Mba 513 final carpenter


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Mba 513 final carpenter

  1. 1. Carpenter Technology Corporation Phil Sampona Matt Furedi Matt Osterstrom
  2. 2. Overview <ul><li>History - Phil </li></ul><ul><li>Products/Markets - Phil </li></ul><ul><li>Financials - Phil </li></ul><ul><li>Competitors - Phil </li></ul><ul><li>Operational Strategy – Matt F. </li></ul><ul><li>Manufacturing Process – Matt F. </li></ul><ul><li>Improvement Process – Matt F. </li></ul><ul><li>Human Resources – Matt O. </li></ul><ul><li>Supply Chain & Resource Planning – Matt O. </li></ul><ul><li>Locations – Matt O. </li></ul>
  3. 3. History
  4. 4. James Carpenter <ul><li>In 1889, the year the Statue of Liberty first beckoned immigrants to the United States, founder James Carpenter laid the foundation for a legacy of materials innovation that continues today. </li></ul>
  5. 5. Carpenter Beginnings <ul><li>When early industry started turning from iron toward a new era of “special” steels, the Carpenter Steel Company’s premier product at its one-building plant in Reading, Pennsylvania, was an air-hardened tool steel patented by Mr. Carpenter. The company would develop several more tool steels, ultimately offering the range of tooling that would be needed by the burgeoning industrial era. </li></ul><ul><li>Mr. Carpenter’s tool steel patent would be the first of more than 200 issued to the company for developments in melting technology, powder metallurgy, stainless steels, high-strength alloys, superior corrosion-resistant alloys, and other specialty metals. </li></ul>
  6. 6. New Product Timeline <ul><li>1928 : The world’s first free-machining stainless, Type 416 (still in use today). </li></ul><ul><li>1937 : The Matched Set method of tool steel selection and heat treatment. “Tool Steel Simplified” would become an industry standard in tool and machine shops for 40 years. Carpenter continues to produce a broad spectrum of tool and die steels including gas-atomized powder metallurgy alloys. </li></ul><ul><li>1934 : the first chrome-nickel free-machining stainless steel known today as Type 303. Fabricators were thrilled that the free-machining stainless improved tool life and productivity. As a result, the Carpenter name quickly became synonymous with stainless steels. </li></ul><ul><li>1950s : Thanks to Carpenter’s Stainless No. 10, cold-heading wire customers dramatically improved production of bolts and other fasteners. </li></ul><ul><li>1950s : Carpenter's 20Cb-3® stainless (Stainless 20) became a staple in the chemical-processing industry for decades. </li></ul><ul><li>1968 : name changes to Carpenter Technologies to better reflect a diverse product line and technological capabilities </li></ul><ul><li>1992 : received patent for super-strong AerMet 100 alloy. The alloy was first used on landing gear of jet fighters and aircraft carriers. </li></ul><ul><li>1997 : introduced Custom 465 stainless steel to the aerospace industry. The alloy greatly exceeded expectations, finding many applications in diverse industries such as marine equipment, firearms, oil and gas drilling, and the medical industry. </li></ul><ul><li>2002 :Carpenter metallurgists released the Project 70+® family of stainless machining bar. </li></ul>
  7. 7. <ul><li>Carpenter Technology (NYSE:CRS) develops, manufactures and distributes high-performance specialty alloys to meet the challenges of advancing technologies. </li></ul>
  8. 8. Products / Markets
  9. 9. Carpenter is all around you in these major global markets <ul><li>Aerospace </li></ul><ul><li>Automotive </li></ul><ul><li>Consumer Products </li></ul><ul><li>Defense </li></ul><ul><li>Energy </li></ul><ul><li>Industrial </li></ul><ul><li>Medical </li></ul>
  10. 10. Cars run hotter, jets fly faster , and golf clubs hit farther . Helping products perform better
  11. 11. Where performance is critical
  12. 12. A diverse product catalog <ul><li>High-strength steels </li></ul><ul><li>Superior corrosion-resistant alloys </li></ul><ul><li>High temperature alloys </li></ul><ul><li>Titanium alloys </li></ul><ul><li>Controlled-expansion alloys </li></ul><ul><li>Stainless steels </li></ul><ul><li>Tool and die steels </li></ul><ul><li>other specialty and custom grades </li></ul>
  13. 13. A full range of product forms <ul><li>Billet </li></ul><ul><li>Bar </li></ul><ul><li>Wire </li></ul><ul><li>Precision strip </li></ul><ul><li>Hollow and multi-dimensional bar </li></ul><ul><li>Plate </li></ul><ul><li>Fine wire and ribbon </li></ul><ul><li>Loose powder </li></ul>
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  16. 16. A global presence <ul><ul><li>About 50 manufacturing, sales and distribution facilities on four continents </li></ul></ul><ul><ul><li>in 18 different time zones </li></ul></ul><ul><ul><li>in more than a dozen languages </li></ul></ul><ul><ul><li>in which more than 10% of our employees work outside the U.S. </li></ul></ul>More than a steel company Since the early 1990s, Carpenter has grown from a U.S. specialty steel producer to a specialty materials producer with a global reach.
