Pace Industries Announces Doug Albert, as Chief Executive Officer

April 4, 2023

Pace Industries, LLC (“Pace” or the “Company”), North America’s leading full-service aluminum, zinc and magnesium die casting manufacturer, today announced that Doug Albert has been appointed as Chief Executive Officer.

Mr. Albert brings more than 20 years of leadership experience in the industrial sector, having served in a range of general management, commercial, manufacturing, financial, and operational roles. From 2014 until its sale in 2022, Mr. Albert was the President and Chief Executive Officer of Resco Products, Inc., a leading North American manufacturer of refractory products serving steel and industrial end markets. At Resco Products, he oversaw key strategic initiatives that drove growth and improvements in commercial, operating, and financial performance.

“Doug is a seasoned leader bringing a deep understanding of our customers, markets, and industry,” said Jeffrey P. Pritchett, Executive Chairman of Pace. “His knowledge, combined with an impressive commercial and operational background, makes him a great fit for Pace. Alongside our talented team, Doug will help Pace become an even stronger partner to our customers and expand in our core markets. We’re thrilled to have him at the helm in this next chapter of growth for Pace.” 

Prior to Resco Products, Mr. Albert held leadership positions at Environmental Filtration Technologies and GE Fanuc Automation. Earlier in his career, he spent several years at global consulting firm Booz Allen where he supported a broad range of companies on manufacturing and supply chain management strategies. Mr. Albert earned a B.S. in Mechanical Engineering from the University of Rochester and received an MEM and MBA from Northwestern University’s McCormick School of Engineering and its J.L. Kellogg Graduate School of Management, respectively.

Mr. Albert added: “Pace has been a trusted partner for more than 50 years because of its unwavering commitment to quality and value. This is a dynamic time for the Company, and I’m excited to join the dedicated team. Together, we’ll strengthen our platform, accelerate our commercial strategy, and expand in strategic markets. I’m grateful to Pace’s Board and shareholders for their support and look forward to delivering best-in-class service and great value to customers.”

Comment

Pace Industries Honored with “Supplier of the Year Champion” Award from Acuity Brands

October 13, 2022

Pace Industries, LLC (“Pace”) or (“The Company”), North America’s leading full-service aluminum, zinc and magnesium die casting manufacturer, is proud to announce they received two awards at the inaugural Acuity Brands Supplier Appreciation Event in September at the Georgia Aquarium in Atlanta.

The two Fiscal Year 2022 awards include the prestigious Supplier of the Year Champion and the Top Supplier Profit Award. Both awards recognize Pace’sstrategic partnership, outstanding service, and cost savings for Acuity.

“Winning these two awards symbolizes the powerful relationship Pace and Acuity Brands have developed over time, and it’s an honor to achieve this milestone together,” said Jeffrey P. Pritchett, Executive Chairman at Pace Industries. “Our leadership team and our associates are committed to providing the highest levels of quality and service to Acuity Brands in order to deliver successful outcomes, ultimately aiding them to accomplish their strategic goals.”

The September Acuity Brands Supplier Appreciation Event brought together nearly 40 of Acuity’s top 500 suppliers. The dual award recognition is a result of the strategic partnership between Acuity and Pace, as well as the dedication and contributions of Pace associates servicing the Acuity business every day.

Honorees were judged across Scorecard Performance, Cost Productivity, EarthLIGHT Participation results, and a final Customer Service survey. The final voting process included a review by an Acuity Brands sourcing leadership committee.

“I am grateful for the partnership with Pace Industries to support Acuity’s growth and for advancing our EarthLIGHT initiatives,” said Stephanie P. Perez, Supplier Development Director for Acuity Brands. “EarthLIGHT is a central tenet of Acuity Brands’ strategy and reflects on our comprehensive approach around Environmental, Social, and Governance (ESG) topics.”

Pace Industries has been a supplier for Acuity for more than 40 years providing solutions across a variety of products in their portfolio. From product conception and tooling design to production, collaborative efforts take place on every Pace project between supplier development, sales, product engineering, and more.

Associates at Pace facilities in Saltillo and Chihuahua, Mexico oversee part production, and quality assurance, ensuring the highest levels in service in support of Acuity’s goals.

These combined efforts of subject matter experts yield an optimal product that can be manufactured in a cost-effective manner that contributes to Acuity’s overarching objectives. Pace Industries values their ongoing partnership and aims to be a direct contributor to Acuity Brands’ 2023 strategy and beyond.

Pictured left to right at the Acuity Brands Supplier Appreciation Dinner on Wednesday September 21, 2022, at the Georgia Aquarium in Atlanta: Terry Patterson (Acuity), Luis Guerra (Pace), Steve Johnson (Pace), John Wisdom (Pace), and Neil Ashe, CEO of Acuity.

Comment

Pace Industries Announces New Organizational Structure to Deliver Best-in-Class Customer Experience

July 7, 2022

NOVI, Mich. – (July 07, 2022) – Pace Industries, LLC (“Pace”) or (“The Company”), North America’s leading full-service aluminum, zinc and magnesium die casting manufacturer, announced that it is evolving to a new organizational structure designed to drive operational effectiveness and enable the company to continuously improve and better meet the needs of customers.

“Exceptional customer service is at the core of our business, and I am both excited and proud that this new structure will allow our teams to provide a more responsive and streamlined service,” said Donald Hampton Jr., Pace Industries’ chief executive officer. “This is a natural next step in striving towards our vision and goals, and we are confident that it will create a stronger, more dynamic business positioned for future growth through our customers, capabilities and cost.”

Over the coming months, Pace will shift to a customer-focused sector model, by market, to ensure a focused approach on the distinctly different market segments the company serves as the largest diversified high pressure die caster in North America. The four sectors of the new structure will help deliver best-in-class customer experiences and results by increasing transparency and accountability, deepening customer relationships and sector expertise, increasing agility, and enabling the growth and development of Pace’s people.

Going forward the four strategic market sectors will be: home and lighting, powersports and lawn & garden, specialty markets and, automotive.

To lead the advancement of these strategic market sectors, Pace has assembled an exceptional team with extensive experience in die casting and related industries.  Stephen Pridmore has been promoted to president of powersports and lawn & garden, after eight years at Pace most recently serving as senior vice president of sales. Jason Allen has been promoted to president of home and lighting after serving in a variety of roles over a 25-year career at Pace, most recently serving as chief marketing officer.  Vince Marino, previously chief strategy officer, has over a decade of experience as an executive and operating partner in private equity across a variety of industries has been promoted to president of specialty markets.

Matt Kato recently joined Pace Industries to serve as president of automotive. With 24 years of leadership experience in the automotive supply industry, Kato is a proven business leader with a successful track record of trusting, effective relationships with customers. He joins Pace from Quala, a bulk container cleaning company serving the chemical and transportation industries, where he served as president of IBC Services. Prior to his time at Quala, Kato also held leadership positions at: TRW Automotive, Hayes Lemmerz and, Faurecia. In his new role, Kato will work closely with the Pace leadership team to help the company make a seamless transition to the new organizational structure.

About Pace Industries, LLC

Headquartered in Novi, Michigan, Pace Industries is North America’s largest high-pressure aluminum, magnesium and zinc die casting company. Strategically located throughout North America, Pace operates a diverse manufacturing footprint with 18 manufacturing locations across the US and Mexico. Pace offers a wide array of services and capabilities to customers across numerous markets including: automotive, commercial vehicle, powersports, lighting, lawn and garden, appliance, aerospace, defense, medical, and other industries. For more information about Pace Industries, please visit www.paceind.com.

Comment

Simultaneous Engineering:  From Prototype to Full-Scale Production

March 17, 2022

If you’re in the automotive market, new advances in electrification constantly unfold – each presenting their own respective opportunities and challenges. One of the primary challenges arising in electrification is scaling up from prototype part designs or low-volume production stage into a high-volume manufacturing environment. At Pace Industries we have the expertise and experience to help customers to optimize and simplify multiple part designs to ensure a seamless transition to mass production by way of early supplier involvement and simultaneous engineering.

Simultaneous Engineering

Recently the Pace product engineering team had the opportunity to partner with a customer’s engineers to convert an EV battery enclosure prototype originally designed to be made from aluminum extrusions into a lightweight and more integrated design optimized for high pressure die casting full-scale production. The customer came to Pace as a trusted engineering partner as they faced a roadblock in their design phase, which initially had been created for a prototype build. However, in its current state it would not be feasible for high pressure die casting (HPDC) mass production.

Through the discipline of simultaneous engineering, the product engineers at Pace applied their knowledge and expertise of HPDC to complete a comprehensive Design For Manufacturability (DFM) assessment of the prototype design to integrate multiple functions for an optimized component design.

The prototype design was optimized through assessing DFM criteria including:

  1. Reviewing and advising on ejector pin locations
  2. Adding draft according to die pull
  3. Adding radii and fillets
  4. Reviewing wall thickness
  5. Reviewing undercut to ensure there is no hung part during the casting process

The optimized part design recommended by Pace provided a solution for the customer in the transition from a functional prototype to production-ready components for HPDC. Early supplier involvement was an important factor in the process, allowing for strong collaboration and a guided approach on the design change process between subject matter experts on both sides. This early collaboration also identifies potential challenges prior to launch, which mitigates costly corrections once in full-scale production.

Through both early supplier involvement and simultaneous engineering, Pace can assist customers in the design phase providing customers with confidence that their final product will meet durability, quality, and design expectations.

Look to Pace to add more value and more functionality to your total system.

To read more about the Pace Industries approach to simultaneous engineering, read the article “What is Simultaneous Engineering” at: What is Simultaneous Engineering? | Pace Industries

To connect with the Pace Industries Product Engineering Team, visit “Technical Expertise” at Contact | Pace Industries

Comment

What is Simultaneous Engineering?

March 10, 2022

At Pace Industries we are more than just a supplier – we are your trusted engineering solutions partner. With the end goal of creating value for our customers we deliver engineering excellence through the practice of simultaneous engineering.  Simultaneous engineering at its core is a partnership – it is a disciplined and collaborative approach to the product development cycle.

Through simultaneous engineering, the Pace product engineering team works in parallel with our customers which allows for innovative design resulting in the most reliable products with the best performance possible. Our engineering team has expertise in the fields of product engineering, tooling design, structural analysis, advanced process simulation, process development and quality assurance to deliver top quality, mass produced light metal cast parts. Leveraging this expertise, our technical team understands the value of producing a part that features an optimal design, while being both high quality and cost effective.

The process starts with early supplier involvement (ESI). Under ESI, Pace product engineers collaborate with the customer’s engineering team to evaluate concepts, early design work, and to understand their overall objectives. Challenges our customers face may include:

  1. Complex castings
  2. Non feasible designs
  3. Cost concerns
  4. Tight timelines from design to launch
  5. Transitioning to light metal castings from another type of process (sand casting, investment casting, gravity casting, extrusions, additive manufacturing, etc.)
  6. Transitioning materials (iron, between aluminum, magnesium, and zinc, etc.)
  7. Shifting from a prototype to a feasible design for mass production
Pace Industries Simultaneous Engineering discussion

Once key objectives and desired customer outcomes are identified, the simultaneous engineering process moves to the next phase:  utilizing high pressure die casting best practices to design for manufacturing both the part and corresponding tool. With the assistance of state-of-the-art metal simulation software, our engineering experts design robust tooling and processes for both maximum die life and cycle time optimization to reduce program lifecycle costs. As part of the tool design process, Pace will simplify die complexity to minimize or reduce maintenance that will require unnecessary downtime. The Pace technical team has the skill and expertise to design the best tooling concept for your needs, while also performing a cost evaluation to determine the most cost-effective solution for your application.

The application of simultaneous engineering at Pace Industries provides customers with a streamlined product development approach to assure optimal speed-to-market with a high-performance product that can be manufactured in the most cost-effective manner.

The primary benefits of simultaneous engineering at Pace Industries include:

  1. More robust part and tooling design
  2. Flawless launch
  3. Cost reduction
  4. Optimal speed-to-market
  5. Superior Quality

Pace offers exceptional “Design for Manufacturability” engineering services that will allow our customers to meet their market demand while producing the reliable products that continually exceed customer needs and expectations.

Pace Industries Simultaneous Engineering discussion
Comment

Pace Industries Announces Sale of its Patterson Mold and Tool Business

December 21, 2021

NOVI, Mich. – (December  21, 2021) – Pace Industries, LLC (“Pace”) completed the divestiture of its Patterson Mold and Tool (“Patterson”) operation  in St Charles, Missouri to Capital For Business, Inc (“CFB”).

“The sale of Patterson is in line with, and completes our strategy of divesting our tool and die operations. Our quest for operational excellence must include a focus on our core competencies of die casting and machining, and this step allows for further reinvestment into our core assets for expanded capabilities, capacity and footprint,” said Vince Marino, Chief Strategy Officer of Pace Industries.

“Patterson is a strong business and quality supplier in the mold and tooling industry. Under the name Patterson Mold and Tool, LLC, Patterson will continue to be a strategic supplier of tooling to Pace Industries,” said Donald Hampton Jr., Chief Executive Officer of Pace Industries. “We are very excited for the associates of Patterson.  We have turned the operation over to a financial  buyer committed to investing and providing excellent opportunities for growth for the associates. Pace has had a relationship with Patterson  spanning three decades. We will be leaving personal friendships and wish them all the very best”  Hampton concluded. 

CFB, headquartered in St. Louis, Missouri, is a middle market private equity firm, singularly focused on industrial growth company investment opportunities, with a nationwide footprint of 33 portfolio companies, generating more than $675 million in annual revenue and employing more than 2,700 employees.

