About Avtron - meparts.net
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About Avtron - meparts.net
About Avtron filename:c:/My Documents/Winword/AboutIAAvtron i Preface Following is a brief history of Avtron Manufacturing, Inc., our organizational structure, products, technical support, and quality assurance. filename:c:/My Documents/Winword/AboutIAAvtron ii CONTENTS Cover .......................................................................................................... i Preface .......................................................................................................ii Contents ...................................................................................................iii History.................................................................................................... 1-2 Organization........................................................................................... 2-3 Customer Support ..................................................................................... 3 Quality Assurance .................................................................................. 3-4 Avtron Employees ..................................................................................... 4 Products.................................................................................................. 4-7 Aircraft Test/Support Equipment................................................ 4-5 Digital Drives and Digital Drive Systems ....................................... 5 Digital Pulse Generators .............................................................. 6-7 Electrical Load Banks ..................................................................... 7 Manufacturing........................................................................................... 7 Project Management ............................................................................. 7-8 Control of Work ......................................................................................... 8 Future Upgrades ....................................................................................... 8 Financial Status ......................................................................................... 8 Closing ................................................................................................. 8 Avtron Facilities .................................................................................... 9-11 Cleveland Facility ............................................................................ 9 Systems Facility ..............................................................................10 Digital Facility................................................................................ 11 filename:c:/My Documents/Winword/AboutIAAvtron iii History Avtron is a growth oriented technology company, headquartered in Independence, Ohio, U.S.A., with manufacturing and engineering facilities in Independence and in the nearby City of Cleveland. Avtron has been in business continuously since 1953, and currently occupies the leadership role in those customer areas it serves. complementary, and sometimes overlapping categories. These categories are: Aircraft Test/Support Equipment Electrical Load Banks Industrial Automation Avtron’s steady growth and stability are results of the management philosophy of developing the highest quality products for niche market applications and expanding and diversifying the product lines by building on its strengths. Diversification of the Industrial Automation Division from its start in Pulse Generator and into Digital Drives and Systems is a good example of the successful implementation of Avtron’s management philosophy. Avtron’s Systems Division in Independence, Ohio Mr. Dwain Fritz founded the company concentrating on electrical system component testing. Avtron remains wholly owned by the family of its founder, and the family participates in day-to-day operations of Avtron. This allows the company to put concerns of its customers and employees first without concern for outside stockholders. Earnings are used to improve the company instead of being paid out in dividends. Mr. Robert Fritz, Avtron’s president (and son of its founder), has developed a strategic plan to increase business growth through Avtron’s entry into selected, core markets. During the 1960s, Avtron digital control and metering products became industry standards for both aerospace related test equipment and material processing industries. Through the 1970s, Avtron expanded and improved upon its digital product lines and developed integrated instrumentation and control systems. Gradually, Avtron’s product lines have developed into three distinct yet filename:c:/My Documents/Winword/AboutIAAvtron Avtron’s Industrial Automation Division in Independence, Ohio Avtron’s senior management has always known that industrial automation equipment is an area in which Avtron could succeed. A strategic plan was developed and implemented for Avtron to serve the metals, mining, port, paper, plastics and rubber markets. The key to Avtron’s success in industrial automation is the correct combination of personnel coupled with existing expertise in designing and manufacturing highly reliable equipment at a competitive price. To this end, industry experts in mechanical, electrical and 1 control systems engineering, and technical sales staff who are thoroughly knowledgeable of pulse generator and drive components and systems were recruited. Avtron has been very successful in its Industrial Automation business, with systems in place at industrial installations all over the