Uncover the seven-step journey to continuous improvement, seamlessly aligning with the Pro-Line's CPB's modular design and customizable features. From identifying opportunities to celebrating achievements, explore a transformative approach to workbench design and efficiency enhancement.

compiled & written by Bernard Martin

In the pursuit of operational excellence, businesses often turn to methodologies like Kaizen to foster continuous improvement. Kaizen, a Japanese philosophy centered around making small, incremental changes for improvement, is exemplified in Pro-Line CPB.  

Pro-Line's Complete Packaging Workbench (CPB) becomes a powerful ally in implementing the Kaizen cycle, providing a versatile platform for organizations to design and optimize their workbenches. Let's explore the seven-step Kaizen cycle and how it aligns with the features of the CPB.

1. Identify Opportunities for Improvement: Begin the Kaizen cycle by identifying areas for improvement. Pro-Line's CPB, with its modular design and customizable features, provides an ideal starting point. Evaluate the current packaging workbench setup and identify aspects that could be enhanced for better efficiency, organization, and ergonomics.
2. Design Your Ideal Workbench: Leverage the flexibility of the CPB to design an ideal workbench that aligns with your specific needs. From selecting the right work surface material to incorporating accessories like shelves, bins, and dividers, customize the CPB to optimize the packaging process. Pro-Line's design tools and expertise facilitate the creation of a workbench tailored to your unique requirements.
3. Implement Changes: Once the ideal workbench design is established, implement the changes seamlessly with the CPB. Its modular nature allows for easy installation and adjustments. Whether integrating additional storage options or reconfiguring the layout, the CPB ensures a smooth transition during the implementation phase.
4. Monitor and Measure Results: Kaizen emphasizes the importance of monitoring and measuring results. With the CPB in place, track key performance indicators such as packing time, workflow efficiency, and ergonomic improvements. The workbench's adaptability allows for ongoing measurement and adjustments, ensuring continuous refinement.
5. Standardize Processes: Standardizing processes is a crucial step in sustaining improvements. The CPB's modular components and standardized accessories enable organizations to establish consistent packaging processes. Standardization reduces variability, enhances quality, and fosters a culture of efficiency.
6. Reflect and Repeat: Reflection is integral to the Kaizen cycle. Use the CPB as a reflective tool, gathering feedback from workers about the new workbench design. Assess the impact on productivity, identify any unforeseen challenges, and refine the workbench accordingly. The CPB's adaptability makes it easy to repeat the cycle of reflection and adjustment.
7. Celebrate and Recognize Achievements: Celebrating achievements is a crucial aspect of Kaizen. Acknowledge the efforts of the team and recognize the positive impact of the CPB on packaging operations. Pro-Line's CPB, with its capacity for continuous improvement, supports a culture of recognition and motivation within the workplace.

Pro-Line's Complete Packaging Workbench (CPB) seamlessly aligns with the principles of the Kaizen cycle, providing a platform for continuous improvement in packaging workstations. By identifying opportunities, designing customized solutions, and leveraging the adaptability of the CPB, organizations can achieve sustained efficiency gains. The CPB becomes not just a workbench but a catalyst for fostering a culture of continuous improvement and excellence in packaging operations.

E-Commerce and Fulfillment Centers
With the demands of e-commerce always increasing and where order fulfillment demands efficiency, the CPB excels. Its thoughtfully designed workspace provides an organized hub for packing, labeling, and preparing shipments. With integrated storage solutions, the CPB ensures that packers have easy access to materials, minimizing handling time and optimizing the packing process.

Manufacturing and Assembly Lines 
For manufacturing environments, the CPB serves as an ideal companion to assembly lines. With its modular design and customizable features, it adapts seamlessly to various production needs. Workers can efficiently package and label products without interrupting the flow of the assembly line, contributing to a smoother production process.

Pharmaceutical Packaging
In the pharmaceutical industry, precision and cleanliness are paramount. The CPB's stainless-steel construction and clean, organized layout make it an ideal solution for pharmaceutical packaging workstations. Its design supports compliance with stringent hygiene standards, ensuring the integrity of pharmaceutical products during the packaging process.

Laboratory Environments
Laboratories require specialized workbenches that can accommodate a variety of tasks. The CPB, with its modular accessories and ergonomic design, caters to the needs of laboratory technicians. From packing and labeling research samples to organizing supplies, the CPB enhances workflow efficiency in a laboratory setting.