For additional information, visit: www.paceind.com.

About Pace Industries, LLC

Headquartered in Novi, Michigan, Pace Industries is North America’s largest high-pressure aluminum, magnesium and zinc die casting company. Strategically located throughout North America, Pace operates a diverse manufacturing footprint with 17 manufacturing locations across the US and Mexico. Pace offers a wide array of services and capabilities to customers across numerous markets including: automotive, commercial vehicle, powersports, lighting, lawn and garden, appliance, aerospace, defense, medical, and other industries. For more information about Pace Industries, please visit www.paceind.com.

Comment

Pace Industries Expands Manufacturing Footprint with Acquisition of Jackson Die Cast

November 8, 2021

NOVI, Mich. – (November 8, 2021) – Pace Industries, LLC (“Pace Industries” or “Pace”), North America’s leading custom die casting, engineering and manufacturing provider to the automotive, commercial vehicle, powersports, lighting, lawn and garden, appliance, aerospace, defense, medical, and other industries – has closed on the acquisition of an aluminum high-pressure die casting facility, Jackson Die Cast (“JDC”), from Metal Technologies of Indiana, LLC (“MTI”).

Located in Jackson, Tennessee, the acquisition of JDC adds a strategic location to Pace Industries’ already extensive footprint across the United States and Mexico. The facility offers core competencies in aluminum die cast and trim operations, machining and assembly that fully align with and expand the Pace capabilities portfolio. JDC’s location in the Southeast amplifies Pace’s ability to service and grow their strategic customer base.

“Pace Industries continually evaluates strategic opportunities in the marketplace to complement and strengthen our portfolio. With its experience, capabilities and regional reach, Jackson Die Cast is an ideal addition to the Pace family,” said Vince Marino, Chief Strategy Officer of Pace Industries. 

The 140,000 square foot facility in Tennessee employs over 100 associates. The addition brings  Pace to a total of 18 manufacturing facilities and nearly 4,000 employees within North America. With Pace’s extensive and diverse customer base, Pace plans to grow the facility rapidly to meet its increasing customer demands.

“Our Vision is to become the premier die casting manufacturing and engineering solutions supplier serving customers within multiple sectors worldwide. This acquisition marks yet another exciting step in our journey to excellence,” said Donald Hampton, Jr., Chief Executive Officer of Pace Industries. “We have great admiration for both the city of Jackson and the state of Tennessee. It is an honor to become part of this growing, diverse community. We are delighted to have the experienced workforce of JDC join the Pace team.”

For additional information, visit: www.paceind.com.

About Pace Industries, LLC

Headquartered in Novi, Michigan, Pace Industries is North America’s largest high-pressure aluminum, magnesium and zinc die casting company. Strategically located throughout North America, Pace operates a diverse manufacturing footprint with 17 manufacturing locations across the US and Mexico. Pace offers a wide array of services and capabilities to customers across numerous markets including: automotive, commercial vehicle, powersports, lighting, lawn and garden, appliance, aerospace, defense, medical, and other industries. For more information about Pace Industries, please visit www.paceind.com.

About Metal Technologies of Indiana LLC

Metal Technologies of Indiana LLC is a metal casting and precision machining company, committed to providing customers with the highest quality products tailored to their unique needs.  MTI strives to add value for its customers at every phase, from design to casting, to finish-machining and assembly. Metal Technologies is headquartered in Auburn, Indiana and has plants in both the United States and Mexico. The company operates five iron foundries and two machining facilities.   Metal Technologies has a capacity of 340,000 tons of iron castings with a focus of providing strategic value to our customers in the markets we serve. Additional information about the company can be found at Metal-Technologies.com.

Metronome Partners, LLC served as exclusive financial advisor to Metal Technologies of Indiana, LLC. 

Comment

Pace Industries Relocates Global Headquarters to Novi, MI.

June 23, 2021

NOVI, Mich. – (June 23, 2021) – Pace Industries, North America’s leading custom die-casting, engineering and manufacturing provider to the automotive, commercial vehicle, powersports, lighting, lawn and garden, appliance, aerospace, defense, medical, and other industries – has relocated its global headquarters from Fayetteville, AR., to Novi, MI. The move expands Pace Industries’ presence in the Detroit area. 

The new state-of-the-art headquarters is located at 28125 Cabot Drive, Suite 120, Novi, MI 48377. Pace Industries expects to initially employ 75 full-time employees with the intent to expand.

“Pace Industries has a rich history of supplying the transportation and industrial manufacturing industries and is poised for continued growth,” said Donald Hampton, Jr., CEO of Pace Industries. “Relocating to the Detroit area provides us with more access to our extensive customer and supply base and to the rich talent in the region. Our vision is to become the premier die casting manufacturing and engineering solutions supplier serving customers within multiple sectors worldwide.”

“The decision by Pace Industries, a leading national die casting manufacturer, to relocate its headquarters to Michigan underscores the strength of our business climate and creates more good-paying, high-skill jobs for our talented workforce,” said Governor Gretchen Whitmer. “This is great news for workers, their families and our economy as we continue our economic jumpstart and put Michigan back to work. With the help of companies like Pace, we can build back our state’s economy stronger than ever before.”

Pace Industries, which started as a small die-casting facility in Harrison, Arkansas in 1970, was acquired by TCW Group and Cerberus Capital Management, LP in June 2020. The company currently provides a variety of structural, cosmetic and machined products to several market leading transportation, recreational and consumer goods manufacturers.

As part of the move, a new Shared Services Center has been established in Fayetteville, while the executive, engineering, sales, marketing and other customer-facing teams are based in the new Detroit office.  

“As our company looks at what’s next, our ability to exceed the needs of key customers through various metals, and engineered solutions  make us a natural partner for leaders in those markets,” Hampton said.

For additional information, visit: www.paceind.com.

About Pace Industries, LLC

Headquartered in Novi, Michigan, Pace Industries is North America’s largest high-pressure aluminum, magnesium and zinc die casting company. Strategically located throughout North America, Pace operates a diverse manufacturing footprint with 17 manufacturing locations across the US and Mexico. Pace offers a wide array of services and capabilities to customers across numerous markets including: automotive, commercial vehicle, powersports, lighting, lawn and garden, appliance, aerospace, defense, medical, and other industries.  For more information about Pace Industries, please visit www.paceind.com.

Comment

Pace Industries completed the divestiture of its Mangas Tool and Die operation in Muscle Shoals, Alabama to Aarkel Tool & Die Inc (“Aarkel”)

January 26, 2021

DETROIT, Michigan – On January 8, 2021, Pace Industries, LLC (“Pace”) completed the divestiture of its Mangas Tool and Die operation in Muscle Shoals, Alabama to Aarkel Tool & Die Inc (“Aarkel”).

Donald Hampton Jr., Pace CEO, commented “We strive to be world class, known as the premier high pressure die casting and engineering solutions supplier serving customers within multiple sectors worldwide. Our quest for Operational Excellence must include a focus on our core competencies of die casting and machining.  The divestiture of our Mangas operation is in line with our strategy and aligns our former associates with an industry leader in tool and die making.”

Aarkel, headquartered in Canada, is a global tool and die manufacturer with full-service tooling and engineering capabilities in Canada, Mexico, India, China, Europe and Brazil. Mangas expands Aarkel’s manufacturing footprint in the USA.

“We are very excited for the associates of Mangas. We have turned the operation over to a strategic buyer committed to investing and providing excellent opportunities for growth for the associates. Pace has had a relationship with Mangas spaning four decades. We will be leaving personal friendships and wish them all the very best” Hampton concluded. 

Aarkel and its new Mangas division will continue to be a strategic supplier of tooling to Pace Industries.

About Pace

Strategically located throughout North America, Pace operates a diverse manufacturing footprint with 12 die cast plants in the USA and Mexico, 1 tool and die shop, 2 finishing and painting facilities, 1 plastic injection molding plant and 1 machine and fixture building shop. Pace offers a wide array of services and capabilities to blue-chip  household name customers across numerous industries including passenger and commercial automotive and trucking, powersports, barbecue grills, recreational vehicles, lawn and garden, lighting, electrical, medical, telecommunications, defense, and aerospace.  Pace offers unmatched end-to-end value-added solutions, which include early supplier engineering support and design for manufacturability, machining and other finishing services including: shot blasting, impregnation, tumbling, chromating, wet painting, powder coating, polishing and assembly. For more information about Pace Industries, please visit paceind.com.

Comment

Pace Industries Successfully Completes Financial Restructuring

June 2, 2020

Emerges from Chapter 11 Protection with Strengthened Balance Sheet and Well-Positioned for Success
Donald Hampton, Jr. Named CEO to Drive Company’s Go-Forward Growth Strategy

FAYETTEVILLE, Ark., June 2, 2020 /PRNewswire/ — Pace Industries, LLC (“the Company”) today announced that it has emerged from Chapter 11 bankruptcy protection, successfully completing its financial restructuring plan to deleverage the Company’s balance sheet and create a sustainable capital structure. This milestone marks the implementation of the Company’s Plan of Reorganization (“the Plan”), which was confirmed by the U.S. Bankruptcy Court for the District of Delaware on May 29, 2020. The Company completed its restructuring in approximately a month and a half and met all commitments to the Company’s stakeholders throughout the Chapter 11 process.


The Company emerges from Chapter 11 protection with a strengthened balance sheet and well-positioned to realize the full benefit of its previously initiated operational improvements as well as additional cost structure improvements. Through the Plan, the Company has converted its existing senior secured notes into 100% of the equity of the reorganized Company and looks forward to benefiting from the support and operational expertise of its two largest senior secured lenders, TCW Group and Cerberus Capital Management, L.P.
Effective immediately, Donald (Donnie) Hampton, Jr. has been appointed as Chief Executive Officer to lead the Company going forward.


“We begin this next chapter for Pace Industries as a financially stronger company, which will enable us to capture the full benefit of the cost-saving initiatives implemented prior to the COVID-19 outbreak as well as new market strategies,” said Donnie Hampton, Jr., incoming Chief Executive Officer. “I am excited to lead Pace Industries forward as we execute on our strategic growth opportunities and continue to harness our market-leading capabilities to deliver for our customers as a fully-integrated provider.”
Mr. Hampton joins Pace Industries with more than two decades of industry experience and global P&L leadership. He has leveraged Six Sigma, Kanban, JIT and synchronous manufacturing strategies for companies such as Honeywell International (previously Allied Signal), Hayes Lemmerz, Rea Magnet Wire Company and, most recently, Faurecia. In his roles he has consistently ignited revenue and profit growth, equity value creation and world-class standards of operational excellence. He is a member of the Association for Manufacturing Excellence, Automotive Industry Professionals Worldwide and OPEX – Global Operating Excellence Network.
Outgoing Chief Executive Officer Scott Bull will be supporting Mr. Hampton in an advisory capacity to ensure a smooth transition. The Board is grateful to Mr. Bull for his 41 years of service to the Company – including 12 years as Chief Executive Officer – and wishes him well in his future endeavors.
“Pace Industries has a bright future ahead of it, and I am confident handing the reins to Donnie, who I know will do an outstanding job leading the Company,” said Scott Bull. “He is committed to maintaining the same energy with which Pace Industries serves its customers and provides high-quality products to meet their unique needs. Donnie’s experience and leadership will help the Company execute on its strategy and position Pace Industries for success.”


Looking forward, the Company plans to pursue a new go-forward growth strategy, focused on building its position in key industries and expanding in growth markets. Pace Industries will continue to keep customers at the core of everything it does and, with a bolstered financial foundation, is poised to invest in the capabilities to meet their needs now and in the future. The Company will continue to maintain and build on its current standards for safety, quality and corporate citizenship moving forward.

“From the implementation of new programs and initiatives, through the COVID-19 outbreak and this Chapter 11 process, this Company would not have been able to reach today’s milestone without the dedication and support of our team members,” Mr. Hampton continued. “I look forward to meeting many of the Company’s employees and customers in the weeks and months to come and am excited to roll up my sleeves and get to work.”
Filings and additional information on the Company’s emergence from bankruptcy can be found at http://www.kccllc.net/pace.
The Company was represented in this matter by Willkie Farr & Gallagher LLP and Young Conaway Stargatt & Taylor, LLP. FTI Consulting served as financial advisor. The senior secured noteholders were represented by Schulte Roth & Zabel LLP and the revolving credit facility lenders were represented by McGuireWoods LLP and Conway MacKenzie.

Comment

Pace Industries Reaches Agreement to Strengthen Its Balance Sheet, Announcing Plan to Position the Business to Realize the Full Benefit of Its Operational Improvements Following COVID-19

April 12, 2020

Expects to Deleverage Balance Sheet, Creating Sustainable Capital Structure

Initiates Voluntary, Prepackaged Chapter 11 Process to Achieve Its Financial Goals

Anticipates Completing the Process in Q2 2020, Paying All Unsecured Creditors in Full

FAYETTEVILLE, Ark., April 12, 2020 /PRNewswire/ — Pace Industries, LLC (“the Company”) today announced that it has reached an agreement with its senior secured lenders on the terms of a comprehensive financial restructuring plan, which will deleverage the Company’s balance sheet. This agreement has support from 100% of the holders of its senior secured notes as well as its revolving credit facility lenders.

Upon implementation, this agreement will give the Company the financial foundation necessary to resume normal-course operations following the COVID-19 outbreak, realize the full benefit of its cost-savings initiatives and strategic investments recently executed, and continue to serve its customers as a leading fully-integrated provider of die cast aluminum, magnesium and zinc components.

