Trenton Forging has a Zero Defect Policy
Zero defect is a way of thinking and doing that reinforces the notion that defects are simply not acceptable. It was first developed in the aerospace industry by what is now Lockheed-Martin to ensure their safety critical Titan Missile program, which carried astronauts in to space in the 1960’s. Manufacturers around the world now use the system regularly. Trenton Forging has decided to enact this policy to improve upon our already-thorough quality system. We need to strive for perfection in our product..
Products that we produce have a certain number of requirements that we are expected to meet. When these requirements are met or exceeded, we have produced a quality product. Fixing problems after they happen is a troublesome task and they cause downtime and rework. It is undoubtedly less expensive for us to prevent defects than it is to discover and correct them after they happen. The goal of our Zero Defect policy is prevent problems before they occur.
This goal can only be achieved if each individual fulfills his or her own quality duties. Quality checks will be done at every workstation to ensure that parts that do not meet their quality specifications cannot continue through the workflow. It is up to the individual to make this group effort work.
Trenton Forging Adopts 5S Approach to Manufacturing
Trenton Forging has recently adopted a lean manufacturing methodology for workplace organization called “5S”. This method, born in Japan, is now used worldwide as the basis of lean manufacturing. By simplifying the work area and creating visual references we improve efficiency, quality, and delivery throughout the plant.
The five primary 5S Phases are as follows:
- Sort: This process allows us to identify things that are necessary to do the work at hand. We can prioritize supplies and tools, store the ones that may be needed but not always necessary, and eliminate the ones that aren’t used at all.
- Straighten: We then arrange the necessary tools, parts, and instructions so that they are easy to locate and use. This eliminates wasted time searching for the right tool. The most frequently used tools are at hand and the others are stored in a place where we know exactly where they will be at all times.
- Shine: Keeping the workspace and equipment clean and tidy is key. Leaving with a clean workspace ensures that other shifts won’t have to clean your mess, or that you can get right to business the next day knowing everything is in it’s place and working properly.
- Standardize: By standardizing all workstations we create adaptability. They become a standard. Any person who can operate a certain type of machine should be able to move to another workstation and know exactly where everything is and where it belongs. If it’s the same job, it should have the same tools, in the same location, at every station.
- Sustain: The hardest part of using the 5S system is sustaining it. Once the other S’s have been established they need to become a working lifestyle. Focus is needed to change the way things are done and keep them going in that direction. This also means to sustain the whole 5S belief system by continuous improvement. Things can always be better, faster, or easier for the operator.
TRENTON FORGING FIRST TO MARKET
With an expanding base of in-house machine tools, Trenton Forging continues with the “first to market” concept by producing production tooling in as little as one day to meet customer demands. A prime example of this concept in action is the development of the ATV ball joint housing.
Upon receiving a 3-dimensional model of the requested part from our customer, Trenton Forging engineers created a forging blueprint for inspection purposes and in-plant reference using software programs Solid Works, AutoCAD and Pro “E”. Our engineers developed the machine tool path required to manufacture the die and programmed the specifications into the 18,000-rpm CNC milling machine tools. Within just ten hours, the forging tooling was 100% complete. Trim and coin tooling was completed on complementary CNC equipment and sample forgings ready the next day.
Providing plastic models of customer designs and concepts has become a high demand service Trenton Forging offers. The plastic models are important customer tools for evaluating new ideas and potential cost savings. Customers can identify design flaws, make necessary modifications or enhancements and measure how the designs will affect their internal operations before committing to production.
Please allow us to work with you to get your product to market first or to enable you to evaluate your latest designs quickly and cost-effectively.
RE-CERTIFICATION OF ITS ISO/TS 16949-2002 QUALITY SYSTEMS
Trenton, Michigan (March 5, 2008) – Trenton Forging Company a leading independent producer of closed die forgings for a number of North American industries, announced today that it has received re-certification of its ISO/TS 16949-2002 quality systems. Trenton Forging has been a leader world wide in the forging industry promoting accountability within all systems in the production of all products including critical safety suspension components. In keeping with its tradition of being a world leader (Trenton was the first forging operation world wide to receive the QS9000 certification) Trenton passed the three day audit by independent auditor SGS with recommendation for recertification without any non-conformities.
