school and industry, said Lise Baker, general manager of Champ Industries. Red River College The Notre Dame Campus of Red River College offers a seven-month certificate program open to Manitoba residents. Participants learn gas tungsten and gas metal arc welding, along with mathematics, science, industrial communications, and blueprint reading. Upon graduation they receive a Red River College certificate and a student CWB ticket. We work in collaboration with the college and provide work experience for students just before they graduate. We have them here for the last two weeks of the program to provide work experience. If any of those students is interested or shows a particular skill, we ve been known to hire them, said Baker. Neeginan Institute of Applied Technology Neeginan Institute of Applied Technology, a postsecondary training division of the Centre for Aboriginal Human Resources Development, is funded by the federal Aboriginal Skills and Employment Training Strategy program. Baker said, This is an excellent program. The work center offers underpriviledged First Nations, Métis, and Inuit people the opportunity to learn welding at no cost. This program has been helpful in supplying welders for the manufacturers in our area. About 700 shipments leave the Champ dock each week. Photo courtesy of Champ Industries. of our customers consider a redesign of their products to improve upon the overall manufacturing process and costs. Along with the significant growth and diversification that the tube laser offered, a fourth flat-sheet laser was added to meet the increasing demand. Today 90 employees keep components and assemblies moving out the door three shifts a day, five days a week. Canadian Welding Bureau-certified welders make up 30 percent of the work-

force, creating welded assemblies for everything from small components to large frames for the transportation and agricultural industry.

Magikist, a Winnipeg distributor of car wash equipment, became a key component in the success of the company and continues the relationship today.

5 force, creating welded assemblies for everything from small components to large frames for the transportation and agricultural industry. From Glass Washers to Car Washers Equipment for cleaning glasses transitioned to equipment for washing cars. Magikist, a Winnipeg distributor of car wash equipment, became a key component in the success of the company and continues the relationship today. Magikist manufactures the majority of the car wash equipment you see in North America the vacuum towers, the pressure washers, and the car washes that you do by hand with a wand. We provide the components, Baker said. These components for the Magikist units are basically produced from thin-gauge stainless cut on a laser, sent to the punch for added features, formed on the brake, and sent to one of the 30 welding stations for assembly. Cosmetics are very important. We have to make sure the final product is without any scratches, said Production Manager Joseph Habtemicael, who joined Components for the transportation, agriculture, aerospace, food service, and commercial manufacturing industries are fabricated in Champ s 58,000-sq.-ft., full-service shop. the company as a finisher after immigrating to Canada from Africa over 30 years ago. We have first-off quality inspection and continue with in-process inspection for all of our jobs. ISO 9001:2008 certification helps keep the focus on quality. We have approximately 3,000 active parts. We ship 642,000 parts a year, almost 700 shipments a week, said Baker. The company stocks a limited number of parts for a handful of customers, but most jobs are just-intime. Flashing signs located in the production bays praise and thank employees for achieving nearly perfect, percent, on-time delivery. Seventy other companies join Magikist on the Champ customer roster. Components typically go to the transportation, agriculture, aerospace, food service, and commercial manufacturing industries. All come under the category of original equipment manufacturer. Of the seemingly endless component configurations that Electrical box assemblies require laser cutting, punching, forming, and assembly before final powder coating. Capabilities of the 20-ft. TRUMPF TruLaser 7000 tube laser with automation, one of Champ s newest equipment additions, expanded the company s customer list.

Once welded, each tank goes to our test area to make sure it is 100 percent leakproof before it goes to painting.