To effectuate the plan and facilitate these important changes to the Company’s capital structure, the Company and its U.S. subsidiaries have initiated a voluntary prepackaged Chapter 11 process in the U.S. Bankruptcy Court for the District of Delaware.

The Company’s operations in Mexico are unaffected by the filings, although they will benefit long-term from the actions the parent company is taking to strengthen its financial position.

The Company’s senior secured noteholders, along with its existing revolving credit lenders, will provide commitments for up to $175 million in debtor-in-possession financing to help ensure that the Company can meet its commitments during the process. Under the terms of the proposed prepackaged plan, the Company will convert its existing senior secured notes into 100% of the equity in the reorganized Company. As a result of its noteholder and lender support, the Company expects to complete the process in the second quarter of 2020 – emerging as a financially stronger company that is well-positioned to succeed in the post-COVID-19 environment.

“Over the past two years, we launched significant new programs for the automotive industry to further penetrate this important growth market and implemented a series of cost-saving initiatives to position our business for long-term success,” said Scott Bull, Chief Executive Officer. “Unfortunately, we were not able to realize the full benefits of these new programs and initiatives before the coronavirus weakened demand, disrupted our supply chain and forced us to temporarily close many of our plants in the United States.”

“We are confident in our go-forward direction and the underlying strength of our business and are taking these actions now to ensure we are positioned to realize our full potential when we – and our customers – are able to resume normal-course operations,” Mr. Bull continued. “We thank our lenders, employees, customers and suppliers for their support and look forward to being an even stronger partner as a result of the actions we’re taking to enhance our financial position.”

The Company has filed customary motions that will allow it to maintain employee wage and benefit programs, honor customer warranties as usual and continue to pay suppliers. Although the motions remain subject to Court approval, the Company expects that all trade creditors, employees, sales agents and unsecured creditors will be paid in full and on time in the normal course of business. Additionally, the Company will maintain all of its current standards for safety, quality and corporate citizenship both during and after the Chapter 11 process.

Further information about the case can be found at http://www.kccllc.net/pace or by calling (866) 967-0269 (in the U.S. and Canada) or (310) 751-2669 (outside the U.S. and Canada). Implementation of the restructuring plan and other relief is subject to Court approval, regulatory approvals and other customary closing conditions.

Pace Industries is represented by Willkie Farr & Gallagher LLP and Young Conaway Stargatt & Taylor, LLP. FTI Consulting is serving as financial advisor. The senior secured noteholders are represented by Schulte Roth & Zabel LLP and the revolving credit facility lenders are represented by McGuireWoods LLP and Conway MacKenzie.

###

About Pace Industries, LLC

Pace is North America’s leading full-service aluminum, zinc and magnesium die casting company. Pace offers end-to-end, nonferrous, die cast supply chain solutions, and a wide array of capabilities and services, including advanced engineering, tool and die fabrication, prototyping, precision machining, assembly, finishing and painting. Headquartered in Fayetteville, Arkansas, Pace operates the largest number and broadest range of clamping force die-casting machines in North America, which has positioned Pace uniquely to offer die-cast products for practically any customer requirement. Indeed, Pace is the only vertically integrated major die casting supplier in North America providing customers one-stop-shop services on a mass scale. For more information, visit paceind.com. 

This press release is for informational purposes only and shall not constitute a solicitation to accept or reject the Prepackaged Plan or an offer to sell or the solicitation of an offer to buy securities, nor shall there be any offer or sale of securities in any jurisdiction in which such offer, solicitation or sale would be unlawful prior to registration or qualification under the securities laws of any such jurisdiction.

Media Contact:

John Wisdom

+1 (479) 973-2164

[email protected]

Comment

Pace Cambridge brings home another award

November 21, 2017

The Cambridge Division of Pace Industries continued its history of winning awards at the NADCA International Die Casting Design Competition.  In fact, it was just two years ago when we last won an award at this very competition.  Check back in our blog archives for our January 14th, 2016 blog to learn more about that story.

This year, Cambridge won the Aluminum under 1 lb. division, with a Mid – Housing for L3 Technologies.  This is the main housing for a Next Gen Aiming Laser to be placed on many weapons for the U.S. military, to pair with all generations of night vision devices. The Cambridge team was given a tough task in replacing a piece that was previously conceived in plastic, that now needed to be cast in aluminum.  We designed a part that would not add weight, but significantly increase the structural integrity on the part.  Not only did we succeed, but we exceeded all expectations creating a part with walls less than 0.05” thick, yet with tremendous detail and durability.

The Cambridge division was excited to partner with L3 Technologies on this project.  Through many hours of discussions and brain storming sessions, together we designed a part that both Pace and L3 Technologies were proud to be producing. Keith Liadis of L3 Technologies said this about Pace, “It was a great experience working with the Pace team on this project, Pace certainly deserves the accolades.” Cambridge was able to showcase their full-service abilities on this part, providing everything from early supplier involvement, die casting, machining, anodizing, assembling and part packaging to be delivered to L3 Technologies.  We always strive to be the highest quality supplier to our customers and this is an example of the processes that we can perform.

Cambridge Division excels in serving niche and specialty markets, by expertly producing difficult die castings and providing exemplary project management and engineering support.  In addition, Cambridge’s value-added services includes a spectrum of capabilities including, in-house assembly, machining, finishing, and creating a total solution provider.  Situated just outside of Boston, the Cambridge Division is prepared to serve the innovative customers and countless startups in the area and all over the world.

Comment

Pace Grafton thrives in Competition

November 7, 2017

For the past 45 years, the North American Die Casting Association (NADCA) has sponsored the International Die Casting Design Competition where they recognize, reward and publicize the outstanding casting designs of the year.  This annual competition provides a competitive environment where submitted parts are judged on four equally weighted criteria, ingenuity of casting/product design, overall quality, cost savings and market-expanding potential.  The competition is broken down into several categories by both weight of castings and material used.

Pace Industries is no stranger to this competition, in the past 10 years, 6 divisions of Pace Industries have brought home a collective 12 awards. Pace has shown its expertise, by taking home awards in multiple different material and size divisions of the competition.  This year we are proud to announce that we have yet again brought home 2 awards from 2 of our divisions.

We are excited to celebrate with the Grafton Division on their winning part for the Aluminum casting 10lbs and up division.  The Grafton Division submitted a part cast out of 413 aluminum as their 2017 choice, the 44 lb. LED Light Fixture for Cree, Inc. This part was designed to increase the illuminated area by adding extra LED’s into the larger housing. What makes this light excellent is that the part not only maximizes its size, but also minimizes wind load requirements and reducing the overall part weight, helping to make the installation process much easier.  This part delivers many benefits such as reducing energy requirements, reduced maintenance cost and easier installs, allowing for rapid return on investments.

We are proud to partner with Cree, Inc. on the casting of this challenging part.  We know that our success ultimately comes when our customers succeed, and this part is truly raising the industry standard, and we are excited to be part of that.  Lisa Ruffalo from Cree, Inc. had this to say about her experience working with Pace on this project, “I was very impressed with Pace, it was a challenge to find a die caster who was able to produce a part this large but who could also produce a part with such detail.”  She went on to say “the software and mold flow analysis they used was outstanding, and they were constantly supportive and present through the entire process.”

The Grafton Division is an industry leader in complex high pressure die castings primarily for customers in the automotive, lighting, large and small engine industries.  Grafton can provide many value added services in house including machining, painting, polishing testing and assembly to name a few. Pace Industries is committed to providing uncommon solutions that contribute to the success of our customers.

Comment

Pace Industries announces leadership changes

August 8, 2017

Pace Industries announces the recent leadership changes at the Airo and Harrison Divisions. These divisions are cornerstones of the Pace network that consists of 12 divisions, 21 facilities and over 3,500 associates across the U.S. and Mexico. Pace Industries is North America’s largest aluminum die casting company and also provides magnesium, zinc high pressure die casting, and plastic injection molding.

Effective immediately, Marshall Haines, division president of Airo Division for the last 2 years will be transferring to the Harrison Division, located in Harrison, Arkansas, to serve as their new division president. Haines has had multiple leadership roles for Pace Industries since joining the team 12 years ago, ranging from division president to being the pioneer of the current purchasing department where he served as the VP of Purchasing. In his time at Airo, Haines continued to build on the tradition of excellence and performance at Airo. Most recently, that division supported a major customer launch of a new engine platform, the first major change in the engine for that customer in many years.  Haines continued to develop his team and supported them too, while returning the highest and most successful performance levels in the last 10 years.

As Haines leaves for Harrison, Mike McDoniel, a 20-year Pace veteran, will be filling the position of division president of the Airo Division, located in Latrobe, Pennsylvania. Mike has served in multiple capacities for Pace, ranging from division president of our B&C Division, sales and account management for our largest customers, and VP of Purchasing. Mike recently helped to further foster the growth of the purchasing department that was started by his predecessor, Haines. The hard work and contributions made by them to the purchasing department has provided a solid foundation as a crucial department of Pace Industries, helping to save millions of dollars for the company over the past few years.

 

About Pace Industries

Pace Industries is North America’s leading full-service aluminum, zinc and magnesium die casting company. Pace is a solution provider, offering a wide array of capabilities and services, including: advanced engineering, tool making, prototyping, precision machining, assembly, finishing and painting. Headquartered in Fayetteville, Ark., Pace operates 12 divisions, 21 manufacturing facilities and has more than 4,000 associates across the U.S. and Mexico.


 
 
 
 

Comment

Show for Product Design and Manufacturing

July 13, 2017

On June 7th, Pace Industries attended the Upper Midwest Design2Part Show in Minneapolis, MN.  The Design2Part Shows are a collection of trade shows that specialize in connecting engineers, product designers and manufacturers to some of the country’s top suppliers of custom components, parts and manufacturing services.  This event was one of the 11 shows that will be put on this year all around the US.

The team from Pace Industries provided 50 years of experience in industry sales and product engineering and design which showcased the breadth of our company. The divisions represented all the materials Pace Industries specializes in, making Pace one of the most diversified suppliers there.  We had Sales Managers from our Minnesota-based locations of St. Paul Division, specializing in Aluminum Die Casting and the Product Tech Division, which specializes in Magnesium Die Casting. The team also included Sales Management from the Arkansas-based B&C Division, one of our two Zinc Die Casting facilities, and Port City Custom Plastics, our only Plastic Injection Molding division located in Muskegon, Michigan.

This annual show is a favorite of Pace Industries and attracts potential customers Pace is eager to work alongside.  We visited with folks from a cross section of industries such as; Medical Devices, Lighting & Electrical Components, Meters & Industrial Controls, and Lawn & Garden. Pace has decades of manufacturing experience, product development and design expertise to serve these and other industries so it was a great opportunity to see new and exciting products.  Product Tech Sales Manager, Jim Hegland, had this to say about the show, “I feel this show captures more of the type of engineer who we like to meet. People who are designing new parts and are out searching for new ideas.”  Our sales managers came to the show with a desire to reach new markets and meet new potential customers.  David McWilliams from B&C, spoke on how the team worked together, “We have a great team, with knowledgeable people from Aluminum, Magnesium, Zinc and Plastics, we were able to provide information to the visitors that guided their initial material decisions (whether it be aluminum, zinc, magnesium, or plastic) which in turn helped all of our businesses.”  Our sales managers walked away with many good qualified leads, while also laying a foundation with several new potential customers.  Hegland said it best, “The way I look at it, if you get one deal out of a show like this, it was a home run” looks like Pace may have hit a Grand Slam.

Please check out Pace Industries’ booth at these upcoming Design2Part shows in Marlboro, MA (September 27th – 28th) and San Diego, CA (November 15th – 16th).

If you would like more information on how these divisions could further serve your needs, you can learn more about each division below.

 
 
 
 
 
 
 
 
 
 
 
 

Comment

Port City Custom Plastics Division Grows

June 22, 2017

Port City Division (PCD), a division of Pace Industries, has long stood as a well-respected Aluminum Die Cast supplier to a majority of the automotive industry. In 2000, they established Port City Custom Plastics (PCCP), hoping to further serve their current customers through plastic products. Specializing in plastic injection molding, PCCP quickly found their niche within their automotive and recreational vehicle customers that PCD had already served with aluminum products. Plastic seems to be a popular trend in many industries right now, as many customers are looking for an economical advantage. PCCP gives Pace Industries the opportunity to support those customers who are looking for that advantage by providing plastic injection molded products.

PCCP also compliments the die casting locations by providing overmolding options, a task that used to be outsourced that can now all be handled in-house further serving the customer. PCCP quickly grew working side by side with the die casting operations which allowed PCD to better serve their customers.

PCCP specializes in over 12 plastic materials utilized in various applications.

Almost 20 years later, PCCP has expanded into many new industries. Along with automotive they now serve the appliance, office furniture, roofing, and industrial control industries, and are seeking opportunities to serve new industries. Seeing the potential for growth, PCCP has begun to equip themselves, first by hiring a new sales manager who is dedicated to the growth of PCCP, secondly specializing in over 12 plastic materials, with nylon, polypropylene, HDPE, LDPE, Acetyl, polycarbonate, and PBT, being a few.

PCCP has continued to see success in the fast-changing automotive industry.  This industry pushes design to the limits, looking for parts that are lighter but stronger and at the same time thinner yet still safer, and often the responsibility of creating these innovative parts becomes the job of the supply base.  This is when PCCP thrives, being able to respond to industry needs and produce parts that are significantly lighter than their metal counterparts. PCCP has continually provided improved product quality for customers who are looking for those weight reductions and better product longevity.

PCCP has expanded into several new industries including appliance, office furniture, roofing, and industrial control industries.

