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On October 22 Eaton EAMO (Engine Air Management Operations) held their annual Supplier Summit in Atlanta,GA. Approximately 75 vendors from
throughout the world were supplied with the latest information and statistics concerning a wide range of business activities as it relates to
the Eaton EAMO plans and for the companies future successes.
Topics for the day included the general economic outlook for business and industry, the automotive outlook, the strategy for growth, the
Eaton business system and supplier quality. Then breakout sessions were held to cover a range of business topics.
During the breakout sessions the general topics were Commercially, Planning/Scheduling, Supplier Quality, Engineering and Operations support.
The discussions and points raised were of benefit to both parties.
At the conclusion of the day 15 companies from the vendor base were awarded Quality Excellence Awards. These awards were based on their prior
years participation and determined from scores on the Supplier Balanced Scorecard. The criteria measured total quality, delivery, IDEAS, total
cost and technical support. Flame Treating is pleased to have received such an award.
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West Hartford, CT
April 16, 2002
Company president, Tom Benoit was arrested and incarcerated today. He has been charged with being Kind to People with Muscular Dystrophy.
The West Hartford Police Department sent a deputized volunteer to escort him to the West Hartford lock-up. It should be noted that the lock-up
was more than adequate. The Muscular Dystrophy Association petitioned the court to insure that all "prisoners" were treated humanely during their
"jail time." Served chicken parmesan, Caesar salad and cheese cake is not the usual jail food as seen on Gunsmoke or Law and Order.
With the help and contribution of friends, business associates and family he was able to raise a total "bail" of $1225 and was promptly released.
It is believed that the charges will be dropped in the immediate future.
The Muscular Dystrophy Association and Flame Treating thank all of you who assisted in this program. Collectively this days activity raised some
$45,000 for the benefit of MDA in the greater Hartford area.
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FTECO realized several years ago that the flame hardening process was antiquated at best. Its biggest drawback may have been the
need for highly trained operators and its dependence on the variation in those skills on a day-to-day basis.
To eliminate those problems and increase the reliability and accuracy of the process FTECO undertook several steps to improve the operating conditions.
First optical pyrometers were adapted to each operation to provide technicians with accurate temperature readings. Operators were then able to improve results
knowing accurately the temperatures of the surfaces being heated.
Secondly the optical pyrometers were adapted to automatic indexing operations. Specific long running jobs were tooled to allow for presentation of the part
to the flame and the ejecting of the part from the heat at the prescribed temperature. Now every part is heated to the same, known temperature. Remember, metallurgical
results are directly dependent on the temperature.
Thirdly, FTECO designed and built an automated machine for flame hardening straight edge type parts such as rails, turbine buckets, links, racks and other components
that have straight sections to be hardened.
A current customer brought his retired metallurgist, acting as a consultant, to discuss our ability to flame harden stainless steel edges of various machined components.
After some discussion we visited the shop where a similar operation was ongoing. As we arrived at the equipment the operator lit the torch and left the machine to attend
to other parts of the process. Dismayed at first the consultant was shown the pyrometer, the output to the PCL and the resulting motion and control. After viewing the
operation with a temperature variation of about 10 F, he said to his employer, "Get out of their way. These people are out of the dark ages." They summarily left and are
now a very significant and important customer.
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As seen in Industrial Heating April 2001
In 1940, Leo T. Benoit, a former engineer for Linde Division of Union Carbide, started The Flame Treating & Engineering Company (FTECO) in what
used to be a small horse barn. His first customers included Hartford Empire, Torrington Manufacturing, Hartford Special Machine, Cushman Chuck, and Pratt and Whitney Machine.
In 1956, after moving into a 3,000 square foot building in West Hartford, the company began induction hardening parts after purchasing a 25 kW Westinghouse generator at an
auction at Springfield Armory. In 1976, the company purchased the adjoining manufacturing building and constructed a bay connecting the buildings.
Today, as FTECO celebrates its 60th anniversary, it continues to enhance its technical ability and competence in the localized heat treatment of metals. Operating out
of its 15,000 square feet of manufacturing facility, the company currently has ten generators ranging in size from 5 to 120 kW. All generators operate using optical pyrometers
to control temperature and PLCs to control process temperature and location of parts. The combination of the output from the pyrometer and the PLC provides complete process
control for flame-hardened parts.