  17. 17. International presence ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●
  18. 18. Financials
  19. 19. Carpenter Sales FY 2009
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  24. 24. Corporate Financial Information <ul><li>Traded under ticker symbol “CRS” on New York Stock Exchange since 1937 </li></ul><ul><li>Fiscal 2009 (ended 6/30/09): </li></ul><ul><li>Sales - $1.36 billion </li></ul><ul><li>Net income - $47.9 million </li></ul><ul><li>Total assets - $1.49 billion </li></ul><ul><li>Market capitalization - $794.7 million </li></ul>
  25. 25. Competitors
  26. 26. Allegheny Technologies Nucor Corp United States Steel Corp
  27. 27. Operational Strategy
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  29. 29. Carpenter’s Manufacturing Process
  30. 30. Carpenter’s Manufacturing Process Carpenter manufactures hundreds of grades of specialty cast and powder alloys including stainless steels, high temperature (nickel, iron and cobalt-base) alloys, high strength steels, magnetic and controlled expansion alloys, tool steels, and other special purpose alloys. Product forms include bar, billet, large-diameter hollow bar, wire, fine wire and ribbon, precision strip, special shapes, plate, powder shapes.
  31. 31. Carpenter’s Manufacturing Process Stainless and Specialty Metals <ul><li>Electric-Arc Melting </li></ul><ul><li>Argon-Oxygen Decarburization (AOD) </li></ul><ul><li>Continuous Casting </li></ul>1 of 5 PRIMARY MELTING: Primary melting produces specialty alloys in ingot or powder metal form for further processing. The arc melting process allows for certain alloys to be continuously cast into long “ingots” before hot rolling.
  32. 32. Electric Arc Melting
  33. 33. Carpenter’s Manufacturing Process <ul><li>Vacuum Induction Melting (VIM) </li></ul><ul><li>Vacuum Arc Remelting (VAR) </li></ul><ul><li>ElectroSlag Remelting (ESR) </li></ul>PREMIUM MELTING: Carpenter has one of the most advanced premium melting operations in the world. VIM furnaces melt raw materials under controlled vacuum conditions to produce high-purity ingots and pre-alloyed powders. The VAR and ESR processes re-melt ingots to further impart desirable properties. Ingot HEAT TREATING 2 of 5
  34. 34. Electroslag Re-melting
  35. 35. Carpenter Manufacturing Process FORGING AND COGGING: Large ingots are rolled, pressed or forged into intermediate-sized billets for further processing. Some billet product may be shipped directly to customers. 4,500-Ton Forge Press SX-65 Rotary Forge SX-32 Rotary Forge In-Line Cogging Mills Billet HEAT TREATING 3 of 5
  36. 36. Rotary Forge
  37. 37. Carpenter Manufacturing Process HOT ROLLING: Billets are progressively rolled to smaller cross-section sizes and emerge as hot rolled bars or coils of rod, wire, flat strip, or special shapes. Wire Rolling Mills Bar Rolling Mills Custom Lot Mill (Hand Mills) HEAT TREATING Coil Bar Strip 4 of 5
  38. 38. Hot Rolling Mill
  39. 39. Carpenter Manufacturing Process COLD FINISHING: Various cold drawing, turning and rolling operations produce finished forms of bar, wire, fine wire and ribbon, strip, plate and special shaped bar and wire to exacting customer specifications. Product is then shipped to Carpenter distribution centers or direct to the customer. Large Bar Finishing In-Line Bar-to-Bar Finishing In-Line Coil-to-Bar Finishing Wire Finishing Strip and Plate Finishing 5 of 5
  40. 40. Cold Rolling Mill
  41. 41. Carpenter’s Improvement Process
  42. 42. <ul><li>Manpower </li></ul><ul><li>- Training Within Industry (TWI) training program (P&M, supervisor) </li></ul><ul><li>- Lean training </li></ul><ul><li>Machine </li></ul><ul><li>- Process capability study </li></ul><ul><li>- Overall Equipment Effectiveness (OEE) </li></ul><ul><li>Maintenance practices </li></ul><ul><li>- Preventative maintenance </li></ul><ul><li>- Daily maintenance </li></ul><ul><li>– 5S, oil & lubrication, tool checking </li></ul><ul><li>- Corrective maintenance – fixtures, jigs, overhaul </li></ul><ul><li>- Maintenance prevention- spare parts control </li></ul>Establish Stability -> Improve Process Flow -> Develop Pull -> Level Production <ul><li>Material </li></ul><ul><li>Availability – define stock levels </li></ul><ul><ul><li>- Cycle stock – inventory required to fulfill average demand </li></ul></ul><ul><ul><li>- Buffer stock – inventory to buffer against fluctuations in orders </li></ul></ul><ul><ul><li>- Safety stock – inventory to buffer against variability in internal mfg process </li></ul></ul><ul><li>Quality </li></ul><ul><ul><li>- Job Instruction sheets, standard work sheets, quality check sheets </li></ul></ul><ul><li>Method </li></ul><ul><li>- 5S, Visual Workplace, Standardized Work </li></ul><ul><li>Metrics </li></ul><ul><li>- Safety, Quality, Delivery, Cost </li></ul>Stability Tools Lean Manufacturing Implementation Sequence Carpenter’s Improvement Process
