Manufacturing Today - Volume 18, Issue 2 - 74

Midwest

Conex Cable LLC

In 2004, a private investment group in Chicago bought
Conex, resulting in the firm moving its plant from Dublin
to DeKalb. Although it required the company to move all
of its machinery and wiring, the transition was seamless,
Production Manager Brian Starr says. Starr celebrated
his 25th anniversary with the company in February.

New Methods
The 18,000-square-foot expansion to Conex's manufacturing facility includes a galvanization line. The line includes areas where steel wire is drawn and stranded. The
company manufactures both Class A zinc-coated galvanized steel wire as well as its own brand, CONZINAL, a
zinc and aluminum alloy with rare earth metals.
The company uses the Deloit process to galvanize steel
wire. The process involves using an electrical current to
wipe the zinc to a specific coating, Dobbel says.
The galvanizing process is unique in that it is environmentally friendly, as the company does not use acids or
high oxidizing materials to prepare material for process

and produces no waste byproducts to prepare products.
The process also reduces the ferrite properties of the
zinc used to make the wires, making them more resistant
to cracking and bending than competitive products.
The steel used in Conex galvanized wire is coated before it goes through one of the company's two draw lines,
giving it a smooth surface, Starr notes.
Conex's AS wire is manufactured by the continuous
extrusion method, which bonds high-purity aluminum
to high-strength steel wire. "The thick aluminum cladding provides AS wire with superior corrosion resistance
as well as high conductivity," the company says. "AS wire
incorporates the capability to vary the aluminum thickness as required for the higher conductivity described in
the latest ASTM and IEC standards."
The company produces and stocks a variety of strengths
of wire from utility grade to extra high strength. Coated
steel wires are offered in 3-, 7- and 19-wire constructions.
Wire packages are available in 250-foot or 500-foot hand
coils and in reels up to 20,000 feet long.

High Quality
Conex closely monitors manufacturing quality. Quality
begins with the machine operators, each of whom reports to a supervisor. The supervisor performs quality
checks and sends samples to the quality control department, which is managed by a quality engineer. The company's quality auditor audits the entire factory and provides manufacturing staff with feedback, Starr says.
The company has several Six Sigma techniques and
tools in place and receives materials on a just-in-time
basis. "Right now, [Conex] is 4.4 Sigma," Dobbel says.
"I'm certified as a leader in Six Sigma and I've got two
trained inspectors." Conex is always looking for ways to
improve. This includes implementing a 5S program.
Conex works closely with its suppliers. "We work together jointly to improve quality at all times," Dobbel
adds, recalling a case when a client requested more flexibility in its product.
Although flexibility is not the first thing many associate with steel, "We joined [together and] worked on a
very much-improved product," he recalls. "We got full
customer satisfaction."
The company also hones its workers' skills with training. "It's a continuous process," Starr says. "Whenever
we come across a situation where somebody falls behind,
we always retrain and review progress to meet the required customer demands." mt
74

manufacturing-today.com VOLUME 18, ISSUE 2


http://www.manufacturing-today.com

Table of Contents for the Digital Edition of Manufacturing Today - Volume 18, Issue 2