Electronics Manufacturing and Testing
 In the electronics industry, precision and organization are critical during the packaging and testing phases. The CPB's anti-static work surface and customizable features make it an excellent choice for electronics manufacturing workbenches. Workers can efficiently package and test electronic components without the risk of electrostatic discharge.

Shipping and Receiving Departments 
Shipping and receiving departments require versatile workstations that can handle a variety of tasks. The CPB, with its integrated storage options and ergonomic design, creates an efficient workspace for managing incoming and outgoing shipments. From unpacking received items to packing outbound orders, the CPB streamlines shipping and receiving operations.

Customizable Solutions for Any Industry One of the standout features of the CPB is its adaptability to diverse industries and applications. Pro-Line offers customizable solutions to tailor the CPB to the specific needs of each industry. Whether it's specialized storage options, additional shelving, or specific accessories, the CPB can be configured to optimize efficiency in virtually any workspace.

​If you are considering adding or upgrading your marking process, laser technology might serve you well. However, the investment requires doing some homework to ensure the system you choose will optimize your capabilities and allow room to grow. Whether looking for a dedicated workstation or integrating the marking into a production line, identifying the primary features to fit your budget need consideration. Finding the best partner to provide the solution becomes important. What one machine shop finds suitable for them does not always prove the best for another shop.

Laser marking offers more flexible technology over chemical etching, which it most commonly replaces. Programming through the software provides the ability to quickly change marking details without having to print a mask specific to each marking file. Upgrading from dot peen can prove beneficial, however for applications where stress fractures might be a concern, you may want to think again.

Understanding Marking Areas
Within the laser marking solutions you will find different power sources that are specific to the types of materials you need to mark. Fiber sources are most suited for metals and some plastics, while CO2 sources best serve organic materials like wood, leather, and glass, along with some other plastics. Applications where heat may impact the product, or high contrast is needed there are other specialized laser sources such as UV, Green, Mopa and Solid State.

When referring to laser marking systems, the "marking area" is the maximum surface area on which the laser can engrave, etch, or mark at one time. This area is crucial for determining the size of the designs or texts that can be applied without repositioning the material. The size of this marking area is largely determined by the lens that is used in the laser system.

Standard Marking Area
The industry standard for a marking area is often cited as 4 inches by 4 inches (approximately 102mm x 102mm). This size is suitable for a wide range of applications, offering a good balance between size and precision for many products and components. However, specific requirements can vary, and so laser systems are equipped with lenses that can offer both smaller and larger marking areas.

Role of the Lens
The lens in a laser marking system functions similarly to a lens in a camera or a magnifying glass. It focuses the laser beam to a precise point on the material's surface. The characteristics of the lens, including its focal length, determine the size of the marking area and how finely the laser can focus.

• Smaller Lenses: These can focus the laser beam to a very fine point, allowing for detailed marking on a smaller area. They are ideal for applications requiring high precision and fine details.
• Larger Lenses: Lenses designed to cover a larger marking area can focus the laser over a wider surface. While they allow for marking larger designs or texts, the focal point is less concentrated compared to smaller lenses. This means that while you can mark larger areas, the level of detail might be slightly reduced compared to using a smaller lens.

Impact on Focal Distance
The focal distance is the distance between the lens and the material being marked. It is critical for achieving clear, precise marks:

• With larger lenses, the focal distance increases. This is because the lens needs to be further away from the material to correctly focus the laser beam over the larger area. A longer focal distance can lead to variations in the intensity and distribution of the laser's power across the marking area, which can affect the uniformity and quality of the mark.
• Dispersing Power Differently: As the focal distance increases with larger lenses, the laser's energy can be dispersed over a wider area. This dispersion can result in variations in mark depth and quality, especially at the edges of the marking area. It's crucial to adjust the laser's power and speed settings accordingly to ensure consistent results across the entire marking area.

The choice of lens impacts both the size of the marking area and the quality of the marks produced. Understanding the relationship between the lens size, focal distance, and laser power distribution is essential for optimizing laser marking processes to achieve the desired outcomes on various materials and for different applications.

