Awards of Excellence
Pridgeon & Clay, Inc. Wins Quality Award
Monday, November 12, 2012
For more information, please contact Christie Carmigiano
CLEVELAND, OH—November 12, 2012—Pridgeon & Clay, Inc., Grand Rapids, MI, has received the 2012 Waukesha® Metal Products Excellence in Quality Award as part of the Precision Metalforming Association (PMA) Awards of Excellence in Metalforming. The company is one of the largest independent, value-added manufacturers and suppliers of automotive stamped and fineblanked components in the United States.
At Pridgeon & Clay, scorecards are used to highlight key metrics in each area of the business. The quality department tracks progress on the scorecard, which is reviewed monthly with top management.
The quality department streamlined the gage-planning process in 2010 and enjoyed a 50 percent reduction in the cost of gage changes. The group challenged itself to make another significant reduction in 2011. The tool engineering group was responsible for completion of the dimensional plan. The quality group developed a new document that was used for this process so that the gage shop received a specific outline of their requirements. It was determined that this information could be further integrated into Pridgeon & Clay’s quality requirements by redesigning the form to mirror the control plan and supporting inspection checksheet used by production personnel. As a result, a Preliminary Dimensional Plan form was developed.
During the past year, Pridgeon & Clay’s customers required annual validations on all service parts, leading the company to review its labor and machine resources. As a result, Pridgeon & Clay adjusted its gage technician staff to allow further CMM work on third shift, reviewed production CMM programs that were being run in production for ongoing capability studies and incorporated these dimensional reports into its validation program.
Pridgeon & Clay also introduced several new products with extremely tight tolerances, which required new measurement equipment. The company integrated a science scope to check for chamfers, radii, small teeth and centers of arcs; a multisensory vision system was purchased for fuel cell components; and the company is evaluating the addition of portable Renishaw equator machines to replace CMMs on the production floor. Another challenge revolved around machine downtime, so Pridgeon & Clay began monitoring CMM downtime events greater than four hours. Adjustments were made to reduce downtime, resulting in only four events occurring in 2012.
With the close monitoring and effective action plans for metrics, Pridgeon & Clay has seen many benefits. Getting PPAP records 100 percent compliant to customer requirements is a goal, and the company has improved to 95 percent, compared to 88 percent previously. On-time completion of system 8Ds from internal audits also has improved to 91 percent, from 26 percent. Pridgeon & Clay also reached its annual cost reduction goal of $150,000 in April. Finally, in 2010, there was a difference of $185,000 between costs and quotes of gages; in 2011, the difference was $37,334 and through May 2012, the amount was only $2,175.
The Quality Award is one of eight Awards of Excellence in Metalforming, presented annually by PMA. Sponsored by Waukesha® Metal Products, Sussex, WI, the award recognizes outstanding achievement by a manufacturing company in the development and implementation of a company-wide quality system that effectively uses continuous improvement. Along with recognition in industry publications and at exhibitions, Pridgeon & Clay will receive a $1,500 cash prize.
PMA is the full-service trade association representing the $113-billion metal-forming industry of North America—the industry that creates precision metal products using stamping, fabricating, spinning, slide forming and roll forming technologies, and other value-added processes. Its nearly 900 member companies also include suppliers of equipment, materials and services to the industry. PMA leads innovative member companies toward superior competitiveness and profitability through advocacy, networking, statistics, the PMA Educational Foundation, FABTECH and METALFORM tradeshows, and MetalForming magazine.
Editor’s Note: Information on PMA’s Awards of Excellence in Metalforming is available at www.pma.org/awards.