PCCP has also found success in the roofing industry. Many homes in the northern states have roofs that are reinforced with ice/snow supports, which have in the past been made of steel. These parts would cost customers nearly $25 per piece. The engineering expertise at PCCP designed plastic pieces that would not sacrifice on strength or longevity of the parts but were priced around $10 or less per piece.  Additionally, the plastics could easily be colored to match the varying roof colors. Not only did PCCP improve the quality of these products, but helped to reduce the cost.

PCCP is located in Muskegon, Michigan along with the other PCD die casting facilities. This location has proven to be very strategic whether it be for the home construction industry, or being a few hours outside of the automotive capital of the world, Detroit. Being positioned in the Midwest provides a logistical advantage to PCCP and provides improved logistical expenses.

PCCP plastic injection molding products are made to the highest industry quality standards.

PCCP has quickly grown into an integral piece of Pace Industries, and gives us countless opportunities to further serve our current customers and to broaden our reach to new ones. We believe that PCCP helps give us a competitive advantage over our competitors and we know that PCCP can help you to achieve that same advantage.

If you have any questions or would like more information regarding Port City Custom Plastics or Plastic Injection Molding, please reach us here.

Comment

Pace to Receive the First Board of Trustees Partnership Award from Northark College

May 17, 2017

Scott Bull (left), President of Pace Industries, accepted the Northark Board of Trustees Partnership Award on behalf of Pace Industries during the Northark Graduation Ceremony from Jane Adair, Chairman of the Board.

In recognition of our years of cooperation with Pace and Harrison’s Northark College, Pace Industries was presented with the first Northark Board of Trustees Partnership Award at the school’s commencement ceremony on May 6th.

Over the years, Pace and Northark College have cooperated to support one another in their endeavors, strengthening both the relationship of the organizations and their ability to service their students and clientele. Northark has even developed customized workforce training and specialized class offerings to help train more skilled workers for Pace’s operations.

When these classes needed equipment to provide the best possible training, Pace donated and installed a $150k die cast machine at the school. Many Northark graduates from these classes went on to join the Pace team, with the graduates’ specialized training improving the quality of Pace’s work nationwide.

(From left) Steve Kruse; Kevin Roberts; Dr. Rodney Arnold, Northark VP for institutional advancement; Justin Rummer; Cheryl Goodman and Nell Bonds, dean of community education & workforce development at Northark.

Pace and the Northark Foundation have worked together to establish a scholarship to assist manufacturing technology and industrial electronics students with their tuition. Each year, Pace donates $20,000 to support aspiring manufacturing professionals and foster job growth in the Harrison community.

“Pace has been such a good friend to this College over the years. The board felt the time has come to recognize their contributions by creating an award to recognize the vital importance of our business and industry partners,” said David Evans, Chair of the Award Committee and Northark board member.

It’s not only in Harrison that Pace is working to improve education within the community. Pace is partnering with 70 high schools and technical colleges nationwide in an effort to educate students and be a community leader in those locations.

Patterson Division (in St. Charles, MO), along with other industry leaders, sits on several advisory boards for many of Ranken College’s programs. Industry leaders look to hire as many Ranken students as possible. Student tours are constantly coming through the plants so that students can connect classroom theory with real world experience.

At our Product Tech Industries Division, Pace works with Wright Technical Center in Maple Lake, MN. Their partnership is one that supports students’ desire to explore career opportunities through state registered youth apprenticeships. Students are able to work at PTI and gain school credit, while earning a good wage for their efforts.

Pace’s long-term goal with school involvement is to show students that advanced manufacturing does not happen in dark, grimy buildings, but in places that make use of new technologies and skills that translate into rewarding, lifelong careers. Pace is looking to usher in a new generation of leaders in advanced manufacturing. Proud to be the first to accept this award from Northark, Pace is committed to growing and maintaining our participation with the college. This kind of acknowledgement from partners and clients keeps us confident that we’re fulfilling our mission to provide the highest quality in casting and manufacturing.

Scott Bull receives award for Pace Industries.
Scott Bull addresses the crowd at the NorthArk award ceremony.

 

Comment

Pace Looking Forward to Lightfair 2017

April 27, 2017

Lightfair 2017 is just around the corner, with the 2017 event being held from May 9th to the 11th at the Pennsylvania Convention Center in Philadelphia. Lightfair 2017 will play host to members of the architectural and commercial lighting industries, as they meet to learn about new solutions, knowledge and discoveries in lighting.

A hot topic at Lightfair 2017 is sure to be LED technology, with improvements to the technology a focal point of discussion. Pace is excited to attend and learn more about the technology.

One of Pace customers’ primary concerns is to dramatically reduce lead time to market. With LED technology improving so rapidly, the lighting company able to bring that new LED technology to market first, will dominate. Pace is assisting customers on the front end, with early supplier involvement (ESI) in the engineering and design of LED castings. By also getting designs to be die cast friendly, reducing their weight, and making them as cost-effective as possible, Pace is meeting customer demand.

By addressing these concerns at the beginning of the process, Pace can generate a quote faster, get their tool shops involved quicker, and reduce the lead time to build new tools. This is enabling customers to get their product out into the market faster than their competitors.

While Pace will not be showing at Lightfair 2017, they will be present to meet with industry experts to learn about advances in the lighting industry, and what role they will play in the future of lighting. Stay tuned for what they learned at the show.

Comment

Pace’s Port City Division Awarded Certificate of Achievement from Toyota

April 10, 2017

Pace’s Port City Division was recently awarded a Certificate of Achievement at Toyota’s Supplier Conference. A casting division of PCD supplies Toyota with the vacuum pump bracket used for the hydraulic brakes in the Toyota Tacoma TRD Off Road package. The certificate was awarded to PCD for achieving a 100% on-time delivery rate and a zero PPM defective for the year of 2016.

A PPM (Parts per Million) score relates to the number of parts per million that are defective. If a supplier produces 10,000 parts and just one of those parts is defective, that supplier has a PPM of 100. PCD was responsible for production of over 30,000 parts, a relatively small number, but achieved a PPM of zero. While many other companies avoid taking on smaller production volumes, PCD was able to deliver these parts with a zero PPM, while remaining 100% on time.

Being on time once is easy. Being on time thousands of times, across all areas of production, throughout an entire year is a difficult task without doubt. In 2016, PCD not only met Toyota’s strict production requirements, they did it on time every time. Being on time saves the customer downtime, money, and in the end, cultivates a sense of trust between supplier and customer. When a customer knows they can depend on the supplier, they don’t need to look elsewhere.

Not only is PCD responsible for the casting of the part, they also provide secondary machining and assembly for the vacuum pump bracket. PCD machines the part, inserts a gasket (assembly), and then pressure tests the assembly to ensure the highest quality and functionality is being delivered to Toyota.

With Port City Division able to offer these secondary operations, they provide an added value to their customers. While competitors may only supply the raw casting, PCD goes above and beyond to ensure that whatever they produce is being sent to the customer when they need it and how they need it. The secondary operations for this part include machining, blast finishing, assembly, and pressure testing.

This award from Toyota stands as a testament to the Port City Division’s uncompromising commitment to excellence, upholding the values of Pace as a whole. By accommodating all processes in-house, PCD helps Toyota optimize their total cost by providing an end to end solution, saving time and money. At PCD, our culture of zero defects and exceeding our customers’ expectations ensures that partners like Toyota remain just that.

Comment

20 Years of Growth

February 9, 2017

Ever since it was founded in 1970, Pace Industries has been committed to providing uncommon, creative die casting and support solutions to their customers. While our goal has always been the same, the tactics for achieving it have understandably changed, especially when looking at the last 20 years.

Predictive Analysis

It was important for us to constantly improve the design of our tools to ensure we were providing the highest quality products to our customers. Starting in 1996, we began to employ the following analyses to better understand our designs:

  • Flow analysis – shows the flow pattern during die cavity fill. Reveals temperature, pressure, and velocity.
  • Thermal analysis – shows how the metal solidifies within the steel die.
  • Thermal stress analysis – shows how the castings distorts as it cools after being removed from the die.
  • Finite element analysis (FEA) (added in 1998) – analyzes high stress areas in castings which can be used to improve strength of future castings.

We often have a new cast tool running with changes implemented within six months of studying insights from the analyses.

Die Life Guarantees

Thanks to research done by NADCA, we began to understand how to optimize die steel performance in the casting process. This was information that affected our language when communicating with customers about the length of die life. We took the research and successfully applied it to our process in the late 90s. How successfully? Well, prior to that, several of our tools were suffering premature failure yearly. Since that implementation, there hasn’t been more than two failures in over five years.

New Alloys

In order to offer even more abilities to our customers, we entered the new millennium with the development of several new specialty alloys:

  • High elongation aluminum alloys – for use in thin-wall structural applications. This plays a major role in helping reach mandated fuel efficiency levels for automotive companies.
  • Specialty aluminum alloys – allows the die casting process to compete with other aluminum processes that standard die castings cannot meet.

 

Automation

We are devoted to making sure we are using the most efficient technology, and our increased use of automation has led to some groundbreaking developments. In 2013, we began to use dosing furnaces that led to energy savings, and in 2002, we saw emphasis on the use of robots. There was a learning curve for our associates during this time, with many requiring training on the new methods, something that was surprisingly enjoyable. “Most of our people enjoyed the training because it was a challenge, and several requested to work with the robots,” said Arnie Fulton, vice president of engineering.

Furnace Design

In early 2004, we began to examine the best design that would lead to increased energy efficiency and melt rate. In five months, we had reached our goals by improving insulation, improving refractory, and applying a new burner design and molten metal pumps. In the time since, we have built approximately 15 more furnaces, all using the same effective design as that first one.

Bigger Die Cast Machines

In 2015, customer needs required bigger machines than what we had. To continue to best serve our customers, we worked to acquire machines up to 3,000 tons, when our previous leading machine maxed out at 1,800. This change maximized satisfaction and allowed us to foray into new areas such as alternate alloys.

The past 20 years have brought tremendous growth to our company, our associates and our customers. But we aren’t stopping. We are excited about what will come in the next 20 years.

Pace Industries 20 Years of Growth

Comment

Learning and Growing: Pace Further Adapts Competitive Advantage Strategy

January 5, 2017

pace-business-excellence

Business Excellence is Pace’s systematic approach to identifying and eliminating waste through continuous improvement and making products that meet our customers’ needs. As its director, Bill Turner is focused on the company’s wins, as well as the growth opportunities that become apparent after setbacks.

As 2016 ended, he reflected on the past year and looked ahead to Business Excellence in 2017:

Strategy Deployment (SD) is a structured process that motivates us to work on those things paramount to the success and longevity of our business, including safety, quality, delivery, inventory and cost. It has been an integral part of our business for 10 years. In 2017, SD will continue to be key in helping us achieve a compelling competitive advantage. Associates from all levels of our company participate on multi-functional teams to achieve the goals established through this process.  From there, teams are empowered to develop and execute action plans, measure progress and resolve problems.  Through this, we build a culture of continuous improvement through associate engagement, teamwork and problem solving.

This year provided evidence that this strategy is positively affecting our work. In 2016, there were several new product introductions across the business, many of which were in the automotive industry. Serving this industry’s customers can be a challenge due to the complexity of the parts and their stringent quality requirements. Despite those difficulties, in 2016, we improved our parts and customer satisfaction significantly increased, allowing for a growth in the automotive segment of our business. Our quality was better though the work was more complex. We consider this a great success story!

So where is Business Excellence going in 2017?  First, we will reinforce our commitment to SD by engaging even more associates in the process. Second, we will be expanding the utilization of ongoing improvement methodologies and tools, including value stream mapping, 5S, standard work, poka-yoke, SMED and kanban.  We need to take advantage of these proven improvement techniques.  And third, we will remain diligent problem solvers.

In 2017, we will be relentless in our pursuit of achieving a compelling competitive advantage.
mangas-strategic-deployment-team-1

mangas-strategic-deployment-team-2
A team at Mangas Tool & Die complete a value stream mapping exercise as part of Strategy Deployment.

Comment

Manufacturing Trends Shape Pace’s 2017 Goals

December 20, 2016

manufacturing-trends-shape-paces-2017-goals

As 2016 comes to a close, everyone is inevitably curious about what the new year will bring. Arnie Fulton, Pace’s vice president of engineering, provided insight on manufacturing trends that will influence the company strategy in 2017.

  1. Automation Continues – Collaborative robots are a trend that has received a lot of attention in industry publications. The great thing about these robots is that they are designed to work alongside our associates. We have found they are easier to program and safer to use than conventional robots. Pace will continue to implement automatic equipment, and our main focus will be on the further utilization of collaborative robot applications.
  1. Larger 3-D Printing Presence – Pace dabbled in 3-D printing this year, but we really want to grow that over the next 12 months. The trials completed this past year have been quite successful. We’ve used 3D printing for both die components and machining fixtures, and we will be expanding to castings next.
  1. Focused on Thermal Control – One of our goals for 2017 is to delve even more into the process of controlling the die temperature for the purpose of improving the quality of die castings. Further understanding of the thermodynamic process will result in an improved consistency, which will lead to an improved product.
  1. Integration of Laser Manufacturing – Laser manufacturing is not new to Pace Industries, but there is opportunity for it to continue to evolve and become more integrated throughout our company over the next year. We are currently in the process of researching and developing its use within our facilities, and the goal is to complete that research in 2017 so we can begin implementation. As a company, we are eager to incorporate laser manufacturing into a variety of functions, including the repair of tooling and machine components, extending the life of casting dies and even fabricating new parts for increased performance.