This article is part of the Fundamentals Series, a collection of in-depth guides covering essential marking technologies and processes. Explore the full series here to gain deeper insights into industrial marking solutions.

compiled and edited by Bernard Martin

Quick-Drying Ink Technology
One of the standout hardware features is the incorporation of quick-drying ink technology. The Jetstamp 1025's ability to produce swift and efficient imprints on various surfaces sets it apart. This innovation not only accelerates the marking process but also guarantees clean and smudge-free results, contributing to enhanced productivity. But is also has an integrated capping system to seal the print head which keeps ink from drying out even with longer breaks between uses.

User-Friendly Interface: Intuitive Controls for Seamless Operation
Navigating the complexities of marking technology becomes intuitive with the user-friendly interface of the Reiner Jetstamp 1025. The latest software features empower operators to set-up and initiate marking tasks with ease. The interface is designed for efficient programming, ensuring a seamless experience for users at various skill levels. The integrated display shows the set print image easily legible at all times! Reiner has  made several upgrades to software features that redefine versatility in marking capabilities. From product identification to date coding and batch numbering, this handheld inkjet printer adapts to diverse marking requirements. 

Wireless Connectivity
The Reiner Jetstamp 1025 embraces the future with its wireless connectivity capabilities. This hardware feature allows users to control and program the device remotely, offering unparalleled flexibility in marking processes across different settings. Print images can be transferred to the mobile marking device by Bluetooth or USB. The integration of wireless technology positions the Jetstamp 1025 as a forward-thinking solution for those companies seeking enhanced operational efficiency.

compiled & edited by Bernard Martin

The TapMatic MH Series Marking Heads has emerged as a real game-changer by eliminating the need for costly secondary marking operations. These marking heads redefine the landscape by seamlessly integrating into the CNC machine just like any cutting tool in a rotary tooolholder, marking workpieces with unparalleled accuracy and speed.

At the core of the TapMatic MH Series is a commitment to efficiency and precision. Unlike traditional methods that necessitate separate marking processes, these marking heads allow users to mark workpieces directly during the machining process. This not only streamlines operations but also significantly reduces costs associated with secondary marking.

The Northwestern Pennsylvania (NWPA) Chapter of the National Tooling and Machining Association (NTMA), in collaboration with Northwest Industrial Resource Center (NWIRC) and NEFF Automation as the premier sponsor, is thrilled to announce two exclusive events to learn about the latest developments in the  manufacturing industry.

Join Leading Marks LLC on April 30th a Red Fern in Kersey, PA, and May 2nd in Erie, PA, at the Ambassador Center, for the Manufacturing Advanced Expo 2024. These events offer a unique platform for manufacturers and job shops to explore the latest advancements in automation technology, robotics, manufacturing processes, and their role in enhancing the skilled workforce in Northwest Pennsylvania.

​A Glimpse into Tomorrow’s Manufacturing
With a focus on educational sessions that spotlight advanced technology and applications, attendees will gain invaluable insights into how the industry is evolving. Experts will delve into topics that are at the forefront of manufacturing innovation, including 3D Robotic Guidance, Deep Learning Machine Vision, Robotic Palletizing, Welding, and Machine Tending, as well as Industry 4.0 Solutions. These discussions are designed not only to inform but also to inspire action and innovation within your operations.

Whether it is the elegant requirements of architectural signs, meeting ADA (Americans with Disabilities ACT) wayfinding requirements, or durable safety signs that survive rugged environments how you make the sign matters.
​
Leading Marks is an authorized distributor of the GravoTech engraving systems and the MAX USA Bepop 4-color thermal printers. Specializing in identification requirements, Leading Marks believes in presenting options that allow the customer options to meet the expectations of the job and work within the available budget for the capital investment.

If you are not sure investing in capital equipment for your label and sign needs makes sense, Leading Marks also provides stocked and made-to-order solutions too. When these needs arise, it is always helpful to understand your needs.

​It is also helpful to know the environment for which the label and sign will be used, and the driving need for it. With this information we can recommend the applicable material the sign should be made of meeting ANSI and OSHA requirements. Artwork in digital format expedites the ability to respond quickly.

Common standard and customized signs are available for biohazard and hazardous materials, safety, first aid, lockout tagout, machine operation and personal protection. Even rugged applications for aerial, pipelines, substations, traffic signals and other rugged industrial or construction site requirements.

This article is part of the Fundamentals Series, a collection of in-depth guides covering essential marking technologies and processes. Explore the full series here to gain deeper insights into industrial marking solutions.