6 FABRICATING flow across the floor, 47 percent are produced from mild steel, 47 percent from stainless, and 6 percent from aluminum. Various fuel tanks and frames are produced for the transportation industry. Habtemicael explained that the fuel tanks require added steps to meet certifications. Once welded, each tank goes to our test area to make sure it is 100 percent leakproof before it goes to painting. There are absolutely strict certifications, everything has to be to standards, and they have to last 10 years. In some tank configurations, the welds need to be done from the inside. Crossing the Border Jamestown, N.D., became the home of Champ s second facility andit is outfitted with equipment to provide the same production services laser cutting, bending, welding, and assembly. It started production in 2006 in a 10,000-sq.-ft. building and experienced the same success and growth as the shop in Winnipeg. After only two years, customer demands necessitated expansion. A larger building in the same city met the space needs and added to overall production capacity and capabilities. Now we have a 37,000-sq.- Photo courtesy of Champ Industries. ft. manufacturing facility and we were lucky enough to find a building with a powder coating booth, said Baker. In Winnipeg we outsource that function locally. The Baker Touch Bridges, who passed away in 2007, left the company in good hands. Dedicated people with core skills on the shop floor and Baker s team approach to management ensure that the company s success will continue. For the future, Baker sees steady growth, maintaining and building new relationships, and continuing with their ongoing commitment to new advances in technology. Our success is about our people, said Baker. It started because of David s dream and Precision punching is an integral step in several components produced at Champ. The image of Marilyn Monroe was created with a series of holes punched in a stainless sheet. skill and has continued because of our people. I m here to facilitate and motivate, but they are the ones who do the incredible work. b Reprinted with permission from Canadian industrial MaChineRy, July Visit our website at FMa Communications inc. all Rights Reserved. Foster Printing service: ,

Our History In 1967, David Bridges embarked on what has evolved into a very successful career journey, by joining the employ of the Paul Moore Co., a manufacturer of hospitality equipment.

7 Our History In 1967, David Bridges embarked on what has evolved into a very successful career journey, by joining the employ of the Paul Moore Co., a manufacturer of hospitality equipment. Employed initially as an assembler, David quickly rose through the ranks to become the Shop Foreman. In 1988, Champion Industries, a manufacturer of commercial dishwashers from North Carolina acquired the Paul Moore Co. to establish a U.S. presence in Canada. David accepted the position of General Manager. To address a downturn in the hospitality industry, David diversified the operation to include not only the manufacture of glass washers, but also other outside work. Magikist, a Winnipeg distributor of car wash equipment, became a valued customer, and in essence the backbone on which the company s viability was assured at that time. Four years later, David seized the opportunity to purchase the company, renaming it Champ Stainless. With a loyal group of employees from the Paul Moore Co., David embarked on the challenging adventure of Owner. As the industry recognized Champ s reputation for quality and diversification as a full-service metal fabrication and assembly facility, the customer base expanded to include many new customers. In particular, New Flyer Industries, a stalwart in the bus manufacturing industry, has been a key player in the growth and success of Champ Stainless. By 1998 Champ had outgrown its facility on Dufferin Avenue and relocated to 360 Dawson Rd. In order to remain on the cutting edge of the industry, Champ acquired state of the art lasers, brakes, punches and a tube bender. Quality Control also became an integral part of its operation, with ISO 9001:2000 certification in A name change to Champ Industries in 2004 more accurately reflects the company s diversification. In order to accommodate the growing U.S. content requirements of its customers, Champ Industries opened its second location in Jamestown, North Dakota, USA in Champ Industries is a success story and is well positioned to support the local and global economies well into the future. Every endeavor requires inspiration and our company draws on the strength and determination of Champ, a long ago, loyal canine friend of the owner. His legacy is reflected in our loyalty to employees and steadfast relationships with customers and suppliers. Trust our Experience. Benefit from our Expertise. About Us Champ Industries is one of the largest metal fabricators in Western Canada. We offer custom fabrication at a full-service assembly facility located in Winnipeg, Manitoba. We have also recently opened a second location in Jamestown, North Dakota to accommodate a growing demand in the U.S.A. Our services reflect a variety of specific customer needs, from fuel systems to brackets to large assemblies. Using state-of-the-art equipment, we offer quality workmanship, cost-efficient production, effective customer service and timely shipping to any location in North America. Champ Industries prides itself on providing its clients with solutions to meet their fabricated metal needs. Its mission is to provide great products through experience and technology and building relationships for the future. We welcome you to contact us for your metal fabrication needs. We manufacture solutions.

8 Winnipeg, Manitoba (204) Jamestown, North Dakota (701)

TESTIMONIALS CREATIVE CUSTOMIZATION CALL US, NO MATTER WHAT

TESTIMONIALS CREATIVE CUSTOMIZATION ATEC Electronics Recycling, Inc. is a Computer Monitor and Television (CRT Glass) handling and recycling organization. We were called to fabricate an extraction system