Other areas of technical competence include automated parts feeding, multiple heating of parts to improve productivity and costs, process control, continuous
improvement activities, and magnetic particle inspection certification. A metallurgical lab includes mounting, polishing, microhardness testing and metallographic examination
capability, with a computerized photomicrograph system and document preparation. FTECO´s expertise in localized heating extends to the automotive, bearing, machine tool, capital
equipment, power transmission, powder metal, and screw-machine products industries. The company has a staff metallurgist, lab technician, and consulting metallurgist on staff.
Keeping to its commitment to continuous improvement, the company recently added its tenth generator, a 40-kW Inductoheat unit and an Eitel straightening press.
Other recent developments include a localized aging process used to locally repair an Inconel assembly and a dual-heating process to induction harden a power metallurgy gear
for an automotive application. In addition, FTECO developed a flame hardening machine using pyrometry and PLC to ensure accurate temperature and motion for hardening the leading
edge of steam-turbine buckets used in the power generation industry. As a result of this successful installation, FTECO currently uses this technology to heat the edge of straight
parts.
In October 2000, the company obtained ISO 9002 certification and incorporates these standards and procedures in order processing. The processing systems uses Visual
Shop (Cornerstone Systems, Inc.) plant management software, and flow charts govern each step of the process to ensure accuracy. "The ISO registration confirmed our status as a
provider of quality services with an internationally recognized system of quality," said FTECO President Tom Benoit. "It also provided an opportunity for all employees to
participate in its development and implementation," he added.
Benoit feels confident in the future of the heat treating industry in general. "FTECO will grow as the industry around us changes With the level of process control
we have developed, we are able to adapt to the changing needs of the customer base. Our father started the business with intent on being successful. We have worked to
distinguish ourselves as a provider of these services and to continue to be recognized as a leader, " said Benoit.
The management team of FTECO includes Tom Benoit, president, a 1966 WPI graduate and Dave Benoit, treasurer, a 1970 graduate of the United Technology Apprenticeship Program.
Founder Leo Benoit graduated from WPI in 1936.
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From CBIA News December 2000
By Debra Susca
Suddenly, the shop floor surrounding a chain wheel to be used in the New York state locks system bursts into an eerie white light. A computerized screen in the background rapidly
tallies numbers as two men wielding blowtorches aim their fire at the inner section of the wheel. The instant the number reaches 1600 - degrees Fahrenheit, that is - the flames are
killed, the part cooled with an automated spray of water, and all goes back to normal.
A visitor has just witnessed the computerized business of "localized" flame treating done at The Flame Treating & Engineering Co.(FTECO) of West Hartford.
The section of the wheel that has just been heated and cooled - and hardened in the process - will now be able to withstand the constant wearing of the chain against it as the
locks are opened and shut. Before the end of the day, the rest of that inner chain area will have been hardened in the same way.
FTECO, a family-owned business started in 1940, is as successful as they come, from the easy camaraderie of the two owner brothers, to the profitable niche market they´ve
developed and their commitment to staying current with new technology and processes in the industry. They also run an environmentally friendly shop and earned ISO 9002 certification
in September, underscoring their commitment to quality.
"We´ve come a long way since the days when we started working for our dad in the business by mowing the lawn and weeding dandelions," says Dave Benoit, treasurer,
as his elder brother Tom, president, chuckles and nods in agreement.
Back then, the shop was run out of a horse barn on Homestead Avenue in Hartford. Now it operates out of a modern, 15,000 square-foot building on Oakwood Avenue in west Hartford.
Inside, many of the firms 18 employees run computerized equipment to complete jobs for clients ranging from one person shops to fortune 500 companies like GE and Daimler Chrysler.
Sitting at their stations, employees use one of two heating processes -- flame hardening uses oxy-acetylene fuel gas, as with the chain wheel, or induction heating to harden parts
such as cams, machine tool beds, rolls, shafts and gears used in the automotive, machine tool, print, powder metal, packaging machine, and screw machine industries.
"We´ve developed some extensive expertise in our niche market," says Tom, who along with his brother took over the business in 1977. "There are 30 or 40 different
heating processes, but we´ve chosen just two. More and more, companies are using induction heating because it´s less expensive and it´s environmentally friendly.
That´s becoming a big thing in the industry and we've got the experience."
In induction heating, a high frequency electrical current is passed through a conducting coil surrounding the part to be heated. The electromagnetic energy created induces a current
to flow on the surface of the part.
"We´re able to control the time and the temperature through the computers and infrared sensors to produce the correct metallurgical results," says Dave, as he stops at
one workstation where shafts to be used in the Toyota Corolla steering column are being hardened in certain spots. "Induction Heating is energy efficient and reduces distortion.