world. Pictured above is Avtron’s ADDvantage-32 Drives installed on a Cast Film Line Avtron’s management format has proved to be extremely effective on both the day-to-day pulse generator business and the large drive systems. A typical example is the recent concurrent development of the industries' first 32-bit digital drive and the only diagnostic pulse generator on the market. Sales have steadily grown each year from 1976 to the present. Over that same time period, floor space has grown by 350%, employment increased by 200%; sales have increased by 225% ($37 million in 2001, and we anticipate $41 million in 2002). Avtron spends 8-10% of earned revenue on Product Research & Development, insuring that our products keep pace with emerging technologies. Avtron senior management has positioned the company so that it has no debt earnings have financed all growth providing filename:c:/My Documents/Winword/AboutIAAvtron longevity and assurance of long-term support availability. Organization Avtron currently employs about 350 people, and the employment level has remained stable for the past five years. Approximately 90 employees are technical personnel, each with at least a four-year degree. The majority of these employees have backgrounds in electrical engineering, mechanical engineering, electronics, and computer hardware and software design. Avtron has been successful in staffing its engineering and technical support departments with personnel from a wide spectrum of engineering backgrounds. Many of Avtron’s product design engineers began their careers at Avtron in the Customer Support Engineering Department. There they learn first-hand, how the customer utilizes Avtron industrial automation equipment, how to use on-site trouble-shooting techniques, and how to quickly resolve customer problems. Avtron has developed an excellent reputation through Cooperative Education and Employment Programs with local academic institutions. As the head of the Electrical Engineering Department at Cleveland State University once said when touring Avtron’s facilities, “My graduates can see more technologies under one roof in your building than in any other company that recruits in Cleveland.” Finally, Avtron has drawn directly from the industrial automation industry for a source of trained, skilled engineers. Designers from wellknown automation firms such as Rockwell Automation and Westinghouse Electric have been retained and are presently employed at Avtron. 2 Avtron’s Load Bank Division in Cleveland, Ohio Long-term booking forecasts are reviewed monthly. Anticipated growth is met with advance hiring. Experienced workers are teamed with new hires for training purposes. Avtron’s success is directly attributable to its senior management’s sound business approach. Only a stable management team with clearly defined corporate objectives could maintain such growth. Avtron's senior management team, including the president and the heads of major functional departments average 26 years of service with the company. The Director of Quality Assurance reports to the President, not to the Director of Manufacturing. This means that Avtron’s President has direct, unfiltered input from the Quality Assurance Department. Customer Support Avtron maintains a Customer Support Engineering Department with highly qualified personnel available for field trouble-shooting on short notice. All pulse generators and drives are fully tested before shipment to ensure proper performance and smooth start-up. The support offered by Avtron in start-up training, operation, and maintenance of the equipment ensures maximum customer utilization. filename:c:/My Documents/Winword/AboutIAAvtron Avtron provides a 24-hour/day emergency service hot line. Once a problem has been identified and reported by a customer, Avtron teams begin working toward a solution. This may include trying to duplicate the problem with test and demonstration systems in Cleveland. Responses to customers’ calls are immediate from the Customer Support Engineering Department. Depending on the severity of the problem, an engineer from CSED may be sent to the facility to assess the problem and implement corrective action. Avtron’s newest drives and systems are being shipped with Ethernet Communications and advanced diagnostic computers. With customer permission, Avtron’s Customer Support Engineers can tie directly into a drive system at the customer’s site to perform trouble-shooting and software updates. This service reduces downtime during equipment failures, travel time and expenses, and speeds up the fault isolation process. All these items save Avtron and its customer's time and money and provide greater value to Avtron’s industrial automation equipment. Avtron encourages its users to become selfsufficient. Avtron offers training and technical support for user on-site repair of Avtron equipment. Avtron provides comprehensive technical support in all areas of software and hardware for its products. Quality Assurance Avtron Manufacturing is ISO 9001 Quality System Certified. This certification ensures that detailed formal processes are followed in all aspects of the design and manufacture of Avtron products. The Director of Quality Assurance reports directly to the President, thus assuring that Avtron provides the highest quality test equipment to our customers, and that pressures to meet shipments will not override Avtron’s quality assurance process. 