MATERIAL UTILIZATION
Material Utilization in the Manufacturing Industry
The process of reducing material thickness is a critical component of cost-saving in the manufacturing industry. In order to effectively reduce material thickness, manufacturers must analyze the formability of a given material. This involves assessing the material’s ability to undergo deformation without cracking or breaking. By identifying opportunities to reduce material thickness without compromising the integrity of the final product, manufacturers can optimize material utilization and achieve significant cost savings. Formability analysis plays a crucial role in identifying the optimal thickness of a material, which ultimately helps manufacturers save costs and improve production efficiency. At The Phoenix Group, we offer manufacturers comprehensive solutions to optimize material utilization, reducing waste and improving sustainability throughout the production process.
Optimizing Material Utilization for Cost Savings
Continuous improvement activities aim to enhance the overall efficiency and effectiveness of an organization’s processes, systems, and products, among other things. One of the critical areas that continuous improvement activities focus on is material cost savings. By identifying opportunities to reduce material waste and optimize material usage, organizations can achieve significant savings in their overall production costs.
The Phoenix Group provides continuous improvement services related to material cost savings such as process optimization, waste reduction initiatives, and supplier evaluation and optimization. In addition, we help organizations explore alternative materials, redesign products to use less material, and recycle or reuse materials to reduce costs.
Material Utilization Case Studies
QMS Consulting
Metal suppliers
Ford Motor Company
Civil Affairs Battalion
Worldauto Steel
General Motors
Meet The Material Utilization Experts
About Craig Jankowski
Bio
Craig brings to us over twenty five years’ experience in the Tool & Die trade, working at Tier 1 & 2 and Chrysler Tool and Die facilities. At Chrysler, Craig spent thirteen years as a die maker working on large steel and aluminum body panels with several of those years operating the Argus optical measuring system. He also worked as Manufacturing Engineering Operations Support Analyst and Formability Engineer for stamped aluminum parts, circle grid and thinning analysis, and support for material blanking.
Education
- Associates Degree (General Studies) Baker College, Auburn Hills, MI
- Bachelor’s Degree, Industrial Management, Baker College, Auburn Hills, MI
- MBA, Baker College Center for Graduate Studies, Flint, MI
Experience
- 22+ years Die Maker
- 2 years, Manufacturing Engineering Operations support analyst
- 1 year, Formability Engineer
- 4 years, Director of Forming systems
Skills
- Die Build, Die Tryout, Draw dies
- Soft tooling binder development
- CGA, TSA, Formability systems installation, GMAW, GTAW
About Russ Balzer
Bio
Since 2007 Russ has provided expertise in various roles at The Phoenix Group. Russ began his career with Phoenix as a Lab Supervisor, then took on responsibility for Safety and Quality Compliance. In addition to supporting our Quality System services projects, Russ currently serves as Technical Director for WorldAutoSteel, a global consortium of steel producers serving the automotive market. As Technical Director, Russ manages a variety of engineering projects, and has tactical and strategic responsibilities in WorldAutoSteel’s efforts to use and promote Life Cycle Assessment (LCA).
Education
- B.S.S. Environmental Compliance, Ohio University
Experience
- 15+ years Mfg. Operations Management
- Engineering Project Management
- Safety & Quality Management Systems
Skills
- Materials Testing
- Project management
- Life Cycle Assessment (LCA)
- Safety & Quality Management Systems
- SQA - Level 2 containment
- 2nd party audits
Certifications
- Lead Auditor ISO9001:2015
- Lead Auditor IATF16949:2016
- Life Cycle Assessment Certified Professional
Key Projects
- QMS Auditing:
Midwest Fabricating – internal audit
Hayes Performance Systems – internal audit
AK Steel (AW) – internal audit
- Project Management:
WorldAutoSteel – manage global Life Cycle Assessment (LCA) policy project, including advocacy, and education, across a wide range of stakeholders (government, academia, industry).
WorldAutoSteel – manage modeling and engineering projects including component design, benchmarking, LCA and cost modeling.
About George Coates
Bio
Since 1991, George has been providing engineering and consulting services for industry leaders in the steel, automotive, and manufacturing industries. George’s areas of expertise include: management and strategic consulting, project management, automotive stamping throughput improvement, supplier metal conversion, metal formability and reference panel systems, and new vehicle launch manufacturing support. George is an active contributor to WorldAutoSteel technical programs, including project manager / instructor for AHSS Application Guidelines, Version 6.0.
Education
- B.S. Metallurgical Engineering, University of Cincinnati
- MBA coursework, Miami University (Ohio)
Experience
- Twenty-eight years with The Phoenix Group
- 10 years with a major US steel producer
- 5 years with the Procter and Gamble Company
- 10+ years Consultant to WorldAutoSteel
Skills
- Management and strategic consulting
- Leadership development
- Team installations
- Project management
- Metal formability and reference panel systems
- New vehicle launch support
- Technical director for the WorldAutoSteel program staff; emphasis on AHSS implementation solutions, strategic implications for steel in future mobility, materials and environmental impacts from vehicle light weighting.
Case Studies
About Kirk D. Wiley
Bio
Starting his career on the manufacturing line at General Motors, Kirk has experienced nearly every aspect of the automotive and manufacturing industries, developing a comprehensive perspective for clients. Kirk’s areas of expertise include: systems design and team processes, metal formability, stamping and assembly optimization, die shop management, throughput improvement, process engineering, manufacturing systems design and implementation, supplier metal conversion programs, manufacturing cost savings, production troubleshooting and die optimization, and tool and die training programs.
Education
- BBA Industrial Marketing, Western Michigan University
- Coursework completed, MS Manufacturing Management, Kettering University
Experience
- 25 years manufacturing experience
- Operating Systems design, implementation and maintenance
Skills
- Team concepts
- Leadership development
- Tool & Die training programs
- Formability
- Lean applications to maintenance departments
Key Projects
- Manufacturing Cost Savings project at Chrysler Sterling Stamping. Realized $3.4M savings on a 10 month, A Transfer press project , $1.5M savings on a 8 month, B Transfer press project.
- Formabiility System Installation at 12 OEM Stamping Plants. T&D training events at another 6. Significant savings recorded in individual case studies.
- Leadership Training design and delivery across the Ford Motor Company Stamping Business Unit plants.
- Pioneered application of Lean Manufacturing principles to Tool & Die department operation.
Case Studies
SEARCHING FOR WAYS TO OPTIMIZE THE USE OF MATERIALS IN MANUFACTURING? THE PHOENIX GROUP IS HERE TO HELP!
If you’re interested in learning how The Phoenix Group can help your company, contact us today.