Not only has the company developed it´s niche market over the years and stayed current with technology, FTECO has been deeply involved in the Metal Treating Institute, an
international trade organization Tom presided over as president last year, and with the Center for Heat Treat Excellence, a business/academia consortium founded two years ago. Those
involved work collaboratively through the Worcester Polytechnic Institute to improve the efficiency, reliability, and quality of the heat treating industry. FTECO is also
collaborating with another person on a patent for induction carburizing.
"We do keep up with technology and trends," says Tom, who predicted way-back-when to his skeptical father that the business would one day run with computers. "It gives
you a step up."
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Wow! What a day. The sun was bright, the tent stood cheerfully in the back yard, the Dixie land band was at their finest and magician, Charlie Hayden
brought a buzz of excitement to FTECO´s 60th anniversary open house.
As they say, "You´ve come a long way, baby!" A very long way since that day in October of 1940 when Flame Treating opened its doors for business. Of course, before
the business could open the inside of the former horse barn that served as the companies original location had to be thoroughly cleaned of the remnants of the former occupants.
In those days the country was in the city and the city in the country.
Originally providing flame hardening services to the manufacturers of special equipment in the greater Hartford area, two employees began that early trek that has led to 60 years
of successful localized heat treating operations. Currently FTECO provides flame and induction heating to a wide range of manufacturers throughout the northeastern US. From those
early days FTECO has grown to 15,000 square feet with 16 employees. It is an ISO registered company and has adopted a wide range of automation and process control that has set it
apart from most of the other companies in its field.
We were pleased to be able to entertain some 150 customers, suppliers, and business associates this day. It was our efforts and their requirements that have gotten us to this
point in our business career. And it is our plan to continue its future growth. New induction generating equipment is being added. Automation and process control in both the flame
and induction area are being updated and improved. Our ISO quality system is moving towards QS 9000. Class room training situations are being used to complements the typical OJT.
The company is active in the Metal Treating Institute, the trade association of companies in the heat treating industry. FTECO is also a participant in the Center for Heat Treating
Excellence; the industry academia alliance working to develop advances in the heat treating industry located at WPI in Worcester, MA.
Plans are already underway for the celebration of our 75th. Mark your calendar of the first week of October in 2015 for a bigger and better celebration.
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L. Thomas Benoit Jr. has been named President of the Metal Treating Institute, an international association of heat treaters, for 1999. President of Flame
Treating and Engineering since 1977, Benoit is a graduate of Worcester Polytechnic Institute with a BS Degree in Mechanical Engineering. He has completed the Management Development
Program at RPI´s Hartford Graduate Center. Tom has taught and participated in education seminars and programs presented by ASM and SME. He is a Registered Professional Engineer
and a Certified Manufacturing Engineer. Tom is a member of ASM, SME and has served on MTI´s Board of Trustees since 1994.
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Commercial Heat Treaters
Establishing a niche market is critical to business success. The Flame Treating And Engineering Company (FTECO)of West Hartford, Connecticut, has its niche
(and success)in the localized heat treating of manufactured parts by flame and induction heating. Localized heat treating of cams, gears, spindles, shafts, machine tool components,
and automobile assemblies is a specialized service with growing demands for precision results with consistent, high throughput.
Precision induction processing at FTECO is accomplished by combining radio frequency induction equipment with the latest process and temperature control devices available and
automated handling systems. Forming the core of their induction capabilities are nine power supplies rated from 7.5 to 125 kW. All generators are manufactured by Lepel, Ajax, and
Westinghouse. Each is controlled by a programmable logic controller and infrared pyrometers. Three programmable controlled scanners are used for the hardening of a wide range of
shafts.
High standards are maintained with the use of the PLC controls, infrared temperature measurement, and photoelectric sensing equipment. PLC controls can pulse the equipment as
quickly as 2/10 of a second. Infrared pyrometers provide set point control for heating in the on-off mode or can provide proportional control that allows heating cycles that have
approached 12 hours. Photo-electric and proximity switches are used to ensure the part is properly fixtured and located prior to heat treating. In addition to adapting controls,
FTECO has developed automated parts feeding equipment used in a wide range of applications for heating powder metal components, investment castings, and screw machine products.
Multiple station index mechanisms automatically present the part to the coil and the quench and run in a continuous operation. Additionally, tooling has been developed to allow for
multiple heating operations during one cycle.
FTECO, as its name implies, also provides flame hardening services. Approximately twelve pieces of equipment provide localized heating using oxy-acetylene fuel gas. Components
hardened are cams, machine tool beds, rolls, and gears. Parts range in size from several ounces to ten tons. The company has adopted the infrared pyrometer and index mechanism to
the flame hardening process as well.