  43. 43. Carpenter’s Metrics
  44. 44. Carpenter’s Metrics
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  47. 47. 5S Examples
  48. 48. Visual Workplace Examples
  49. 49. Total Productive Maintenance Examples
  50. 50. Human Resources
  51. 51. Mission, Vision & Values <ul><li>Aspiration </li></ul><ul><li>Provide high-performance material solutions to our customers. </li></ul><ul><li>Principles </li></ul><ul><li>Our employees’ safety is critically important to our business. </li></ul><ul><li>We are here to make money for our shareholders and ourselves and have fun at the same time. </li></ul><ul><li>Treat the shareholders’ money as if it were our own. </li></ul><ul><li>View everything through the customers’ eyes. </li></ul><ul><li>Transparency is required for good decisions. All news, good and bad, must be delivered timely and straightforwardly. </li></ul><ul><li>Accountability – we are each responsible to meet or beat our commitments! There are no explainable variances… only contingency plans. </li></ul><ul><li>Make fast, fact-based decisions, then execute with passion and focus. </li></ul><ul><li>Partner with our stakeholders to drive enhanced performance. </li></ul><ul><li>Provide a development culture for our people. </li></ul><ul><li>Engage in passionate debate with everything on the table for consideration. Each opinion is respected on every issue, regardless of functional role. Once a decision is made we are one team. </li></ul><ul><li>Plan-do-check-adjust-plan-do-check-adjust. Assess the need, take action, measure results and then improve continually. </li></ul><ul><li>Communicate, listen, communicate. </li></ul><ul><li>Ethical conduct, internal control and risk assessment is good business and is all our responsibility. </li></ul><ul><li>Drive lean and standardized processes and generate results. </li></ul><ul><li>Invest in our business and people for growth and for a future. </li></ul>
  52. 52. Who works there? <ul><li>Carpenter Technology Corporation attracts many of the best and brightest minds in the fields of materials science, engineering, information systems, manufacturing operations, logistics, and electrical, HVAC and other skilled maintenance functions. </li></ul><ul><li>Talented people are attracted to Carpenter’s stability, competitive benefits package, and team approach to accomplishing goals. </li></ul>
  53. 53. Carpenter Careers <ul><li>College Recruitment Program </li></ul><ul><li>Co-op Program </li></ul><ul><li>Why Choose Carpenter? </li></ul><ul><ul><li>We are large enough to provide you with the professional growth and advancement you desire. </li></ul></ul><ul><ul><li>We are small enough to recognize and appreciate your personal contributions. </li></ul></ul><ul><ul><li>We have great success working with and cultivating new talent. </li></ul></ul><ul><ul><li>We provide a work environment that is diverse in its challenges and its opportunities. </li></ul></ul><ul><ul><li>We seek innovative thinkers who will contribute to our international growth. </li></ul></ul><ul><ul><li>We offer a competitive benefit package that exemplifies our position as an industry leader. </li></ul></ul>
  54. 54. Current Career Opportunities
  55. 55. College Recruitment Program <ul><li>Qualified students should have a minimum 3.0 grade point average </li></ul><ul><li>All positions require self-starters who are highly motivated and who have excellent communication and interpersonal skills. </li></ul><ul><li>Students must be able to operate under Carpenter's Company-wide Continuous Improvement philosophy, in which employees are expected to constantly strive to improve both their performance and company performance. </li></ul><ul><li>Students may be asked to serve as members of Continuous Improvement teams, which analyze and resolve problems in production and other processes. </li></ul>