3 In June of 1997, Avtron Manufacturing’s quality system was officially certified as compliant with ISO 9001:1994 standards. This improved on Avtron’s previous ISO 9002 rating. Avtron is very proud of its quality. Because of Avtron’s excellent reputation, a significant portion of its business is repeat business As a result, the design and support of our equipment is directed by the management philosophy of customer satisfaction (the right equipment for the application), reliability, and long-term support. Most of Avtron’s industrial automation equipment-delivered since the division's start in 1965--is still being supported with replacement parts and service. Most of our customers today have been using Avtron equipment for many years. Avtron Employees Avtron promotes cross-training throughout the company. Engineers and technicians are given the opportunity to venture into new product areas to expand their abilities. The company and customers gain from cross-training because of the inherent flexibility that it provides. Avtron’s approach to engineering management ensures a high degree of synergy. Our digital drive system’s dependability (ADD-32™), for example, can be traced through our innovative application of “Lessons Learned.” The aircraft, stand-by power system, industrial manufacturing companies and Avtron have invested considerable sums of money improving the reliability of electronic devices. “Lessons Learned” during these development processes are implemented in future designs. Products (Equipment Design) Experienced and knowledgeable electrical and control system engineers design various types of components and systems which are the foundation for the many Avtron industrial automation customers. Avtron’s extensive experience and tradition of providing Ground Support Equipment (GSE) to the military and commercial aircraft industry, uniquely qualifies us to make highly reliable industrial automation products. This filename:c:/My Documents/Winword/AboutIAAvtron expertise translates into designs that are high quality, reliable, maintainable, and well documented. Avtron's products can quite literally be found around the world. Avtron’s “product lines” can be classified into four major categories. This discussion concentrates on aerospace test equipment. Brief synopses of the product categories are listed below. Avtron’S K938 Drive Stand Aircraft Test/ Support Equipment All major airlines use Avtron equipment, whether it is in the form of Electronic Test Equipment such as the UnivATE™, Electrical Test Equipment for CSD and generator testing, Hydraulic Test Equipment for testing airborne hydraulic components, load banks, or our bonding meters. The US military (USAF, USN, US Army, Coast Guard), as well as many foreign military operations, have Avtron test 4 equipment in service. Our presence across the globe has expanded rapidly to include fluid power testing. This includes hydraulic pumps, motors, servo-actuators, and servo-valves. Avtron has also produced “Iron Bird” prime movers and computer controlled test stands for testing devices such as Aircraft Mounted Accessory Drives (AMADs). paper machines, metal rolling mills and process lines, blown and cast plastic film lines, and rubber calendars and tread lines. Avtron also specializes in cost-effective digital drive retrofits. These limited upgrades provide digital control for older analog controlled drives. Packages are available for both static, SCR drives and for motor-generator sets. These upgrades save customers thousands of dollars in capital equipment costs and they can be implemented during routine, scheduled outages. Avtron maintains full-time system engineering and field support departments to assist customers in drive upgrade projects and ongoing system support. Engineering services include project engineering and management, consulting services, machine surveys, design review meetings, and installation engineering and supervision. Avtron’s ADDvabtage-32 Advanced Firing Module Retrofit on an old General Electric analog drive. Digital Drives and Digital Drive Systems Avtron’s patented ADDvantage-32™ (ADD32™) Digital Drive provides digital control of AC and DC motors. A single drive can be used to very closely regulate the speed of the motor, thereby improving its performance and efficiency. The U.S. Coast Guard uses the ADD-32™ in a variety of applications aboard their ships. Mining operations all over the world use the ADD-32™ for motor control for their gigantic earth moving and mining equipment. Customer support services include factory startup service, 24/7/365 telephone support and remote diagnostic services, emergency field service, preventive maintenance, software archiving, and both field and factory training programs. Avtron also offers state-of-the-art diagnostic software to allow fast, easy customer selfservice of its drive systems. Our PERFORMANCE VIEW Diagnostic Software continuously records process events and control variables. The software allows process problems to be isolated and corrected after a single occurrence, taking the guesswork out of system troubleshooting. The ADD-32™ is also used in large Avtron designed, integrated process control systems where speed regulation is extremely critical, i.e., filename:c:/My Documents/Winword/AboutIAAvtron 5 five different shaft sizes ranging from 0.625” to 2.375”. Heavy Mill Duty Designs: Avtron’s M285 SMARTach Pulse Generator mounted on a General Electric motor. Digital Pulse Generators Avtron has been a leading manufacturer of digital pulse generators for over 35 years. These have developed into the industry standard for digital drive feedback devices on industrial control systems. Our reputation for making the most reliable, highest performing pulse generators in these systems has been built on our quality and world-class manufacturing capabilities. Traditionally, Avtron