Finding a niche and then following through on a commitment to modern equipment and well trained employees is what has made FTECO successful, according to Tom Benoit. He and Dave,
his brother, assumed control of the business in 1980 when their father retired. It was 1940 when Leo T. Benoit first opened the doors to his flame heat treating shop in a small barn
in Hartford. In 1954, a 3,000 square foot facility was purchased in West Hartford. It has grown to 15,000 square feet and 18 employees.
In 1940, the customer list was relatively short, with Pratt & Whitney Machine, Hartford Special, and Emhart comprising the lions share of business. Today however, companies from
the automotive, machine tool, print equipment, powder metal, gear, packaging machine, and screw machine industries all benefit from FTECO's localized heat treating expertise. While
the company specializes in "localized" heat treating, their niche positioning has earned them national recognition from customers as far away as Florida, Illinois, and Texas.
A niche is important, and localized heat treating with the latest process and temperature control systems and automated handling are allowing Flame Treating to serve this market with
confidence and competence. Flame Treating has been a member of MTI since 1983.
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Flame Treating has designed, built and installed a horizontal scanner to provide induction heating services for a customer manufacturing an automotive shaft requiring
localized hardening. The shaft had previously been hardened in a vertical position scanner with manual loading of the shaft provided by the operator.
To improve the operation the team designed out much of the material handling and lost time that was related to the required positioning accuracy and the hardening of the two required areas.
Operators now load as many as 30 parts at a time in a tray. Upon the signal from the PLC one part is isolated and escaped to a shuttle device. The part is then shuttled to a location between centers.
It is grabbed between centers and the process begins.
The control of the process is PC based. Using a Yaskawa Servo Drive with a feed back loop, the THK Linear Motion Slide is able to produce repeatability of locations to less than 0.001".
Sensors and prox switches control the other elements of the process and are networked together to provide the process control for continuous operation and monitoring of the equipment.
Productivity increases of approximately 55% were achieved with this new equipment.
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Flame Treating is pleased to announce that is has
passed the Recertification Audit and continues its ISO registration. This is
the third certification audit for the company. The company has maintained its
certification for the past six years. At the end of the term of the
certification the company will have maintained its registration for 9 years.
Additionally there were no deviations noted in the audit report.
From the report; "Flame Treating has continued to maintain a quality
management system, QMS, which meets all of the requirements of the ISO 9001:2000
with any exceptions as noted. This audit did not identify any non-conformances
that would be expresses as a written deviation. There were two minor deviations
from the previous audit that were closed after the effectiveness of the
corrective actions was verified. Additionally, there were several opportunities
for improvement noted and are covered, in detail, in the final summary of this
report. As a result of this audit, continued registration is recommended by the
auditor."
Until the new certificate is available we are posting the first page of the
audit for your review.
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80 Kw with Scanner is under installation
Flame Treating is pleased to announce the addition of an 80 Kw Induction Generator with 42"
scanning capacity to its list of equipment available to provide localized heat treating
services.
The 80 Kw Generator is remanufactured to new equipment standards and provides continued expansion
of FTECO´s induction scanning capacity. The generator and scanner are controlled by a combination
of PLC´s and Infrared Technology. This allows the correct time and temperature profile to be used
to heat your manufactured components to the strictest tolerances. FTECO now has 10 induction
generators with 4 fully programmable scanners for processing a wide range of shafts, rollers and
wheels. Shafts from several ounces to 300 pounds can be processed efficiently.
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12/18/07
ISO Surveillance Audits
Flame Treating is pleased to announce that TUV has completed the annual surveillance audit and
has confirmed FTECO's certification to the ISO 9001:2000 standard for the Flame and Induction Heat
Treating of Ferrous and Non-Ferrous Metals.
The report states, "Flame Treating & Engineering has continued to maintain a quality management
system, QMS, which meets all of the requirements of the ISO 9001:2000 standard with any exceptions
as noted. This Audit did identify two (2) deviations, although they are minor in nature. There
were no deviations from the previous audit to be closed. Therefore, continued registration is
recommended by the auditor."
FTECO is also pleased to announce that it has again passed the company audit of General Dynamics
Armament and Technical Products in Burlington, VT. The auditor indicated that there were no
deviations in his findings. Flame Treating continues to supply locally heat treating services to GD
and its vendors.
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12/18/07
Trivia Champion Crowned
Flame Treating is pleased to announce that George Hollman has survived a grueling test over the
past 6 weeks to emerge as the Trivia Champion at 702 Oakwood Ave. Under the direction of LouAnn
Strasser, HR/Office Manger, questions were developed and answered for a period of six weeks as part
of the payday activity. Standings were posted weekly and the competition had a close finish with 4
employees finishing within one correct answer of the lead.