 

Given that we pride ourselves on exceeding expectations with our work, it is no surprise that our 2017 objectives reflect constant improvement in areas we are familiar with. We are dedicated to achieving and excelling at these upcoming trends, and continuing to identify new areas for opportunity. That is how we will remain dedicated to providing uncommon solutions to our customers in 2017 and in the many years to follow.

Comment

Manufacturing Day – Preparing Students for Success

December 1, 2016

image-1

This is our Product Tech Division in Maple Lake, MN. Pace Product Tech Division is an integrated magnesium resource for product development from concept to solution.

Here at Pace Industries, we recognize the importance of being passionate about your work, which is why we participate in Manufacturing Day. For three years now, we have invited students into several of our production facilities to give them a glimpse into modern manufacturing and to inspire them to pursue it as a career.

This year, we had a total of 1,228 students visit Pace Industries during October. Attendees ranged from 7th grader through college-aged students. Each Friday in October, at least one of our facilities held a Manufacturing Day event. The Harrison Division hosted two days due to the high volume of students involved in the area. Ethan Robinson, our workforce coordinator, is responsible for connecting with schools and confirming their participation. “I contact about 75 schools in the United States, including technical schools, universities and high schools,” said Robinson.

This is Robinson’s second year coordinating Manufacturing Day, and his learnings from 2015 helped shape his plans for 2016. “Last year, we really focused on the products that we made because we wanted to awe the students,” Robinson reminisces. “After talking to them last year, we learned that what they want to know about is careers.” With that knowledge, he decided to revamp the Manufacturing Day material to be more job-focused. During the students’ visit, we chose to highlight positions that we predict will be in demand when they are completing school and entering the workforce. “We’re looking to get the word out to let kids know manufacturing is a viable career path,” said Robinson.  Robotics is becoming a more prominent part of the industry so there is a lot of encouragement to pursue some kind of automation training.

During Manufacturing Day, students go on a plant tour in which they are able to see every part of the facility and learn about the different machines we work with. Afterwards, they are given the opportunity to ask associates questions they may have about the work and career opportunities available at Pace. When they leave our facility, we hope they walk away with useful information about careers they may have not formerly considered as well as how to pursue them.

We are very proud of the work we do here, and every year we look forward to the opportunity to ignite a similar passion in students that could soon help us grow professionally. As Robinson states, “The kind of work we do requires us to be proactive so we have decided to prepare the surrounding areas for the work we’re going to have. In just three short years, we can already see an impact. We’ve seen a definite uptick in the number of students applying for internships and youth apprenticeships at Pace.”

image-2

Bob D’Ortona, vice president at our Cambridge Division in North Billerica, MA, gives a tour to students from Shawsheen Valley Technical High School. They are looking at an Aluminum melting furnace with 20,000 pound capacity.

image-3

Lee Kittle, die cast manager at Pace Industries, Port City Division in Muskegon, MI, hosts students from the Muskegon Area Technological Center.  He is showing them an 850 ton die cast machine.

image-4

Hannah Niblett, talent sourcing specialist, poses with a group of Harrison High School students at our Arkansas based Harrison Division.

image-5

Bob D’Ortona doing tours with one of our QC engineers, Anne-Marie Buchenan. They are discussing and viewing a Mori Seiki NHX 5000 horizontal machining center.

image-6

Product Tech Division – Lynne McIntosh, safety manager, shows Maple Lake High School students the S56 Vertical Machining Center in the tool room. 

image-7

Product Tech Division – Homeschooled students and some from Maple Lake High School listen to a presentation about our products, career opportunities within Pace and educational paths they should take for those careers.

Comment

Collaborative Robots

September 8, 2016

Why Cobots Are a Game Changer for Die Casting

Pace has been an innovative company since its inception. It’s the basis of our corporate mission statement: provide uncommon, creative solutions, which contribute to the success of our customers. So it’s no wonder we’re leading the industry in technological advances, such as using collaborative robots on the manufacturing floor.

Collaborative robots, which are also called “cobots,” are designed in a way that allows a robot to physically interact with humans in a shared workspace. This differs from a conventional robot in that they don’t require a safety enclosure to operate. Cobots work at full-speed without jeopardizing safety.

Why are they used in manufacturing?

In addition to their safety features, Pace is interested in cobots because they’re affordable, highly adaptable and easy to use. Most of them operate from a smartphone or tablet, so they don’t require a high level of expertise to set up and program compared to conventional robots. This means they can be put into operation quickly and easily. And since they’re generally simpler than traditional robots, cobots are more affordable to maintain.

These robots are also highly efficient. When partnered with an associate, they produce an end result better and faster than either could do working alone. In fact, tasks that normally take days can be completed in a single shift.

How are they being used today?

Pace is still in the early stages of implementation. Right now we’re using them to perform repetitive operations, such as sanding of castings. We’re also using them in the process loading and unloading CNC machines. Having them in this capacity allows more time for a person to perform other value-added operations that require more skill.

Since they’re relatively lightweight, cobots can be moved from one work assignment to another. Because of this benefit, we’re looking at many other applications in die cast machine applications.

What’s the benefit to customers?

While there are multiple benefits to Pace, collaborative robots also benefit customers. They allow us to provide higher quality products while keeping costs in check. For example, when they’re programmed to work with CNC machinery, we can offer a more finished product. This eliminates having to send it out for additional steps in the process. Keeping everything in-house reduces costs and increases quality.

What does the future hold?

There will continue to be applications where it makes sense for associates to perform tasks manually. And some applications require overall automation to keep costs down and safety at a maximum. Cobots are proving to be the best solution for tasks that fall somewhere in between.

We believe there’s a growing need to integrate robots into the workforce to take advantage of the diverse strengths of both humans and robots. So Pace will continue to explore and implement more robots where they fit best in our processes. We’ll keep our focus on uncommon, creative solutions for the success of our customers – always.

image002

Juan Zuniga and Noah Wehn, both seniors at HarBer High School in Springdale and summer interns at Pace, used their skills to integrate a collaborative robot with a CNC machine.

Comment

Top 5 Tips for Die Casting

August 11, 2016

DSC_8725

Die casting can be a tricky thing to master. That’s why at Pace Industries, our experts are here helping through every phase of the process. Pace is constantly working to provide uncommon solutions to customers, and one example is the extensive product design assistance we offer.

We work with our customers on the design of their castings to incorporate features that will maintain functionality while optimizing features that enable the casting to be easier to produce. This allows our customers to receive a casting from Pace that is designed to minimize their cost while allowing Pace to minimize our production costs.

Customers often know what they want functionally and we know how to make a casting that will meet those needs. Here are our top five tips that can help you understand our process and the reasoning behind the design guidance we provide.

TIP #1: Maintain a uniform wall thickness across the casting. (While this is not always possible, try to keep the variations in wall thickness to a minimum.)

• This improves metal flow and the filling of the casting for better quality. It also minimizes dimensional variation due to the differences in cooling rates in the casting walls.

TIP #2: Corner radii (outside corners) and fillet radii (inside corners) on the casting should be as large as possible.

• This improves the filling of the casting for better quality and increases die life due to decreasing of the degradation of the die steel in sharp corner areas.

TIP #3: Include draft (tapered walls) in the casting design. You should have more taper (draft) on the inside walls of the casting than you do on the outside walls of the casting.

• Draft is required in order to remove the casting from the die. (This the same reasoning used in the design of muffin tins, which have tapered walls to aid in removing the muffins.) The reason for more draft on the inside walls is that the casting alloy shrinks as it solidifies. Castings tend to get smaller and fit more tightly onto the inside of the casting. The increased draft then allows for easier removal of the casting from the die.

TIP #4: Keep critical dimensions on the same side of the die.

• Since the die has moving components, dimensions that are based on more than one component will have more variation than dimensions that are based on features in a single die component. Greater variation in dimensions will require larger tolerances, which may not be acceptable to the function of the casting. When that happens, it requires added operations on the casting to meet tolerances, which will result in added costs to the customer. (Something we always want to avoid!)

TIP #5: Avoid undercuts, if possible.

• Undercut geometry cannot be cast in a standard die cast die. This undercut requires the addition of a moving die member called a “slide” in order to cast this piece of the casting geometry. The added “slide” increases the cost of the cast die. The undercut geometry also affects the amount of time required to make the casting, which increases the cost to the customer.

At Pace, we are here to provide hands-on assistance. We can help you understand the design process and what will ultimately be the best fit for your casting needs. We also offer casting design seminars at customer locations where we meet with product design engineers in an informal, educational setting to provide a better understanding of what designs work well for die casting.

Our first priority is always to provide our customers with high-quality products at competitive prices. Working together with our customers, we can help develop casting designs that satisfy functionality and castability requirements.DSC_8684

 

Comment

Maker Movement

July 14, 2016

Why the Maker Movement is Critical to our Future

There’s a trend that has been growing for several years now called the Maker Movement. It’s a modern term to describe the wave of independent inventors, designers and tinkerers who are bringing their ideas to market through the use of new technology.

Typical interests of a maker include engineering-related activities, such as electronics, robotics and 3D printing, which is why Pace is so interested in this movement. We’re constantly evolving in our use of technology to make the highest quality and most cost-effective products for our customers. We’re always improving our processes and strengthening our future. And one of the best ways to stay on course is to find and hire the best of this new generation of makers and give them resources to create industry-changing ideas.

Throughout history, when people have the right tools and inspiration, they have the ability to change the world. That’s what we’re experiencing right now. New tools like 3D printers, laser cutters and open-source hardware, are empowering a generation who have been tinkering in their garages and basements since they were little. It’s up to manufacturers, like us, to encourage these inventors to become team members. They hold the recipe for products of the future, and manufacturers have the means to produce them and make them work. It’s the perfect partnership.

So how do we encourage the Maker Movement and this generation of tinkerers to become part of a company like Pace? We invest in them and provide opportunities to explore and grow.

Investing in the Next Generation

Pace is so committed to young engineers that we have created one-of-a-kind internships for kids as young as 15-years old. We also sponsor high school robotics teams and provide scholarships to college-level students interested in manufacturing. Our ultimate goal is to transform kids’ passions for engineering, robotics and other technologies into real-world business practices. We want to give them a place to grow – and a future to be excited about.

One of our inaugural programs has been an 8-week summer internship for two high school students. Juan Zuniga and Noah Wehn, both seniors at HarBer High School in Springdale, Ark., have been blazing trails since the day they started their internship with us. This is now their second summer to work with Pace.

When they first started, they jumped into an automation project for our division in Harrison. While they’re too young to work on the plant floor, they were able to work with 3D modeling, grow in their understanding of the die casting process, and perform computer work that assisted in perfecting our Automation Training Center.

This summer they’re using their skills to integrate a collaborative robot with a CNC machine. These robots offer multiple benefits to a plant in terms of safety and cost effectiveness. When they’re programmed to work with CNC machinery, it allows us to offer a more finished product for customers. So the projects these interns are exposed to are educational for them and beneficial to the company.

In addition to working with our 3-D printers and robotics, Juan and Noah have participated in safety meetings and other day-to-day activities within the company – giving them a good sense of the business environment and making them smarter about the industry as a whole.

Each summer, the internship culminates in a presentation to the entire home office that includes a summary of what they’ve learned. When asked about their experiences with Pace so far, Juan said, “Pace has offered us a great opportunity, especially for someone our age. I’d like to offer them a big thank you!” Noah was quick to agree.

These two students get credit for bringing the idea of the internship to Pace. They also inquired about funding for their school’s robotics program, which was just getting started. Pace was pleased, and continues to be excited about, supporting and encouraging these young engineers, as well as others who share the same passion. Internships and sponsorships are investments we want to continue to make. In fact, we’d like to branch out into other communities where we have divisions and offer similar programs in the years ahead. We see value in the next generation of makers. They’re our future. And based on what we’ve experienced so far, we’re in good hands.

Comment

Five Things You May Not Know About Aluminum

June 16, 2016

Five Things You May Not Know About Aluminum

When most people think of aluminum, it’s in reference to a soda can or long strips of foil used in the kitchen. An interesting thing about aluminum is that it’s actually found in many places, such as doorknobs, kitchen utensils and even glass production. And it continues to gain traction in many industries.

According to the Aluminum Association, it has been produced in commercial quantities for just over 100 years, which makes it a comparatively new industrial metal.

What makes aluminum so popular?

In addition to being the second most abundant metallic element in the Earth’s crust next to silicon, it’s easy to mold, fold and recycle. This creates a long list of benefits for things like packaging, transportation and construction.

With Pace being an aluminum die casting company, you can imagine our appreciation of this prevalent element. We believe the more that’s understood about the benefits and uses of aluminum the more we can innovate and advance technologies around this plentiful resource.

With that in mind, we’d like to share a few interesting facts.

