When I asked John Warczak, Vice President Materials & Systems, HB Performance, www.hayesbrake.com, in Mequon, WI (Milwaukee area) what they do better than anyone else, he flashed back with such strength and confidence, “We build the best braking systems in the world!”  I just had to use his quote for the title of this article. At that point, I immediately knew my visit to HB Performance would be a journey to find out how?

HB Performance has roots that date back to 1946.  They specialize in braking systems for motorcycles (Harley Davidson), power sports (recreational equipment), specialty products for companies like Cat and Deere and mountain bikes.  They have a 600 employee global presence with most of its manufacturing done in Mequon, WI.  I asked John, so what do you do better than anyone else that allows you to make the claim you just did?  John responded, “Our core competencies are the innovation and design of braking systems, machining, and the assembly with test of the entire systems we manufacture.  We do most of that right here in Mequon.  Another thing we’ve done is develop a supply chain that allows us to offer our customers a jewelry finish to many of the products we manufacture.  For example, we have developed revolutionary processes that allow us to machine our parts after chrome plating.  Finally, a huge differentiation for us is that we test the assembled system before we ship.  Many of the products are shipped to our customer as one complete end-to-end braking system ready to install, significantly streamlining the customer's production line processes.”

The Mequon plant operates 24/5 plus 16 hours on the sixth day and frequently on the seventh day.  I asked John to describe some of the shop floor problems they must handle?  John said, “Many of our cells have older machines and if one machine goes down the whole cell goes down.  We’re moving to change that (Editor’s note:  more about this later).  Supplier variability is another issue.  We look for suppliers who understand the quality equation.  We expect them to deliver a quality product with quality support.  We expect them to be honest, upfront and give us real answers.”  I asked John to rate us, that is Mazak, Machinery Systems and our tooling company, Machinery Tooling and Supply based on the criteria he just stated.  John deferred that question to Paul Gallagher, the manufacturing engineer in the room with us who deals with us on a day to day basis.  He responded, “Great. I especially love working with Gary (Crook), of Machinery Tooling & Supply.” 

At this point, John turned us over to Paul for a plant tour.  Paul has been responsible for one of the most recent plant projects — three Mazak Variaxis 500-5X (5 axis machining centers).  Paul explained how the Variaxis machines have allowed them to reduce their vulnerability to down time with their older cells.  With the Variaxis they have been able to manufacture parts complete in one set-up.  Since they have multiple Variaxis machines, if one machine should go down, the other machines are available to continue production.  The most critical part just goes to the next open machine.  Paul also explained, “We found a very capable company in Taiwan to machine a part.  While they could do the machining, they couldn’t meet our specs due to part tolerance stacking caused by multiple operations.  The part required ten operations over ten different machines.  We now do the part on the Variaxis.  We machine the part complete in one set-up." Paul went on, “Our parts, on the Variaxis are made to a higher level than we can actually measure.”  Paul also stated that they consistently hold a 1.5-2 CPK.  Paul, a very clever engineer, has designed the fixturing for the Variaxis machines as quick change with all the hydraulics through the pallet.  Paul boldly stated, “We can change over in less than five minutes.”

Paul went on to explain (video link) that they fully utilize the Mazak Cybertool Tool Management System resident in the Variaxis Mazatrol control.  The tools are qualified in the tool crib and the information (including expected tool life) is stored in a “chip” in each tool retention stud.  The operator exchanges the tool when he receives notice from the Mazatrol control. All tools are now changed before any unscheduled failure.  This has a significant impact on machining throughput. The chip also has a hole in it so the machine can utilize the advantages of 1000 PSI through the tool coolant.

Paul stated, “I started running one of the Variaxis last February and have never had to make a tool offset.  The parts have repeated over and over.  It’s a phenomenal machine!"

I want to add that this is a union shop but I wouldn’t have believed it if I wasn’t told.  It’s a happy, friendly environment.  The people are very cooperative, easy to talk to.  The plant is spotless, everything is done in a clean and organized environment.

I also found out two other interesting things.  John Warczak is a local rock and roll celebrity.  He’s the lead singer in the Stray Voltage rock and roll band.  Mike Cekanor, Senior Vice President of Machinery Systems, has heard him sing and told me that he’s really good.  And, Paul is a New Berlin, WI alderman and chairman of Sewer and Water Commission for the city.  Finally, one of the things that John mentioned earlier in our conversation was that he was really proud of their people.  You could see it and feel it.  These are very sharp, hard working, creative people.  They are really loaded heavy with engineering talent. I’m proud that they are our customer and to know them more intimately.

 

All tools are qualified in the tool chip.  They are ready to be loaded and immediately placed in operation.  The Cyber Tool "chip" tracks tool life and cost accounting data.

One of HB's world class assembly/test cells.  Their customer receives a tested brake system ready for final assembly.