Issue link: https://iconnect007.uberflip.com/i/582861
October 2015 • The PCB Magazine 29 WHELEN ENGINEERING REDUCES CyCLE TIME By BUILDING A NEW AUTOMATED PCB FACTORy FeATure Just a couple of days ago we analyzed some samples for 32 different elements at once, and you're able to walk away. We have auto titra- tion. We pick the program, put the sample in, and walk away. With all of that automation in there, one person is able to spend no more than six hours a day maintaining all of the chemistry in the factory as well as doing all of our cross- section work. That person still has time to do other things at the factory. I didn't want to manage a factory where I didn't feel good about coming to work. The health and safety of the employees comes first. Matties: I should note that you guys are sitting out here in the middle of nowhere, really. You're the largest employer in this area. Stepinski: Yes, the largest in the valley. Matties: T h e people I've talk- ed to here are really excited about working for this compa- ny. Many have been here for many years and it sounds like a few have moved into this new division. The other thing that I noticed is several young people here—it looks like you're re - ally helping these people. Stepinski: I'm 39 and the average age here I think is about 37, according to my calculations. We have a full range and a nice bell curve of experience here. Matties: Are you doing a lot of cross-training in this factory? Stepinski: Yes, the idea is that the people here are able to do just about every job needed to support the manufacturing operation. With so few people, you have to have that level of cross- training to tolerate a vacation (laughs). Matties: Exactly! Now, in this process I know there are a lot of steps, but what was the thing that most surprised you? Was there anything that you didn't plan for and it was just like, "Wow this really worked out better than I expected"? Stepinski: Actually, the waste water system. When we first started, it was planned to have a waste water discharge. We were actually in the permit application process to have a waste wa- ter discharge, and the more and more I got into the details of the engineering, I actually ended up not having one and continued to realize the benefits that could be had with very minor pro- cess adjustments to eliminate waste. That was something I had never done be- fore. I had never developed a waste water pro- cess or an en- v i r o n m e n t a l control pro- cess in gener- al, along with the manufac- turing process at the same time. Normal- ly, you have s o m e t h i n g p r e e x i s t i n g a n d y o u ' r e adding onto it in a brown- f i e l d o p e r a - tion. From a greenfield perspective, doing both at the same time, the benefits were huge. After doing it, you realize that it can be applied to a brownfield as well after all the things you learn here. Matties: We've been here for three days and you all have been quite accommodating and welcoming, and we greatly appreciate that. I think you may have a lot of disruptions in the future because a lot of people will want to see what you're doing here. Stepinski: We hope it helps the industry in the West. Matties: I think it will. I can't imagine someone not being inspired by this and looking to do this else-