  1. Aluminum is green. There are two types of aluminum: primary and secondary. Primary production is the process by which new aluminum is made. Secondary production is where existing aluminum is recycled into another usable form. This secondary process is extremely environmentally friendly. In fact, it’s 92 percent more energy efficient than primary production.With the ability to recycle aluminum so easily, there isn’t a high demand for mining new resources. The Aluminum Association reports that 75 percent of aluminum ever made is still in use. In our own operations, Pace uses only recycled aluminum. It’s more cost effective and also a responsible way to operate.
  1. Aluminum is extremely lightweight. According to the S. Geological Survey, it’s a third of the weight of steel or copper. What this means for Pace is that it allows us to have greater design capabilities. We can develop products that allow for lightweighting, which is critical for many of our customers – especially those in the aircraft, boating and automobile industries. Lighter machines translate to less energy required to operate.
  1. Aluminum plays well with others. The unique properties of aluminum alloy allow the metal to work well with a steel die, which is what Pace uses. The process moves quickly with aluminum, and we’re able to get fine details on a part. This can eliminate secondary operations and allow us to combine parts. That means less assembly for castings that are lower cost and with a finer detail.
  1. Aluminum was born out of science. Aluminum isn’t naturally found in the Earth’s crust. It comes from bauxite, which has to be processed to get aluminum. What this means is that it required the efforts of chemists and engineers to bring it to life. Essentially, innovation made this metal possible.As an interesting fact, Danish chemist Hans Christian Oersted first extracted aluminum from alum in 1825. It remained a novelty and too expensive to mass-produce until 1886 when American chemist Charles Martin Hall and French chemist Paul Héroult independently invented the Hall-Héroult process, which is still used today.
  1. Aluminum is getting stronger. Scientists continue to search for ways to improve aluminum, and there are currently hundreds of mixes on the market. One of the most recent breakthroughs was in 2010. Yuntian Zhu, a professor at North Carolina State University, and his colleagues subjected aluminum with magnesium and zinc to extreme pressure. The result was an aluminum that’s as strong as steel.The next phase of development is to produce this in large enough volumes for commercial applications, which will be a game changer for many industries.

With so many applications and unique benefits, it’s easy to classify aluminum as the metal of modern life. We’re excited to continue innovating with this resource and watch how it will transform the world around us in years to come.

For a complete history of aluminum, check out this article by the Aluminum Association.

Comment

Educating the Next Generation of Associates

May 12, 2016

The fact that Pace is the largest custom die casting company in North America is the direct result of our associates’ experience and hard work. Our company is staffed with some of the most talented professionals in the industry. In order for us to keep growing and innovating, it’s essential we recruit from a well-trained talent pool.

We’re faced with a unique situation, though. America is experiencing what educators and industry officials call the “skills gap.” This refers to the disparity between the high number of jobs opportunities and the low number of qualified applicants. With technology making huge advances every day, jobs are becoming more and more technical, thus requiring more education. The problem is that students aren’t seeking education in these areas. They believe trade skill jobs are a dead end, but that couldn’t be further from the truth. Students who have knowledge of these trade skills are more valuable than ever, allowing them to achieve high wages and rapid job growth potential.

Our company is dedicated to finding these students with knowledge of our industry and offering them an opportunity to begin an excellent career. These students are the future of Pace. And we expect the same qualities from all associates, whether they have 35 years of experience or are fresh out of high school. We want our associates to join in our culture of innovation, excellence and dedication.

Part of our solution is to put strategic programs in place to help develop incoming talent. We’ve offered job shadowing, internship opportunities and now have a new scholarship program. This new program is called Pace Scholars and is available for students attending North Arkansas College (NAC) in Harrison, Ark. who have an interest in manufacturing. There are a total of 20 individual $1,000 scholarships available to high school seniors on their way to NAC. For anyone interested in applying, contact our HR team.

Our customers have great needs in quality and production, and we have to be prepared to meet those higher needs and perform well. The bottom line is that recruiting is at the top of our list when it comes to making smart investments for the company. We want to continue growing, and training and hiring the best associates will remain the key to our success. As our clients see our new successes with our talent and technology, our business partnerships will grow.

About Pace Industries

Pace Industries is North America’s leading full-service aluminum, zinc and magnesium die casting company. Pace is a solution provider, offering a wide array of capabilities and services, including: advanced engineering, tool making, prototyping, precision machining, assembly, finishing and painting. Headquartered in Fayetteville, Ark., Pace operates 12 divisions, 21 manufacturing facilities and has more than 4,000 associates across the U.S. and Mexico. Learn more at paceind.com.

Comment

Nanotechnology Makes Big Improvements

April 26, 2016

At Pace, we’re committed to bringing our customers the most up-to-date and innovative die casting technology available to provide premium products in a cost-efficient way that benefits them.

For example, through our use of nanotechnology, we are able to fine-tune materials at the atomic and molecular scale, in an effort to make the material stronger. The process changes the performance of the materials without changing the materials themselves, and product performance is significantly enhanced.

The improvements of products produced on a nano scale could result in longer life for perishable tooling in the machining process, better wear resistance in lubrication applications, better corrosion resistance and more. This technology is constantly evolving, and each discovery leads to new areas for possible improvements, such as longer die life, better machine performance, longer cutting tool life and improved casting quality.

We currently have several projects that are either completed or in-process involving nanotechnology. It’s a very exciting time, because the possibilities these processes can yield are vast. At this time, we don’t see an end to the conceivable applications for nanotechnology.

Being involved in this advanced level of technology has opened a new world for Pace. Nanotechnology allows us to be competitive in terms of quality and delivery, letting our customers be confident that we will be long-term partners for their die casting needs.

Comment

Pace receives NADCA Safety Awards 12 years in a row

April 7, 2016

Pace is remarkably proud of our recognition by the National Aluminum Die Casting Association (NADCA). Multiple divisions within the company received NADCA Safety Awards this year, which marks 12 consecutive years we have received these prestigious industry awards.

According to NADCA, the frequency and injury rates for the die casting industry are approximately twice those of other private industries. So safety is a big concern for the industry. To be recognized within the industry for exceptional safety standards is a significant honor, and it shows that our commitment to the issue is making a difference.


About the Award

The NADCA Safety Award Program was developed to honor Corporate Members that both exceed and meet the average U.S. national safety standards for all manufacturing in a given year. There are two award levels within the program. Perfect Safety award winners have an incident rate of 0.00, while Outstanding Safety award winners are companies with a 4.00 or less of total recordable cases. That number is an average of the entire manufacturing industry.

Incidence rates are based on the number of injuries and illnesses per 100 fulltime workers. The average is calculated by the number of injuries and illnesses divided by total hours worked by all employees during the calendar year.

Recognition for Pace

Overall there were nine divisions within Pace that were recognized this year. B&C achieved the highest award for Perfect Safety. Harrison, which has a particularly strong safety record, received the Outstanding Award for the 12th year in a row. Two of those years were for Perfect Safety.

Other Outstanding Safety awards this year were given to Patterson Mold & Tool, Airo, Product Tech, Grafton, Cambridge, St. Paul, and Mangas Tool & Die.

Award winning companies will be featured in the May issue of DCE magazine and will be recognized during a luncheon at NADCA’s Die Casting Congress & Tabletop in Columbus, Ohio, September 26-28, 2016.

Planned Progress

To a large extent, our positive results are due to our Health & Safety Management System (HSMS) and our employees’ commitment to safety. Each division is responsible for implementing four elements within HSMS: Management Commitment & Associate Involvement, Worksite Analysis, Hazard Prevention & Control and Training. To hold ourselves accountable, the corporate health & safety department audits and scores each division every two years.

A few initiatives of HSMS include:

Making safety personal: Each Pace associate is asked to create his or her own Personal Safety Pledge. This could be anything from not texting and driving, remembering to wear seatbelts, and wearing proper PPE while using shop tools.

Having high expectations for contractors: The HSMS requires outside contractors working at Pace to receive the same high quality safety training as associates. They must follow the same rules and policies, as well.

Improving health & wellness: We have held health clinics where Health Risk Assessments are provided to encourage associates and their families to improve their health and prevent serious illnesses.

 

A Measureable Difference

Pace has decreased the recordable incident rate 75% from 2011 to ending 2015. This is due in large part to our CEO, Scott Bull and the executive team’s commitment to safety, as well as all of the associates at Pace, being focused on improving the safety culture.

We’ve learned that when we hold each other accountable to make good, safe choices on the job, we create a safety 24/7 culture. This means greater efficiency for our customers and a better work environment for our associates where they feel valued and safe.

Our commitment to safety is unconditional, and working safely is a condition of employment. We believe all accidents are preventable, and we have clear goal to achieve zero injuries. This should mean many more years of Safety Awards in our future.

###

Comment

Why Aluminum is a Driving Trend

March 17, 2016

We are on the verge of a major shift in the auto industry. The Aluminum Association boasts aluminum as the fastest, safest and most environmentally friendly way to increase performance and fuel economy in vehicles, without compromising safety or durability. It is estimated that automakers will consume nearly 23M metric tons by the year 2020. That’s a 65% increase from today’s usage.

Paving the way for vehicle bodies made out of aluminum, rather than steel, is the Ford F-150 pickup. This is significant because it shows that for the first time, aluminum is being deployed at mass production. This proves aluminum can be a viable substitute for steel.

We’re also seeing Chevrolet tapping into the aluminum-body trend. In 2014, the Chevy Corvette was redesigned to use an aluminum frame – and it doubled sales. They also have plans to begin using aluminum hoods on their mid-sized pickups, the Colorado and GMC Canyon.

General Motors also plans to decide within the year whether to include aluminum on their Silverado and Sierra pickups. When shifting to aluminum-bodied vehicles, repairs and manufacturing costs seem to be the biggest concerns for GM. At a recent technology conference in Detroit, GM Product Chief Mark Reuss, stated, “I read in Automotive News about the tools required to fix an aluminum truck. I saw those costs. We know it’s expensive.”

Addressing customer concerns is something Pace doesn’t take lightly. Whether the concerns are specific to a part or vehicle in question, we are able to work with automakers to find viable and cost-efficient solutions. Through early supplier involvement, we are able to work early on with engineers on design activities, and develop designs that are easier to cast. This reduces time-to-market and lowers the overall production costs.

In addition to aluminum bodies, automakers are turning to aluminum to meet fuel efficiency requirement. Fiat Chrysler Automobiles is using various aluminum components to boast their top-selling Ram as having 25 MPG on the highway. This is the highest of any full-size pickup with the gasoline engine.

The aluminum industry continues to make breakthroughs in technology, and automotive manufacturers are showing a willingness to produce stronger, lighter and environmentally sound vehicles.  As more demands are made and better technology is discovered, more and more vehicles will become increasingly aluminum intensive.

We continue to see an upswing in demand for aluminum automotive needs and our recent merger with Port City Division positions Pace at the forefront of this trend. Pace is dedicated to providing our customers with great, cost-saving solutions. Not only are we equipped with the most advanced technology, we understand the need to move nimbly and to quickly alter or adjust plans as needed.

What will be the next wave of aluminum components? Only time will tell, but one thing is for certain. As our industry changes, Pace will remain at the forefront to provide the best quality solutions in ways that save our customers money.

Comment

Connecting and Educating through Lunch and Learns

February 4, 2016

Darren Bombich, Eric Waa and David McWilliams.
Darren Bombich, Eric Waa and David McWilliams.

In training our suppliers about Pace Industries and our die casting capabilities, we begin the process of Early Supplier Involvement. As we’ve discussed in earlier blogs, Early Supplier Involvement is where our greatest opportunity lies and allows us to work with our customers to find uncommon, creative solutions.

Pace’s St. Paul Division, which produces aluminum die castings for highly cosmetic, complex and difficult-to-fill parts and specializes in flash-free, net-shape production, has become a shining example of this practice. The St. Paul team recently visited GHSP, a leading global supplier of mechanical and mechatronic control systems to surface transportation industries, and held a Lunch and Learn in an effort to educate on zinc and aluminum die casting.

Not only were they able to discuss services, capabilities and processes, but were able to showcase some of the parts St. Paul had die cast for GHSP for the 2015 Ford Mustang. These parts were recently featured in this Detroit Muscle episode on Power Nation TV.

The benefits of the Lunch and Learn were being able to teach and familiarize GHSP’s purchasing team, engineering team and quality team with die casting, the processes involved and the tolerance involved. The results were positive from all teams who felt the meeting allowed them to view Pace as an advisor on future opportunities and gave them a direct contact to follow up and ask questions.
“By establishing a contact, it shortens that bridge in order to have the conversation with somebody. They are more likely to pick up the phone and call you if they’ve met you.”
— Darren Bombich, Sales Manager / Sales Engineer
When conducting your own Lunch and Learns, it’s important to know who your audience is so you can flavor the presentation towards that group of people – an engineering group loves data and very technical information, while a purchasing audience requires less details and more of a bigger picture. Take the time to truly understand your audience and tailor the presentation to them.

Comment

Pace Honored With Four NADCA International Die Casting Competition 2015 Awards

January 14, 2016

We are pleased to announce that the North American Die Casting Association (NADCA) has awarded Pace Industries with four honors this past year. This is a prestigious international competition that brings the best designs in die casting together. Each is judged on the difficulty to cast, the brilliant engineering required and the benefit and value that the design delivers to the customer.

The Cambridge Division won the 2015 International Die Cast Competition for Aluminum Die Castings 1 to 10 lbs for the submission of the JAMCO arm rest. This was an extremely difficult part to design as a die casting. Full credit must be given to Don Tremblay for the excellent design engineering. Don worked tirelessly with the customer, establishing confidence in Cambridge’s engineering prowess and convincing them of the design changes required to make this a successful conversion to a die casting. The overall success of this program extends to our total Engineering and Manufacturing group. Working as a true team, focused on the success of the project, we delivered excellence to our customer and delighted them with our performance.

Our St. Paul Division took second place for this category with its Diffuser Grilles. The amount of detail, looking at a market that normally doesn’t have die casting in it, was particularly impressive to the judges. They also noted how well executed it was for the St. Paul Division to take a bunch of different parts and integrate them into one usable part.

Grafton was awarded the 2015 International Die Cast Competition for Aluminum Die Castings over 10 lbs category for the 824 Crankcase. Beau Glim, Project Manager at NADCA, stated that what made an impression on the judges was the jet cooling. It is something that is typically very difficult to cool so to see it cool that quickly for die casting was an amazing feat that resulted in this award.