served the severe duty market only but recently has begun making units for general industrial use. We currently offer three duty classes with each class offering several electrical and mechanical mounting styles depending on the application. Mill Duty Designs: The Models M3 and M945 can be used successfully in most industrial environments like paper converting, plastics, and metals processing lines. They should not be used in environments with frequent temperature changes and chronically wet conditions. These optical models can be supplied in either shaft, foot or face mounted designs. Available shaft mount designs can use filename:c:/My Documents/Winword/AboutIAAvtron Models in this duty class include the magnetoresistive M285 SMARTach and M4 units. These designs work well for more rugged environments with periodic temperature fluctuations and increased levels of contamination. The SMARTach Line uses highreliability magneto-resistive sensor technology. They also include field replaceable sensors, dynamic duty-cycle adjustment and diagnostic LEDs for predictive maintenance in expensive downtime applications. The M285 mounts directly to a Nema FC face. This results in a highly reliable installation because bearings and couplings associated with a foot of face mount unit are eliminated. The M4 is a more basic magneto-resistive design without the removable sensors or diagnostics and is offered in either shaft, foot, or face mounted configurations. It can accommodate five different mounting shaft sizes from 0.625” to 2.375”. Severe Duty Designs: These include two of our popular SMARTach Family Models, the M485 and M685 units. These models can withstand very wet and dusty environments with large and frequent temperature extremes. They include the removable sensors and diagnostic features like the M285 described above. The M485 is a foot or face mounted unit while the M685 shaft mounts directly to a 1.125” stub shaft. TachTester: A hand-held, portable TachTester is also available that can be used to test any of the Avtron Pulse Generators. The unit allows the user to test their pulse generators before deciding whether to return them to Avtron for repair. This allows the user to save the expense 6 of packing and shipping a suspect unit back to the factory only to find later that nothing is wrong with the unit. The unit can be plugged into any standard connector option on the pulse generator and will show the duty cycle of the pulses, the phase separation between phases, and the pulses per revolution seen (if the unit has the marker pulse option). The TachTester comes complete with a carrying case, long-life battery with charger, AC adapter, and one set of mini-grabber cables. Electrical Load Banks Avtron is the world’s leading supplier of electrical load banks. Avtron ships hundreds of load banks each year for use in testing stand-by commercial generators, aircraft generators, and other electrical power sources. Avtron makes load banks for AC (resistive & reactive) and DC applications from a few watts to several mega watts. Manufacturing Avtron's facilities are comparable to other companies that produce similarly complex products, with a few exceptions. First, Avtron subjects all electronic devices to “burn-in” testing. The burn-in tests are conducted at elevated temperatures to identify and eliminate semiconductor devices that would otherwise fail prematurely if placed in actual service. The Avtron burn-in is far more stringent than that of other companies. filename:c:/My Documents/Winword/AboutIAAvtron Avtron maintains comprehensive manufacturing capacity for our components and systems. Avtron utilizes the Digital and Cleveland facilities as feeder plants for the Systems Division. Major sub-assemblies, machined parts, and system cabinets are manufactured at the Cleveland and Digital facilities. The subcomponents are final assembled into their respective system at the Systems facility. The Systems Division contains 40,000 square feet of flexible manufacturing space, and with overhead cranes and high-power voltage sources, provides an ideal facility for systems assembly and test. Please refer to the last three pages of this document for Avtron’s diverse resource facilities. Avtron’s manufacturing operation is vertically integrated. Avtron has a complete CNC machine and fabrication facility. Avtron has control of all phases of the production cycle thereby reducing lead times and product cost. This capability also allows Avtron to offer excellent long-term support by giving our customers a source for spare parts twenty to thirty years after the original purchase of the equipment. Avtron's design department uses CAD/CAM exclusively. Specifically, AutoCAD, Version 15, is the format in current service. Throughout the company, Avtron maintains a ERP computer and hundreds of high-speed PC compatible computers which are connected to one another through a Local Area Network (LAN). Project Management Avtron provides dedicated project management. Avtron assigns a project engineer to every project, providing a point of contact within the company who can answer technical, installation, and scheduling questions. The project engineer has direct access to the production floor, production scheduling information, purchasing information, and the resources of over ninety qualified engineers. The project engineer follows the program from receipt of the order 7 through scheduling, design, customer design review, production (ISO9001 certified), quality control (ISO 9001 certified), testing, customer demonstration, and shipment. Control of Work Avtron’s quality assurance program mandates