Contents
Manufacturing Today - Volume 18, Issue 2 - Cover1
Manufacturing Today - Volume 18, Issue 2 - Cover2
Manufacturing Today - Volume 18, Issue 2 - 1
Manufacturing Today - Volume 18, Issue 2 - Contents
Manufacturing Today - Volume 18, Issue 2 - 3
Manufacturing Today - Volume 18, Issue 2 - 4
Manufacturing Today - Volume 18, Issue 2 - 5
Manufacturing Today - Volume 18, Issue 2 - 6
Manufacturing Today - Volume 18, Issue 2 - 7
Manufacturing Today - Volume 18, Issue 2 - 8
Manufacturing Today - Volume 18, Issue 2 - 9
Manufacturing Today - Volume 18, Issue 2 - 10
Manufacturing Today - Volume 18, Issue 2 - 11
Manufacturing Today - Volume 18, Issue 2 - 12
Manufacturing Today - Volume 18, Issue 2 - 13
Manufacturing Today - Volume 18, Issue 2 - 14
Manufacturing Today - Volume 18, Issue 2 - 15
Manufacturing Today - Volume 18, Issue 2 - 16
Manufacturing Today - Volume 18, Issue 2 - 17
Manufacturing Today - Volume 18, Issue 2 - 18
Manufacturing Today - Volume 18, Issue 2 - 19
Manufacturing Today - Volume 18, Issue 2 - 20
Manufacturing Today - Volume 18, Issue 2 - 21
Manufacturing Today - Volume 18, Issue 2 - 22
Manufacturing Today - Volume 18, Issue 2 - 23
Manufacturing Today - Volume 18, Issue 2 - 24
Manufacturing Today - Volume 18, Issue 2 - 25
Manufacturing Today - Volume 18, Issue 2 - 26
Manufacturing Today - Volume 18, Issue 2 - 27
Manufacturing Today - Volume 18, Issue 2 - 28
Manufacturing Today - Volume 18, Issue 2 - 29
Manufacturing Today - Volume 18, Issue 2 - 30
Manufacturing Today - Volume 18, Issue 2 - 31
Manufacturing Today - Volume 18, Issue 2 - 32
Manufacturing Today - Volume 18, Issue 2 - 33
Manufacturing Today - Volume 18, Issue 2 - 34
Manufacturing Today - Volume 18, Issue 2 - 35
Manufacturing Today - Volume 18, Issue 2 - 36
Manufacturing Today - Volume 18, Issue 2 - 37
Manufacturing Today - Volume 18, Issue 2 - 38
Manufacturing Today - Volume 18, Issue 2 - 39
Manufacturing Today - Volume 18, Issue 2 - 40
Manufacturing Today - Volume 18, Issue 2 - 41
Manufacturing Today - Volume 18, Issue 2 - 42
Manufacturing Today - Volume 18, Issue 2 - 43
Manufacturing Today - Volume 18, Issue 2 - 44
Manufacturing Today - Volume 18, Issue 2 - 45
Manufacturing Today - Volume 18, Issue 2 - 46
Manufacturing Today - Volume 18, Issue 2 - 47
Manufacturing Today - Volume 18, Issue 2 - 48
Manufacturing Today - Volume 18, Issue 2 - 49
Manufacturing Today - Volume 18, Issue 2 - 50
Manufacturing Today - Volume 18, Issue 2 - 51
Manufacturing Today - Volume 18, Issue 2 - 52
Manufacturing Today - Volume 18, Issue 2 - 53
Manufacturing Today - Volume 18, Issue 2 - 54
Manufacturing Today - Volume 18, Issue 2 - 55
Manufacturing Today - Volume 18, Issue 2 - 56
Manufacturing Today - Volume 18, Issue 2 - 57
Manufacturing Today - Volume 18, Issue 2 - 58
Manufacturing Today - Volume 18, Issue 2 - 59
Manufacturing Today - Volume 18, Issue 2 - 60
Manufacturing Today - Volume 18, Issue 2 - 61
Manufacturing Today - Volume 18, Issue 2 - 62
Manufacturing Today - Volume 18, Issue 2 - 63
Manufacturing Today - Volume 18, Issue 2 - 64
Manufacturing Today - Volume 18, Issue 2 - 65
Manufacturing Today - Volume 18, Issue 2 - 66
Manufacturing Today - Volume 18, Issue 2 - 67
Manufacturing Today - Volume 18, Issue 2 - 68
Manufacturing Today - Volume 18, Issue 2 - 69
Manufacturing Today - Volume 18, Issue 2 - 70
Manufacturing Today - Volume 18, Issue 2 - 71
Manufacturing Today - Volume 18, Issue 2 - 72
Manufacturing Today - Volume 18, Issue 2 - 73
Manufacturing Today - Volume 18, Issue 2 - 74
Manufacturing Today - Volume 18, Issue 2 - 75
Manufacturing Today - Volume 18, Issue 2 - 76
Manufacturing Today - Volume 18, Issue 2 - 77
Manufacturing Today - Volume 18, Issue 2 - 78
Manufacturing Today - Volume 18, Issue 2 - 79
Manufacturing Today - Volume 18, Issue 2 - 80
Manufacturing Today - Volume 18, Issue 2 - 81
Manufacturing Today - Volume 18, Issue 2 - 82
Manufacturing Today - Volume 18, Issue 2 - 83
Manufacturing Today - Volume 18, Issue 2 - 84
Manufacturing Today - Volume 18, Issue 2 - 85
Manufacturing Today - Volume 18, Issue 2 - 86
Manufacturing Today - Volume 18, Issue 2 - 87
Manufacturing Today - Volume 18, Issue 2 - 88
Manufacturing Today - Volume 18, Issue 2 - 89
Manufacturing Today - Volume 18, Issue 2 - 90
Manufacturing Today - Volume 18, Issue 2 - 91
Manufacturing Today - Volume 18, Issue 2 - 92
Manufacturing Today - Volume 18, Issue 2 - 93
Manufacturing Today - Volume 18, Issue 2 - 94
Manufacturing Today - Volume 18, Issue 2 - 95
Manufacturing Today - Volume 18, Issue 2 - 96
Manufacturing Today - Volume 18, Issue 2 - 97