The Product Tech Division won the 2015 Casting Competition for Magnesium Die Castings over .5 lbs category for the Multispeed Wheel. The judges found the wheel to be very innovative. They were impressed by the detail, the control, and the very unique application for die casting that was demonstrated by the Product Tech Division.

Comment

Celebrating Dan Krinock: The man behind Airo for nearly 40 years

December 1, 2015

At Pace, it’s our people who make the difference – who help differentiate our organization from the competition. So, as Dan Krinock transitions from president of our Airo Division in Loyalhanna, Penn. to a consultant for Pace leadership on special projects, we’re using this space to celebrate the man who dedicated nearly four decades of his life to the die casting industry and our Airo Division. After all, it would be difficult to tell the Pace story without feeling Dan’s influence.

Gene Eggman EVP HR & Gov Affairs with Dan Krinock
Gene Eggman EVP HR & Gov Affairs with Dan Krinock

“The early growth and success of Airo Die Casting was greatly influenced by Dan’s relentless search for the next innovative management trend,” said Scott Bull, CEO, Pace. “Dan has always embraced change, and this led Airo to become one of the most versatile and valuable divisions in the Pace family.”

“Dan always had a vision of what the next step should be and was able to communicate that vision – from the operator on the floor to the leadership of the company,” said Vinnie Battaglia, who worked side by side with Dan for the majority of his nearly 40 years at Airo.

Dan’s ability to innovate and lead has always been among his greatest traits. In 1976, he helped establish an identity for Airo as one of just two die casting facilities in North America capable of manufacturing blades for the gaseous diffusion industry. By the following decade, the Loyalhanna-based facility had evolved into a leader in the casting of conversion boxes for the booming cable television industry. In the late 1990s to early 2000s, he orchestrated the implementation to robotic technology, a central melt system and the facility’s first reciprocator. Under Dan’s leadership, Airo has emerged today as a 155,400-square-foot manufacturing facility with a full range of services and capabilities for the automotive, motorcycle, recreational vehicle and heatsink technology industries.

Vince Battaglia, Gordon Silvis, Don Frayvolt, Dan Krinock, Tony Rich, Rick Levrio and Sam Snively.

“I’ve worked with Dan for over 20 years and his focus has remained consistent from the beginning,” said Jeff Wareham, quality manager, Airo. “He always says, ‘If we aren’t improving, we’re going backward.’ He’s never satisfied with just doing what we’ve always done.”

It’s that approach that helped earn Airo the top Jobs First Governor’s ImPAct Award in June 2014. The award ­­– presented annually by the governor of Pennsylvania – recognizes businesses across the state that have made a positive impact on local and state economies through consistent job growth, associate retention and development.

Dan made a habit of extending that level of passion and enthusiasm beyond the walls of Airo and into the surrounding community.

“Dan was one of the first people I met when I became president of the area chamber of commerce – and he’s always been one who just makes things happen,” said David Martin, president, Greater Latrobe-Laurel Valley Community Chamber of Commerce. “He’s always there, helping improve quality of life and working to create opportunity.

“He has a passion for local workforce development,” Martin explained. “Dan went as far as to help coordinate partnerships between local manufacturers and schools. His thought was, if there are kids who aren’t going to four-year universities, we want to make sure they have a trade coming out of high school. These kids could stay local, work local and make careers for themselves.”

That’s the level of commitment Dan used to blaze a trail of success.

“Dan continually reinvented the mindset of his team and the community around him to deliver success,” said Rod Taylor, COO, Pace. “He has a way of finding new thinking to drive results. He’s always learning and that serves as a great reminder to all of us.”

Krinock Family with CEO Scott Bull (Black sweater) seated next to Dan Krinock.
Krinock Family with CEO Scott Bull (Black sweater) seated next to Dan Krinock.

As Dan transitions into his new role as consultant to Pace leadership on special projects – and eventually into retirement – he’ll be doing more fishing, golfing, and spending quality time with family. And, he’ll be the first to tell you, it’s time to ramp up the number of outings with his hunting buddy, his grandson.

Thank you for a job well done, Dan, and enjoy this time of transition. You’ve earned it.

Comment

5 Things A Potential Pace Employee Should Know

September 11, 2015

Chase Foster
Talent Sourcing Specialist

static1.squarespace.com

Pace is a growing company with fifteen locations in the United States and Mexico and the leader in custom die casting in North America. As a result of our growth, we are looking for potential employee to join our team. Finding a job that is right for you can be very difficult. Pace Industries wants you to carefully read the job description and decide whether the position is a good fit for yourself and your family. Stop and think before you hit that “apply now” button and create a job application that will get you noticed by Pace. Here are five things to think about before completing your application:

  1. Be honest about what you can do with your abilities. Few people will have all the skills needed on a new job.  But, if you have had similar experiences that would make the job easier to master make sure to mention them. Most importantly, figure out what you have to offer Pace. Always update your social profiles before applying to a new job. When we research your job history, we’ll want to find the skills and abilities that are already listed on your resume.
  2. Write about a problem you’ve solved before or can solve as it relates to the opening you are applying for. Any skills you can bring with you to a new job is going to be a plus for us here at Pace. Anything we do not have to train you on is a benefit and makes you a more valuable hire.
  3. Be realistic in your compensation expectations. Pay is a big component of your benefit package, but things like vacation time, insurance, chance for advancement and work environment go a long way in making a quality work life. So, make sure you look at the entire package and not just the dollars. Also, make sure you research the company and location. Compensation varies greatly around the United States and it’s important to know the environment if you’re relocating.
  4. Make sure your family is behind you and supports you in this new career. Change is hard on not just you but everyone around you. Learning new skills and a new work environment can affect your mood, which will affect everyone in your household. So, make sure they understand your career path and your immediate focus.
  5. Commit to investing in your career through your own personal efforts and growth. Any new job and work environment will present a whole host of opportunities for you to improve your skill set. Make sure you’re open to the challenge, willing to try new ways of doing things and be optimistic about change.

If after reviewing the above steps, you feel ready to proceed,  go ahead and APPLY NOW! Pace offers great potential for a long future in the manufacturing industry.  We are excited about reviewing your application and look forward to fitting your skills and expertise into the perfect position.

Comment

STEAM vs. STEM

July 30, 2015

STEAM vs. STEM is an ongoing debate about the importance of art and design courses offered in public education institutions and whether or not they improve student behavior, test scores, and so on. The STEAM side argues that Art plays a vital role in letting students express themselves and helps them engage in critical, “outside the box” thinking. Even after 42 seasons of STEM-only teaching, famous children’s show Sesame Street decided to finally integrate the arts into its 43rd season. That said, pro-STEM advocates aren’t necessarily calling for the elimination of art and design classes in school, but instead wish to retain a higher focus on science, technology, engineering, and math, the core subjects that make up STEM.

Some facts that come out of STEM-only research shows that students who progress through at least Algebra II in high school are twice as likely to complete a four-year degree as opposed to those who don’t. Of 15 Major categories, Engineering has the highest median earning, yet less than 20% of students choose a STEM path. Lastly, women make up 23% of STEM workers, but make up 48% of all occupations. More information and summarized research can be found on this round-up by the National Math + Science Initiative.

While brilliant with technology, there are some personalities who STEAM advocates feel were the best of both worlds, such as Albert Einstein, Marissa Mayer, and Steve Jobs, the latter who revolutionized how marketing is done today. William Yu, an economist with the Anderson Forecast at UCLA, states that as more jobs become machine-reliant, alongside economic shifts from agriculture to mechanical, “robots and foreign labors will never be able to replace creative people in creating sectors making new and desirable products and services.”  Alongside this, this piece by edutopia.org explores exactly what skills apply to adding the “A” in STEAM. The program mentioned includes the Four C’s: creativity, collaboration, critical thinking, and communication. By breaking these segments down, professors are more capable of allowing students to take advantage of their education; something that is evidenced by research showing more students wish they had learner agency in STEM education.

Shifting gears, as more machines are developed to help industrial markets and manufacturers, it’s important to note what jobs STEM-geared education creates. For example, in the die-casting industry, half of the jobs wanted require four years of education or more just to reach entry level. While not all of these jobs fall into this spectrum, they include engineering, IT staff, drivers, mechanics, nurses, machinists, and operators. According to this 2015 report by the North American Die Casting Association (slide 20), as the volume of castings required grows, the minimum number of workers hired annually will also increase. This will eventually lead to a need for, at minimum, 2,500 new operators and technicians.

Job processes for these careers include operating machinery, casting, maintenance, safety and energy management, tool designing, and melting and handling. With such an array of specialized job functions, it’s easy to see why half of the top 10 most difficult positions in die casting are hard to fill. Where STEM seems to fall short is within the creation process of prototypes or newly realized tools. The “A” in STEAM better serves those who seek to change how tools work and the convenience they bring to the table, while STEM focuses more on bringing those concepts into reality.

Regardless of the side chosen, education drives markets forward. STEAM vs. STEM may still be an ongoing debate but it’s important to know where to draw the line in the sand and focus on the benefits of each. Does your business grow and prosper more from a creative or mechanical standpoint?

Comment

Pace Industries: A Day In the Life

July 16, 2015

Pace Industries is the leading full-service die casting company in North America. Our Harrison warehouse is more than 600,000 square feet where we specialize in die casting zinc, aluminum and magnesium.

Die casting is a quick and more cost effective production process that produces a high volume of parts than other casting processes.

Aluminum die casting has become the first option among buyers worldwide because of its cost effectiveness and the various finishes it can be cast in. This is possible because its structure is light, strong, corrosion resistant, non-staining, non-magnetic and highly conductive. Buyers in this industry also like that the aluminum alloy is 95% post-consumer recycled material, making the die casts green and sustainable.

Some of our capabilities include Robotic Extraction, Hot Oil Die Heaters, Automated Sanding Cells and much more.

Our die cast machines ranging from 600-1800 ton allows us to serve many industries.

Get to know us a bit better by taking a look at a day in the life at Pace Industries.

Comment

Pace Industries and Port City Division Merge to Create one of North America’s Largest Die Casting Companies

July 15, 2015

We are excited to welcome Port City Division to the Pace family. Together we look forward to working together to take advantage of all the best practices and synergies to help stay at the forefront of the industry and continue to provide uncommon, creative solutions which contribute to the success of our customers.

FAYETTEVILLE, Ark., and MUSKEGON, Mich., July 1, 2015 – Pace Industries, North America’s largest full-service aluminum, zinc and magnesium die casting company based in Fayetteville, Ark., announces the merger with Port City Division in Muskegon, Mich. The merger will provide die casting, machining, manufacturing and finishing capabilities across diverse industries including automotive, lighting, electrical, recreational and others.

The combined company will consist of 12 divisions and 21 facilities with sales of approximately $600 million across the United States and Mexico.

Pace Industries President and CEO Scott Bull said, “Blending the strengths of Pace and Port City Division will result in a formidable automotive supplier and preferred non-automotive supplier in the die casting industry and build our capabilities to deliver better quality, service and value to customers.”

Port City Division will become a division of Pace Industries. John Essex will remain CEO of Port City Division, join the Pace Board of Directors, and become one of its largest shareholders while leading Pace’s automotive growth strategy.

Essex said, “Over the last few years, it became apparent that we needed a platform for our growth that would provide us greater geographical reach than what we had with our Michigan-based facilities. This merger will provide needed capacity in closer proximity to some of our customers in North America while expanding our production capability.”

According to Bull, the companies will work together to take full advantage of best practices and synergies, which will provide both organizations the capabilities and resources to meet and exceed customer expectations.

Comment

Meeting our Customer’s Increasing Market Demands

May 14, 2015

Rod Taylor
Chief Operating Officer

Brian Walker
Executive Vice President of Sales

In order for businesses to succeed in a highly competitive and volatile market, it is critical to partner with the right manufacturers; manufacturers who are large enough to take on any project size, innovative enough to recommend uncommon and cost saving solutions, yet nimble enough to quickly adjust and alter as needed. Pace Industries is just such a company; uniquely positioned to meet the ever-changing market demands of our customers.

What makes Pace so unique?

Size and Capacity: The size of our company both financially and in footprint is unmatched. Pace currently has eight U.S. sites and two sites in Mexico. Within these sites, there are over 200 die cast machines and over 300 CNC machines. We have our own in-house tool shops that assist our customers in designing the most robust and economical tool for each product design. Having multiple well-equipped sites enables us to provide flexibility in scheduling, capacity and manufacturing, ensuring that customer’s needs are met.

Technology: The technology we employ at these sites runs the gamut from the very basic or standard to very advanced state-of-the-art technology. This array of technology enables us to match our customer’s timeline and cost requirements.

“If our customer’s market needs require a lower cost part that does not require extremely tight tolerances, we have the ability to meet those needs without deploying the newest technology and the higher level systems that inevitably drive costs higher. On the other end of that spectrum, customers that require a very high level of control in the area of part tolerances and higher levels of systems, require equipment that has higher levels of technology (automation, tighter thermal control, higher levels of CNC technology, etc.). ”

— Rod Taylor – Chief Operating Officer

Flexibility: Our flexibility with equipment across several sites allows us to respond to customer supply interruption issues quickly and successfully.

About 3 years ago, one of our largest customers’ competitors suffered supply issues due to a long supply chain from overseas.  The market share that this competitor lost became available to our current customer.  With our sizeable footprint and flexibility and large inventory of equipment, Pace was able to increase supply of parts to our customer in a very short period of time enabling them to capitalize on this changing market demand opportunity.