that all project hardware is accompanied by a shop order. The shop order serves several valuable functions in the control of material and labor being utilized on the project. All labor performed is documented on the applicable shop order as the product flows through the Avtron manufacturing system. This method is well proven and provides a complete historical record of any work performed on a given product. Quality Assurance oversees all manufacturing activities, assuring conformance to the required design standards, and stores these records as historical data for future reference. Future Upgrades Avtron provides support for the future and an upgrade path. In five years, when the role of your capital investment needs change, Avtron will still be here, ready to provide you with reasonable upgrades, technical support, and replacement components. Avtron archives on computer tape, disk, and microfilm, all schematics, drawings, wiring diagrams, and documentation required for filename:c:/My Documents/Winword/AboutIAAvtron long-term customer support. Avtron has 30year-old systems in the field that are still supported with identical replacement components or functional equivalents when obsolete components are unattainable. This dedication to field support is extended to all Avtron customers. Financial Status Avtron owns three facilities with approximately $40 million U.S. annual dollar revenue and no long-term debt. Avtron is financially secure with controlled growth financed with earnings. Avtron has an extremely stable operation and workforce. Avtron’s Dun & Bradstreet rating is 4A1. Our D&B Identification Number is 421-4227. Closing It is important to remember that Avtron has a corporate goal to continue to be a leader in industrial automation equipment and also to expand that role. This business is one of our specialties, and we remain dedicated to providing our customers with the finest pulse generators and drives manufactured anywhere in the world. Many customers who have purchased our equipment have told us—months or years after the purchase—that they made the right decision. 8 RESOURCES CLEVELAND FACILITY Sheet Metal Fabrication Equipment A 33-ton CNC Hydraulic Punch Press Finn-Power Model F520, 75 tools A 230-ton Hydraulic Press Brake Cincinnati Model CB2, 12’, 2-axis CNC back gage A 135-ton Mechanical Press Brake Cincinnati Model 5, 12’, 1-axis CNC back gage A 60-ton Mechanical Press Brake Chicago, 8’, manual back gage Other Equipment • • • MIG/TIG Welding, Spot Welder Hydraulic Power Notcher, 2 Shears Clinch Nut Machine Additional Capabilities • • • • • • Load Bank Element Winding Transformer/Reactor Winding, Dip and Bake Silkscreen & Scotchcal Labels Engraver Paint Booth with Curing Oven Load Bank Testing Potting and Encapsulation • Memmert curing oven Other Capabilities • • • Complete paint room with separate paint booth and curing oven Printed Circuit conformal coat room with curing room Large Power Source and Avtron Load Banks for variable speed drive testing filename:c:/My Documents/Winword/AboutIAAvtron CLEVELAND FACILITY: 10409 Meech Avenue Cleveland, OH 44105 Phone: 216-641-8310 Fax: 216-341-8803 Manufacturing – 45,000 sq. ft. Office – 20,000 sq. ft. Land – 5 acres Employees – 75 CAPABILITY: Sheet Metal Fabrication Structure Welding Electrical Assembly\Painting Testing – Electrical MAIN PRODUCT: Load Banks 9 RESOURCES SYSTEMS DIVISION Equipment Resources • Overhead Bridge Cranes: One 20-ton Crane One 10-ton Crane Three 5-ton Cranes • Tubing Bender • Welder • Power Source for Large System Testing Department Resources • • • • • • • Contract Administration Drafting Department Shipping Department Technical Publications Department Photo/Print Shop Test Department Training Department Engineering Resources • • • Customer Support Engineering Electrical Test Equipment Engineering Hydraulic & Fuel Test Equipment Engineering • Research & Development Engineering • Software Development Engineering SYSTEMS FACILITY 7900 E. Pleasant Valley Rd. Independence, Ohio 44131 Phone: 216-642-1230 Fax: 216-642-6037 Manufacturing – 40,000 sq. ft. Office – 20,000 sq. ft. Land 5 acres Employees 200 CAPABILITY: Heavy and Small Assembly Hydraulic Assembly Electrical Assembly Testing – Systems Drafting/Technical Publications Welding Engineering Photo/Print Shop MAIN PRODUCTS: Aircraft Component Test Systems Medium and Large Load Banks Large Variable Speed Drive Systems filename:c:/My Documents/Winword/AboutIAAvtron 10 RESOURCES DIGITAL FACILITY MACHINE SHOP • • • • • • • • • • • • • Monarch VMC 45, vertical machining center Hitachi Seiki HiTec-Turn 20SII, lathe Burgmaster VTC 150, Qty. 2, vertical machining centers Hitachi Seiki 4NEII, Qty. 2, lathes Enshu AccuMill AM1547, vertical machining center Bridgeport Series I, Qty. 2, milling machines South Bend SBL390, lathe South Bend SBL400, lathe Brown & Sharpe MicroMaster 618, surface grinder Cincinnati Hydrashift 15, lathe Radial arm drill Do-All cut-off saw Do-All band saw Quality Assurance • • AlphaMetals lonograph 500M Brown & Sharpe Validator, coordinate measuring machine • Comparator Printed Circuits • Electrovert Econopak II, wave solder machine • DEE 4 station washer • Miscellaneous filename:c:/My Documents/Winword/AboutIAAvtron DIGITAL FACILITY 8601 E. Pleasant Valley Road Independence, Ohio 44131 Phone: 216-642-1230 Fax: 216-642-9743 Manufacturing – 26,000 sq. ft. Office – 4,000 sq. ft. Land – 3 acres Employees – 75 CAPABILITY: Machine Shop Painting Testing – Electrical Manufacturing Engineering Printed Circuit Board Fabrication Wave Solder Small Assembly Quality Control MAIN PRODUCTS: Tachometers Drive Controls Circuit Cards 11