  56. 56. Community Relations <ul><li>Carpenter supports our local communities by: </li></ul><ul><ul><li>Promoting science and math curriculum design in public schools. Providing scholarship funding to educational efforts such as summer materials camps, science & engineering fairs, and Science Student of the Month. </li></ul></ul><ul><ul><li>Providing funding to the arts, including the Reading Public Museum, the GoggleWorks Center for the Arts, and the Reading Symphony Orchestra. </li></ul></ul><ul><ul><li>Supporting the United Way through monetary gifts and employee volunteerism. </li></ul></ul><ul><ul><li>Supporting other human welfare programs such as Habitat for Humanity and Olivet Boys & Girls Club. </li></ul></ul><ul><ul><li>Donating to many locally based non-profit organizations. </li></ul></ul>
  57. 57. Awards <ul><li>Carpenter has been recognized by environmental organizations for the company’s efforts to recycle, reuse and responsibly manage our natural resources.  Environmental awards have included: </li></ul><ul><li>•  Berks County Conservancy Community Excellence Award • Pennsylvania Governor’s Award for Environmental Excellence </li></ul><ul><li>In addition, Carpenter has consistently earned recognition as a preferred or quality supplier from customers including: </li></ul><ul><li>•  Delphi • Eaton Corporation • Fisher • Hamilton Sundstrand • Mercury Marine • Pratt and Whitney • Rosemount • United Technology Corp. </li></ul>
  58. 58. Supply Chain & Resource Planning
  59. 59. Raw Materials <ul><li>Facilities are all located near necessary supplies </li></ul><ul><li>Located on the Reading Railroad </li></ul><ul><ul><li>Helps deliver supplies and finished products to customers </li></ul></ul><ul><li>Centralized in major metro areas & manufacturing hubs </li></ul>
  60. 60. Quality <ul><li>With its main manufacturing facility in Reading, Carpenter’s advanced manufacturing and quality systems enable them to meet a wide range of customer requirements and industry specifications throughout the world, including ASTM, AMS, DIN, and TÜV. </li></ul><ul><li>Carpenter’s quality systems are also approved to ISO 9001:2000 and AS9100 standards. </li></ul>
  61. 61. Distribution Networks <ul><li>Sell through a proprietary sales and distribution network </li></ul><ul><li>U.S. : 6 strategically located warehouses </li></ul><ul><li>International: warehouses in Canada, Mexico, England, Belgium, China </li></ul>
  62. 62. Resource Planning <ul><li>Instituted Enterprise Resource Planning </li></ul><ul><ul><li>Replaced a patchwork of systems </li></ul></ul><ul><li>Cost Reduction </li></ul><ul><ul><li>Information Technologies </li></ul></ul><ul><ul><li>Saved 30% from 2002-2003 ($7 million) </li></ul></ul><ul><ul><li>Cut 60 of 120 employees </li></ul></ul><ul><li>Hh </li></ul>
  63. 63. Locations
  64. 64. Specialty Alloys <ul><li>Located in Reading, Pa since 1889 </li></ul><ul><li>Large Working Class </li></ul><ul><li>Nearby Suppliers and Consumers </li></ul><ul><li>Access to Railroads and close to major metro areas </li></ul>
  65. 65. Specialty Wire Products <ul><li>Located in Orangeburg, South Carolina </li></ul><ul><ul><li>Close to Raw Materials </li></ul></ul><ul><li>Makes specialty alloy fine gauge wire and ribbon </li></ul><ul><li>Finer than a human hair </li></ul>
  66. 66. Talley Metals Technology, Inc. <ul><li>Located in Hartsville, South Carolina </li></ul><ul><li>Produces round, square and hex stainless steels in long product form </li></ul>
  67. 67. Shalmet Corporation <ul><li>Located in Orwigsburg, PA and Elyria, OH </li></ul><ul><li>Trepanning (longitudinal boring) of bars </li></ul><ul><li>Converter of black coil and bar to bright round bar and coil products in a range of alloys </li></ul>
  68. 68. Carpenter Powder Products <ul><li>Manufacturing: Sweden; Bridgeville, Pa; and Woonsocket, RI </li></ul><ul><li>Research & Design is located in Reading, Pa </li></ul><ul><li>Makes loose metal powders, tool steels and niche tool steels </li></ul>
  69. 69. Other Locations <ul><li>Kalyani-Carpenter </li></ul><ul><li>Joint venture with Kalyani Steels Ltd., Pune, India </li></ul><ul><li>26% ownership in steel mill and 51% in distributor </li></ul><ul><li>Dynamet Incorporated </li></ul><ul><li>Located in Washington, Pa & Clearwater, Fl </li></ul><ul><li>Makes specialized titanium wire, precision shapes and bar products </li></ul>
  70. 70. Questions
  71. 71. References