George and James Fiore were tied for first place at the conclusion of the 6 week payroll event.
A final Jeopardy style sudden victory event was conducted around lunch on December 11. Questions
were adopted from Trivial Pursuit, using both 20th Edition and the Baby Boomer Edition. A total of
14 questions were presented to both finalists and George eked out a victory over James by answering
two more questions correctly.
Congratulations to George on a stirring victory.
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12/18/07
Improved Automation
Flame Treating continues to improve and develop new methods and techniques for automating the
localized heat treating process. The continuous heat treating of components has been carried on at
FTECO since the late 80's. At that time we married automated indexing, PLC's and infrared pyrometry
to provide techniques to insure that each component processed was heated to the same temperature.
We are now in our third or fourth evolution of those techniques. These efforts are being made to
allow for more options in sensing and processing of the various heat treated parts.
The expanded PLC allows for additional inputs and outputs. All items processed are sensed for
proper index, location in the coil, hardening temperature, spindle position to allow for error free
index, delayed index to the quench station and feed back to tell the PLC that the part has indexed
and the next cycle can begin. Such tooling allows for controlling heating and provides options for
quenching your most critical components.
Additionally FTECO has the ability to heat two or four items at a time using these techniques.
This provides for additional through put and improved efficiencies.
We welcome the opportunity to discuss using these and other techniques to assist you in solving
your localized heat treating problems.
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9/11/08
Surveillance Audit
Flame Treating is pleased to announce that TUV Rheinland has completed the most recent surveillance audit of the companies ISO 9001:2000 with the following results as noted in the audit report.
CONCLUSIONS/SUMMARY: "Flame Treating has continued to maintain a quality management system, QMS, which meets all of the requirements of the ISO 9001:2000. Therefore the company is recommended for continued certification."
"The audit did not identify any non-conformances in the quality management system documentation and/or the processes."
The report went on to note the following items.
POSITIVE OBSERVATIONS: "The organization has begun the initial stages of 5S projects and lean manufacturing techniques. The results of 5 S are very visible in several areas such as shipping/receiving with a greater level of efficiency.
Daily afternoon meeting is held in the production area to discuss the status of production jobs, materials and/or projects.
The quality objectives for the organization are a critical component of the operation as the data measured is used to provide a benchmark for continual improvement and customer satisfaction."
We look forward to using this system to providing you with heat treating services that meet you companies standards and requirements.
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9/21/09
ISO 9001:2008 Recertification Audit
Flame Treating & Engineering is pleased to announce that TUV Rheinland has completed the re-certification audit of Flame Treating's Quality System to the ISO 9001:2008.
CONCLUSIONS/SUMMARY:
"Within the scope of the audit the company has furnished proof that it maintains a quality management system in accordance with the above mentioned standard and that the requirements are fulfilled. There were no nonconformities issued as a result of the audit. Therefore the company is recommended for continued certification.
The report went on to note the following items.
POSITIVE OBSERVATIONS:
A daily afternoon meeting is held in the production area to discuss the status of production jobs, materials and/or projects.
The 5 S activities in several areas has led to improved housekeeping.
The organization has a very detailed contingency plan developed and in place. The scope of this plan is well defined.
Customer communications are well documented and very detailed.
We look forward to using this system to providing you with heat treating services that exceed your companies standards and requirements.
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9/23/09
Automation advancements
Flame Treating & Engineering is pleased to announce that it has completed the remanufacture of it's automated rotary index tooling with pop-up capability for processing a wide family of cylindrical parts including gears, sprockets, screw machine products, shafts, connectors and bushings. Basically any round part that is to be induction hardened has potential to be processed in this manner.
The equipment runs automatically and continuously. The process is PLC controlled. The controller monitors or controls the positioning of the table, indexing, senses the location of the part at the coil, any delays that are required for processing, timing for heating and quenching. An optical infrared pyrometer controls the temperature of each part heated. This allows us to insure the correct processing of even your most stringent parts.
Over the years Flame Treating has used this technology to harden a wide range of powder metal components for the automotive, office products and hand tool manufacturers. Bearing diameters on spindles for hand and garden tools are a very successful application. Annealing a wide range of stainless steel drawn shells has been performed for the eyelet industry. Finally a wide range of copper alloy connectors has been zone annealed in the area of the crimp to prevent cracking at assembly.
We welcome your inquiries.
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