David Moxlow, Chief Executive Office of Trenton Forging applauded all of his associates at Trenton Forging for their day to day work ethics in keeping with “our tradition of being among the elite in the production of quality forged products”. Moxlow went on to say its been a very exciting period for Trenton Forging, that in the past few months we have added new processes in the production of hot forgings, part specific Micro Alloy Conveyor lines, reducer rolls, and automated bar feeders to our electric heat stations. Our CNC tool room was complemented in the past few weeks with two new vertical machining centers and a new CNC lathe. In the past year Trenton Forging has expanded its market penetration into automotive drive line components, suspension product and the hand tools industry, being awarded new business from each market.
TRENTON FORGING SPONSORS SPEED WORLD CHALLENGE EVENT SPEED World Challenge Weekend presented by Trenton Forging Quality Formed Solutions at Mid-Ohio Sports Car Course.
Detroit – April 20 2005 – Trenton Forging “Quality Formed Solutions” announced today it will host the SCCA Pro Racing SPEED World Challenge Weekend, May 20-22 at the Mid Ohio Sports Car Course in Lexington, Ohio. The event consists of the SPEED World Challenge Touring Car and the SPEED World Challenge GT races. Joining Trenton Forging for the event will be Motorsports Ministries and SPEED Channel’s Sports Car Revolution. Trenton Forging is a Michigan company and leading producer of custom impression die forgings for a wide variety of industries. It’s developed a strong reputation as “supplier of choice” to many Tier 1 and Tier 2 automotive/light truck suppliers. Trenton Forging was the first closed impression die forging company in the world to be certified QS9000/ISO9002. The company also sponsors two teams in the SPEED World Challenge Series, the Autosport Development #5 GTO, driven by Stu Hayner and the #24 Chili Pepper Racing BMW driven by Jim Osborn.
Trenton Forging Completes Re-certification to TS 16949
Trenton Forging Company, the first forging company to achieve QS-9000 in early 1996, has finalized its re-certification to the new industry standard TS 16949. Trenton Forging makes products for a wide variety of industries including automotive, truck, construction, mining and many others. TS 16949 certification is a technical specification that aligns existing automotive quality system standards within the global automotive industry.
The ISO/TS 16949 standard, published in March 2002 by the International Automotive Task Force, focuses on continuous improvement to reduce costs in automotive manufacturing. The standard specifies quality system requirements for the design and development, product installation and servicing of automotive-related products. The certification process emphasizes defect prevention and reduction of variation and waste in the supply chain.
ISO/TS 16949 has become the required standard for the Big Three automakers that now award new contracts only to suppliers that have achieved this certification.
Major New Equipment – Trenton Forging – 2004
Trenton Forging installed four new major pieces of equipment in 2004. The purchase and installation of this equipment brings more of the latest technology to Trenton Forging. Each piece of equipment has engineering and design features that benefit the forging operation by providing the latest in programmable and tolerance controls.
Three new Standard Industrial Corporation 1000-ton hydraulic coining presses give Trenton Forging more productivity, while maintaining superior shape and flatness, closer tolerances and improved surface finishes. The machines offer laser speed measuring, automatic gage controls based on mass flow principle, and shape measurement with automatic feedback control. The presses are 100% American made and include full warranties on all parts for five years. These three units replace ten mechanical presses weighing 150 to 1000 tons.
The Deca Coil High Production Magnetic Particle Inspection System is another valuable addition. This state-of-the-art unit comes with a built-in demagnetizing unit and continuous A/C process. It can be automated to accommodate every degree possible, with speed of inspection set by the size of the part and the belt speed.
The Deca Coil System looks for potential cracks, forging laps and any discontinuity in the forged material and is useful in verifying high volume automotive applications such as steering and suspension components.
Trenton Forging Releases New Aftermarket and Performance Parts
Light truck control arms, muffler flanges and connecting rods are just a sampling of the new OEM, aftermarket and performance parts produced by Trenton Forging. These new products showcase Trenton Forging’s ability to produce technical parts for varied markets in a wide variety of sizes and shapes.
New engineering and die building is complete and fully functional.
The new Deckel Maho Gildemeister (DMG) DMC100V 18,000 RPM high-speed machining centers are the backbone of Trenton Forging. Each machine can produce a new die half in eight to ten hours. The DMG machines will operate “lights out” and are monitored via cameras and the internet.
More new equipment includes a 10,000-rpm Fadal Machining Center and Japax Wire EDM. The addition of high-tech equipment onsite allows for faster and cost effective tooling manufacturing and eliminates transportation and the need to bench dies after receipt. Pro/ENGINEER and Powermill software and hardware are used to enhance equipment capabilities.
Trenton Forging In The News
Our new die making equipment and facility is the talk of the industry. Trenton Forging was recently featured in an article in Modern Machine Magazine. Read the article online at Modern Machine Magazine’s web site.