Additionally, in 2013, our largest operation suffered a major supply interruption that was going to last for many months and potentially impact shipments to several key customers.  Because of our overall company flexibility with equipment capacity and personnel, Pace was able to relocate over 250 tools and approximately $50M in annual sales from the affected plant into other Pace operations with very minimal impact to our customer’s market demands.

Unparalleled Customer Focus: We pride ourselves on providing “uncommon, creative solutions” to ensure our customer’s success. We’ve seen this have a profound impact on our customer’s ability to increase market share, meet customer orders, improve their reputation and thereby successfully get a leg up over their competition. For instance:

  • Early Supplier Involvement (ESI) program ensures and optimizes design of die cast parts right from the start which can save customers a lot of money and time by incorporating features which are efficient and cost effective.
  •  In Production, we adhere to an APQP process in product introduction that helps deliver a more efficient and timely launch of new programs.
  • Our Thermal Control Systems, preventive maintenance programs, DMOs, molten metal management, automation, SWAT teams, Internal Rebuild Teams all help Pace and ultimately the Customer improve their position in the marketplace and helps support market demand.

Executive VP of Sales, Brian Walker, shared an example where one of our clients, a US based manufacturer, implemented a market driven manufacturing model to align with retails sales demand. Pace re-engineered the manufacturing approach, adjusted Kanbans, improved product flow and long range planning to successfully meet these requirements. Our result has successfully reduced manufacturing costs while delivering on customer expectations more consistently. This resulted in market share gain, increased sales and improved margins for the client.

Meeting our customers’ volatile market demands is a very important aspect of achieving our Mission Statement.  Pace differentiates itself from its competition by its flexibility to respond to many different types of market demands, from technology needs, which drives to different levels of product requirements and costs, to successfully responding to changing market demands or supply chain interruptions with its flexibility in the area of equipment and personnel across many different locations.  In these specific areas, Pace is living out its Mission Statement to “Provide uncommon, creative solutions that contribute to the success of our customers”. Give us a call today to see how we can help ensure your success.

Comment

Getting a Handle on Quality

April 30, 2015

St. Paul Division wins 2014 Webasto Quality Excellence Award

By Darren J. Bombich
Sales Manager/Sales Engineer, Pace Industries’ St. Paul Division

Doug Winfrey (left) and I (right) accept the Webasto 2014 Quality Excellence Award from Webasto Buyer Dawn Bostwick
Doug Winfrey (left) and I (right) accept the Webasto 2014 Quality Excellence Award from Webasto Buyer Dawn Bostwick

Doug Winfrey (left) and I (right) accept the Webasto 2014 Quality Excellence Award from Webasto Buyer Dawn Bostwick

It’s the details that make the difference. Pace Industries St. Paul Division proved that recently by serving one of our customers with a unique need — and we were rewarded for it. Webasto-Edscha Cabrio USA,  a manufacturer of automotive convertible roof systems, came to us with a request that looked simple enough on the surface: Supply an overmolded and machined die cast aluminum operating handle for the convertible top on the new Ford Mustang. When they shared their need for a tight turnaround and approval time with us, that’s when things became a little more interesting.

As you can imagine, any component added to an automobile must go through a rigorous approval process by the vehicle manufacturer for safety and durability.  It was discovered early in the APQP process that Webasto had specified a neoprene-type overmold material that had not been approved by Ford. The customer was facing the reality that they might not be able to deliver a solution before the new Mustang was slated to hit the streets.

The St. Paul team was quick on our feet to come up with a solution. By thinking outside the box, we found a material that was already used elsewhere in the vehicle that we thought might also work for this application. We were right. Using this already Ford-approved material allowed the engineering change process to fast track, which solved Webasto’s timeframe problem. It also ensured they got parts at the price point they needed to provide a smooth, on-time launch for the new Mustang.

The hard work and ingenuity led to a solution that recently earned the St. Paul Division Webasto’s 2014 Quality Excellence Award. The two key elements that secured the quality excellence award: 100 percent on-time delivery and zero parts per million defects (PPMD). Pace was able to deliver both and exceed Webasto’s expectations. Doug Winfrey, quality control manager at the St. Paul Division, said it well:

“I am proud of St. Paul and was honored to stand up and receive this award for our team. Our success in our business, which contributed to the Quality Excellence Award, can be shown through the proper execution of Advanced Product Quality Planning (APQP).”

Full utilization of the APQP Workbook at St. Paul is partially to credit for the award. Of course, all those processes don’t mean much if there’s no one there to implement them, and our team stood up to the challenge.

Check out this video on the new Ford Mustang convertible, which includes highlights on the all-new convertible roof system and a look at the operating handle supplied by Pace’s St. Paul Division.

static1.squarespace.com

Comment

Optimizing Cost through Early Supplier Involvement

April 16, 2015

John Scott Bull
Vice President of Sales & Marketing

Arnie Fulton
Vice President of Engineering

At Pace Industries, we pride ourselves on being a true partner with our customer. We’ve long recognized that we need to set ourselves apart from the rest in order to earn and keep your business. Our mission statement is to find uncommon, creative solutions that contribute to the success of our customers. One of the ways we do that is through our desire and ability to optimize cost for our customers.

Cost optimization can be achieved in a number of ways. We are committed to a lean manufacturing process whenever possible. By reducing waste, streamlining production processes and design, as well as improving workflow, our customers benefit by having reduced time-to-market and lower overall production costs. However, Early Supplier Involvement is where our greatest opportunity lies. By working early on with your engineers on the design activities, we can develop designs that are not only functional, but are also easier to cast. There have been multiple times that we have been brought into a project during the design phase and we have been able to reduce metal content, adjust shapes to improve productivity, and even offer alternatives like different alloys that would reduce the cost and meet customer criteria.

“We work with our customers to understand the function of part they want to design and provide design suggestions to achieve the functional requirements while incorporating features that are efficient to cast. In this way we satisfy our customer’s need for a functional part along with our need to have a design that satisfies the requirements for the die cast process.”

— Arnie Fulton, Vice President of Engineering

For example, we suggested a novel approach for a customer who had an automotive application. Typically, the part would be manufactured using a non-die cast process, but we felt that a die cast product would give them the functionality needed but at a lower cost of production. After we conducted casting design training sessions with their engineers and applied our education and expert guidance, we were able to show them how die casting would be a more cost efficient method of manufacturing for them.

In another instance, we worked with a lighting customer on a fast track LED project. At the time we were brought in, they already had a near final design. After review, we realized it wasn’t possible to manufacture the part in its current state. Following two days of discussion and revision, we were able to optimize the design for manufacturing, and remove more than two pounds of aluminum from the design, reducing the cost by several dollars.

Not every manufacturer has the capabilities to work with you in this way. We put a significant focus on working with our customers to find solutions to optimize cost. Being a full-service die cast company means we have the resources and technical expertise to partner with our customers early in the design phase and also once the part is in production. To truly optimize cost, you need more than a good price or a low margin. The value we provide in product design, weight reduction, keeping proper inventory levels on hand, close proximity to delivery locations, internal tool shops, good quality, and other benefits are what truly optimizes the cost of doing business with Pace versus other die casters.  We welcome the opportunity to show you how we can help you achieve the right balance of design, function and cost.

Comment

The Benefits of Magnesium Die Casting

March 19, 2015

Jim Hegland
Director of Sales

My background in the die cast industry up until 1995 was centered on aluminum and zinc. About that time, I was offered an opportunity to work with some people who had a desire to start up a Magnesium Die Cast operation. It sounded exciting, but wait a minute; I didn’t know a thing about magnesium. I started reading and absorbing everything I could find on the subject and quickly realized most everything available at that time had been published 10 to 20 years earlier. The common denominator I came up with was that there were plenty of issues with magnesium – most notably, that magnesium burns at an incredibly high temperature and corrodes. At this point, I thought, this might be a tough sell.

It was difficult at first because we were centered on the challenges we had heard about and not on the positives, which we quickly realized. We soon began to see that the two main issues, flammability and corrosion, were only partly true. A lot of things burn and corrode, it’s all in how you process it and work with it. Both of these conditions have proven to be controllable and can be overcome with proper processes and techniques that allow you to focus on the significant benefits of magnesium.

The real benefits of Magnesium Die Cast fall into two categories: processing and material specific.

Processing Magnesium

In our business there are 2 basic style machines: Hot Chamber and Cold Chamber.

Cold-Chamberstatic1.squarespace.com

The Hot Chamber Process we use has several benefits.

1) With Hot Chamber the molten metal is enclosed in a sealed furnace greatly reducing the risk of a fire. 2) With Hot Chamber the process time is 25-40% faster than the conventional Cold Chamber

3) Hot Chamber casting reduces recyclable scrap by 30-50% versus Cold Chamber.

4) Lower injection pressure, which equals better tolerance control for precision parts.

5) Hot Chamber casting prevents many porosity-type defects.

Material Benefits of Magnesium

The ability to cast fine details, plus the advantage of very thin wall sections gives magnesium a significant advantage over other castable metals. With magnesium, you have an automatic 35% reduction in mass/weight over aluminum. If you combine that with thinner walls you may be 50% lighter. These benefits give magnesium a clear advantage on highly cosmetic parts.

Our experience with magnesium has provided evidence that this material gives the best dimensional part-to-part consistency mostly due to the quick solidification time and a natural lubricity that keeps it from sticking in the mold.

Magnesium machines very nice and with the very low cutting pressure required; very close tolerances are achievable. This low-cutting pressure also significantly lengthens the life of perishable tooling such as end mills, taps and drills.

These benefits go beyond cosmetic parts. All of these advantages apply to many industries. In automotive applications, the fact that magnesium reduces vibration 25 times better than aluminum gives this material a clear advantage by reducing road vibration. Most steering wheels made today have a Magnesium core over-molded with vinyl. This improves driver comfort by stopping the vibration from reaching your hands.

In any other industry that requires very tight tolerances, magnesium can often times be less expensive than the other cast metals by eliminating machine operations and provide many “as cast” features. When you combine this with the fact that magnesium die cast tooling lasts 2-3 times longer than aluminum tooling, some tangible advantages start to develop.

At the end of the day, the customer is the ultimate decision maker on what material they use. Giving them the options is my job. Over the years, many of our associates have asked me, “Jim, why does this part need to be magnesium?” Being a sales guy, my answer is, “That’s what we do.”

static1.squarespace.com

Comment

What the Heck is Die Casting?

March 5, 2015

static1.squarespace.comMy name is Eve Mayer and I don’t work in die casting. I am an author who works in social media, the world of words where everything we create can neither be touched nor felt with the human hand.

So, when I was invited (or rather, I invited myself) to tour the die casting factory of one of my company’s favorite clients, Pace Industries, I think they thought it was pretty odd.

The fact is I love factories because of my parents. For some strange reason, since I was little, they have brought me to see how all types of things are made; and because we are good eaters, it was usually food factories like Ben and Jerry’s or candy or potato chips. These experiences have allowed me to develop an appreciation and curiosity for manufacturing.

Although Pace had described in detail what they do, I just didn’t completely get it until I saw it with my own eyes. After all, die casting to the outside world sounds very ominous and foreign. So, the purpose of my tour was to understand – What the heck is die casting?

Die Casting is using a mold to make stuff out of metal. I’m probably not saying these terms by industry standards, but for those of us in the everyday world, I think that is what I learned that die casting is.

static1.squarespace1Die casting isn’t a glamorous industry. It is a detailed, precision necessary industry where hard working people use machines to carefully craft metal pieces like auto parts, light bulb bases, motorcycle pieces, back sides of carpeting and bed springs. My view is probably skewed as I toured an aluminum factory and die casting is done with several different types of metals like zinc, magnesium and aluminum.

For those of us in the world of creating intangibles, it is pretty cool to see things created that you can touch and feel. The process not only sounds interesting but also uses more necessary creativity than I would have expected.

Let’s say you need a piece of metal for a specific job. First, you must design it in such a way that it can accomplish this job. Next, you need to decide whether it should be forged or die cast. Die cast means that a mold will be created typically out of precision steel and split into two halves. These halves will be put together and held there by hydraulics while hot metal is injected into the mold and cools for up to one minute before the new metal piece is released.

After the piece comes out of the mold, it needs to be trimmed and polished. I thought the polish process was interesting because it basically looked like they put metal pieces into a big bowl of pink rocks and shook the metal piece around until the rough edges cam off.

static1.squarespace.comSome metal pieces need to be pretty and some don’t. For example, if you are having a piece built for the inside of a car engine that someone will never see once built, you don’t want to spend money on making this piece pretty, it just needs to be functional. Another metal piece might be on a motorcycle but sit on the outside of the bike in full view so it needs to be functional but also have a nice look to it. This is where specific processes that deal with painting or chroming parts comes into play.

As you might imagine, the mix of machines and people with high volume makes safety very important in die casting. Pace has an interesting view that has helped them dramatically increase their rates of on-the-job safety. A Pace executive believed that safety is a mindset that is constant – meaning that safety at home and on the job cannot be separated. He asked employees to make a personal safety pledge. Employees wrote down and posted safety commitments that were important to them in their own lives and posted them near the workspace. For example, “I will not text or make phone calls when I drive.” It was pretty inspiring to see these pledges for safety hanging on the wall and to hear about the positive effects this movement has had.

All in all, I really enjoyed my tour of a die casting facility. It was rewarding to see the entire process of how so many parts I take for granted are being made right here in the USA. And for us regular Joes, the answer to “What the heck is die casting?” is – it is the process of making metal pieces out of a mold. See, it’s not that scary after all.

Comment