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37 HERAEUS | MAGAZINE 2015 | STREAMLINING PRODUCTION I n his nearly-30 year career at Heraeus in Wilmington, North Carolina, Production Manager Bruce Bratz has seen countless changes. But one thing remains unchanged and enduring: the company’s commitment to operational excellence. “What we did yesterday, or even today, is not good enough for tomorrow’s production”, he says. “We have to constantly improve and think of new ways of manufacturing.” The Wilmington site, which specializes in quartz manufac- turing for the fiber optic, semi-conductor and life science industries, utilizes all of the Heraeus Excellence initiatives to achieve a high-performing manufacturing environment. This includes Lean principles, Heraeus 5-S standards and goals, the Heraeus Production System (HPS) and a career development program for its two dozen employees that emphasizes cross-training and the advancement of skill levels. To Bratz, the company’s 360-degree approach is critical to success. “A machine is comprised of countless moving parts that have to work together in order to function properly. The same applies to the actual manufacturing environment.” This comprehensive approach is producing results. Re-designed Lean work centers have delivered gains in productivity, manufacturing efficiency and on-time delivery. Modernized fabrication methods and automation have increased quality and reliability. Experience is the foundation of success A recent example of what Bratz calls “excellence in action” took place when the Wilmington facility had the opportunity to fabricate a three-nozzle quartz burner, which is used for soot application in the fiber optic indus- try. Utilizing HPS tools, the Wilmington team designed a fabrication method that dramatically increased output from 40-50 burners per operator per month to 120 parts in 3-5 days of fabrication time. Additionally, the team’s implementation of a repetitive lathe fabrication process ensured quality and reliability of the finished part. To Bratz, the Wilmington team is the most important component of the Heraeus formula for success. He says, “Our production people are on the front lines and know what can and cannot work. Their experience, input and ideas are the reason why we are able to be innovative and successful.” O Bruce Bratz is one of Heraeus’ most expe- rienced production experts. His new ideas are moving production efficiency and quality forward every day. STREAMLINING PRODUCTION

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