Manufacturing Today - Volume 18, Issue 2 - 98
Manufacturing Today - Volume 18, Issue 2 - 99
Manufacturing Today - Volume 18, Issue 2 - 100
Manufacturing Today - Volume 18, Issue 2 - 101
Manufacturing Today - Volume 18, Issue 2 - 102
Manufacturing Today - Volume 18, Issue 2 - 103
Manufacturing Today - Volume 18, Issue 2 - 104
Manufacturing Today - Volume 18, Issue 2 - 105
Manufacturing Today - Volume 18, Issue 2 - 106
Manufacturing Today - Volume 18, Issue 2 - 107
Manufacturing Today - Volume 18, Issue 2 - 108
Manufacturing Today - Volume 18, Issue 2 - 109
Manufacturing Today - Volume 18, Issue 2 - 110
Manufacturing Today - Volume 18, Issue 2 - 111
Manufacturing Today - Volume 18, Issue 2 - 112
Manufacturing Today - Volume 18, Issue 2 - Cover3
Manufacturing Today - Volume 18, Issue 2 - Cover4
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol19_6
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol19_6b
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol19_6a
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol19_5
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol19_5b
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol19_5a
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol19_4
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol19_4a
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol19_3
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol19_3a
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol19_2
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol19_2A
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol19_1
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol19_1a
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol18_6
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol18_5
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol18_4
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol18_3
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol18_2
http://www.nxtbook.com/nxtbooks/knighthouse/mt_vol18_1
http://www.nxtbook.com/nxtbooks/knighthouse/mt_20171112
http://www.nxtbook.com/nxtbooks/knighthouse/mt_201709
http://www.nxtbook.com/nxtbooks/knighthouse/mt_201709_v2
http://www.nxtbook.com/nxtbooks/knighthouse/mt_201708
http://www.nxtbook.com/nxtbooks/knighthouse/mt_201707
http://www.nxtbook.com/nxtbooks/knighthouse/mt_20170506
http://www.nxtbook.com/nxtbooks/knighthouse/mt_20170304
http://www.nxtbook.com/nxtbooks/knighthouse/mt_20170102
http://www.nxtbook.com/nxtbooks/knighthouse/mt_20161112
http://www.nxtbook.com/nxtbooks/knighthouse/mt_20160910v2
http://www.nxtbook.com/nxtbooks/knighthouse/mt_20160910
http://www.nxtbook.com/nxtbooks/knighthouse/mt_20160708
http://www.nxtbook.com/nxtbooks/phoenix/mt_20160506
http://www.nxtbook.com/nxtbooks/phoenix/mt_20160304
http://www.nxtbook.com/nxtbooks/phoenix/mt_20160102
http://www.nxtbook.com/nxtbooks/phoenix/mt_20151112
http://www.nxtbook.com/nxtbooks/phoenix/mt_20150910
http://www.nxtbook.com/nxtbooks/phoenix/mt_20150708
http://www.nxtbook.com/nxtbooks/phoenix/mt_20150506
http://www.nxtbook.com/nxtbooks/phoenix/mt_20150304
http://www.nxtbook.com/nxtbooks/phoenix/mt_20150102
http://www.nxtbook.com/nxtbooks/phoenix/mt_20141112
http://www.nxtbook.com/nxtbooks/phoenix/mt_20140910
http://www.nxtbook.com/nxtbooks/phoenix/mt_20140708
http://www.nxtbook.com/nxtbooks/phoenix/mt_20140506
http://www.nxtbook.com/nxtbooks/phoenix/mt_20140304
http://www.nxtbook.com/nxtbooks/phoenix/mt_20140102
http://www.nxtbook.com/nxtbooks/phoenix/mt_2013fall
http://www.nxtbook.com/nxtbooks/phoenix/mt_2013summer_vol2
http://www.nxtbook.com/nxtbooks/phoenix/mt_2013summer_vol1
http://www.nxtbook.com/nxtbooks/phoenix/mt_2013spring
http://www.nxtbook.com/nxtbooks/phoenix/mt_2012winter
http://www.nxtbook.com/nxtbooks/phoenix/mt_2012fall
http://www.nxtbook.com/nxtbooks/phoenix/mt_2012summer
http://www.nxtbook.com/nxtbooks/phoenix/mt_2012spring
http://www.nxtbook.com/nxtbooks/phoenix/mt_2011winter
http://www.nxtbook.com/nxtbooks/phoenix/mt_2011fall
http://www.nxtbook.com/nxtbooks/businessmedia/mt_2011summer
http://www.nxtbook.com/nxtbooks/businessmedia/mt_2011springsummer
http://www.nxtbook.com/nxtbooks/businessmedia/mt_2011spring
http://www.nxtbook.com/nxtbooks/businessmedia/mt_2011winter
http://www.nxtbook.com/nxtbooks/businessmedia/mt_2010fall
http://www.nxtbook.com/nxtbooks/businessmedia/mt_2010summer
http://www.nxtbook.com/nxtbooks/businessmedia/mt_2010spring
http://www.nxtbook.com/nxtbooks/schofield/mt_2010winter
http://www.nxtbook.com/nxtbooks/schofield/mt_2009fall
http://www.nxtbookMEDIA.com