By Bernard Martin

For almost a century, the Hall family has been at the forefront of the iron casting industry. Starting in the 1920s with Alfred J. "AJ" Hall, and continuing with his son, Alfred B. "Fritz" Hall, who became president of Benton Foundry in 1975, transforming it from a modest operation pouring 22 tons of iron daily into a visionary enterprise. By 1990, under Fritz's son Jeff, the foundry's capacity increased to 80 tons per day.

Benton Foundry has consistently reinvested profits into capital improvements, now operating a state-of-the-art facility with a capacity of 175 tons per day, aiming for 250. Unlike other foundries, Benton has prioritized core room expansion and strategic planning over short-term gains, contributing to its unbroken record of financial growth since 1975.

Back in 2002 Laurie Barcaskey at Leading Marks developed the precursor to the today's Boss Buddy as an application solution at Benton Foundary. Traditional embossing, as was being done at Benton, required a male and female die to create the embossed effect on thin gauge materials, often resulting in tearing of the material and inconsistent quality. 

Fast forward to 2014 and Laurie ran into a similar application problem as the one that she had solved over a decade prior at Benton.  And that began the official creation of the Boss Buddy. The inception of the Boss Buddy stemmed from a need to overcome the challenges that Benton had experienced, and dictated introducing a new method that utilizes a female urethane mating piece instead of both dies. This innovative approach not only reduced material waste but also ensured a more consistent quality of embossed characters on metal tapes, such as the foil or stainless tapes available for use with the today's Boss Buddy.

Unlike the typical wheel system that embosses one character at a time, today's Boss Buddy employs impact presses that emboss a complete set of characters at once. This method allows for the inclusion of custom characters and longer numbers, offering a solution that is both faster and more consistent. The Boss Buddy's adaptability extends to accommodating different types of metal tapes, catering to a wider range of industry needs.

Laurie's expertise in the marking industry played a crucial role in the development of the Boss Buddy, a manual system designed to emboss foil labels used commonly for pattern ID. This system addresses the industry's challenges head-on, providing a solution that leverages traditional components to replace outdated technology. The automation aspect of the Boss Buddy Plus signifies a notable advancement in the foundry sector, where efficiency and reliability are paramount.

The continuing story of the Boss Buddy is also one of collaboration and technical support. In the fall of 2023, Jason Karcher of Benton Foundry reached out to Laurie for assistance with the some of the components on the original design solution at their plant that was not functioning optimally. Actually, it's quite a testament to a design that had been in constant service for 20 years.  

According to Jason Karcher, Tooling Department Manager at Benton Foundry, "There are few options for applying traceability for certified parts so it's essential that this unit remains operational for our process and pattern labeling. The unit was not operating correctly and some band-aids were used until Laurie visited and discussed the replacement parts and shared schematics."

Laurie proposed to replace some press parts and introduce new steel type characters, along with arranging for a spare energy section for hot swaps, exemplifies the ongoing commitment to streamlining maintenance allowing a quick return to operation and customer service at Leading Marks.

Karcher continues the story. "When the parts arrived, the unit was put back into first-class operation very quickly. It was a simple repair. I spent some time pulling the machine apart. Replaced the items that have worn over the 20-ish years in service. Surprisingly it wasn’t in all that bad shape. The replacement parts fit as expected! The Machine runs well. More importantly I have a greater peace of mind knowing I have replacement parts in house in the event something breaks."

"All-in-all the process of ordering, replacing, and stocking the replacement parts/springs & do-dads went very well. I really appreciate Laurie's advice and help on this machine. Her years of knowledge and experience are unmatched. I expect it to run problem free in the back ground for some time." said Karcher.

The Boss Buddy's exemplifies how addressing specific challenges through innovation can lead to advancements that benefit the entire sector. Benton Foundry's history, marked by consistent growth and strategic investments, provides the perfect backdrop for the development of such a transformative solution. The Boss Buddy is not just a product; it's a symbol of progress in the foundry industry, showcasing how traditional processes can be reimagined for greater efficiency and reliability.
​
As the foundry sector continues to evolve, the Boss Buddy stands as a prime example of how innovative solutions can drive industry-wide change. Its development process, from conception to implementation, underscores the importance of expertise, collaboration, and a deep understanding of industry challenges. The success of the Boss Buddy and its impact on Benton Foundry's operations highlight the potential for similar innovations to shape the future of manufacturing and industrial processes, ensuring sustainability and growth in an ever-changing technological landscape.

Benton Foundry, nestled within 200 acres of Pennsylvania's scenic landscape, has been recognized as the "Metalcaster of the Year" by Modern Casting magazine for its significant coremaking expansion. ​​This recent project, completing 70,000 sq. ft. of new and renovated space in fall 2022, has notably enhanced the foundry's capacity, efficiency, and job creation.

​The expansion reflects Benton's long-standing philosophy of reinvestment and modernization, a practice initiated by Fritz Hall in the 1970s and continued today under the leadership of his son, Jeff Hall, the current president.

In July 2023, the Department of Labor made a significant announcement aimed at fortifying workplace safety across the nation. The unveiling of a new national emphasis program specifically targets warehouses and distribution centers, recognizing the unique challenges and potential hazards inherent in these environments. With a focus on reducing and preventing workplace hazards, this initiative underscores the government's commitment to safeguarding the well-being of employees across diverse industries.

From the OSHA News Release:

"In the past 10 years, warehousing and distribution centers have experienced tremendous growth with more than 1.9 million people employed in the industry. The Bureau of Labor Statistics data shows injury and illness rates for these establishments are higher than in private industry overall and, in some sectors, more than twice the rate of private industry.

"Our enforcement efforts are designed to do one thing: lead to permanent change in workplace safety," said Assistant Secretary for Occupational Safety and Health Doug Parker. "This emphasis program allows OSHA to direct resources to establishments where evidence shows employers must be more intentional in addressing the root causes of worker injuries and align their business practices with the goal to ensure worker health and safety."

Under this three-year emphasis program, OSHA will conduct comprehensive safety inspections focused on hazards related to powered industrial vehicle operations, material handling and storage, walking and working surfaces, means of egress and fire protection.

The Department of Labor's initiative comes as a proactive response to the evolving landscape of workplace safety. Warehouses and distribution centers, pivotal components of the supply chain, often contend with a multitude of hazards ranging from tripping and fall risks to more complex issues like equipment identification and emergency evacuation procedures.

What can you start to do right now to address this three year focus program is a comprehensive evaluation of your signage. 

Metalwerks, Inc. has over twenty years of experience melting and processing vacuum melted specialty metals. They operate five vacuum melting furnaces and bar processing equipment at their facilities in Aliquippa, PA.  

Metalwerks serve customers in the medical, industrial, and aerospace industries as well as research and development projects.

​Typically alloy systems at Metalwerks include Fe, Ni, Co, Cu, Ti, and Zr in quantities ranging from 300 grams up to 6000 pounds.  Through their network of outside processors they convert ingot into bar, plate, coil and/or sheet.

"The Easy, the Dot Peen marking system offers an unrivaled level of functionality.  Being easy to use while delivering an exceptional operating experience to the user. Easy is ideal for mobile use, since the unique and durable, yet the lightweight chassis allows a user to mark medium to large parts in even the most difficult and inaccessible locations." said Laurie Barcskey, owner of Leading Marks, LLC.
​
​​"The dot peen marking system has served us quite well:  No more smashed fingers, Clarity of the letters, and no problem training operators." says DeMailo.

I would recommend Leading Marks to other companies because they really understand and know their equipment.  They are great to work with !!!!"

If you have any questions about portable dot peen marking solutions, get in contact with Laurie! 

The Granit 1920i scanner’s highly innovative lighting system allows the imager to optimally illuminate marks of any type, on any surface. Low-angle, direct lighting provides the uniform illumination required for dot peen and laser-etched marks. ​

Low-angle, direct lighting provides the uniform illumination required for dot peen and laser-etched marks. An integrated diffuser delivers the soft, indirect light required for marks on shiny, round or otherwise highly reflective surfaces.

Powered by Honeywell’s revolutionary decoding architecture, the Granit 1920i scanner provides great scanning performance to read every type of direct part mark and ensure high first-pass read rates on even the toughest marks – regardless of size, surface, marking method or contrast.

The scanner is also capable of reading standard 1D and 2D barcodes on printed labels, delivering additional value – a single scanner to address your end-to-end scanning requirements across the complete workflow, from the production line to the warehouse.