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A Two Decade Case Study—How Modeling Drove Exceptional Results

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A Two Decade Case Study—How Modeling Drove Exceptional Results Werner Co.’s Franklin Park, IL Extrusion Operation 34 Million lbs of Annual Production from a Single 8”-Diameter,
2.750 US Ton Press

Craig Werner, Werner Extrusion Solutions LLC (WES), Lake Forest, IL, USA
Richard Kelly, Werner Co., Greenville, PA, USA

Track: MANAGEMENT ISSUES - Operations Management

ABSTRACT --- In 1983, Werner Co. began planning for a single extrusion press
to provide extrusions for its Franklin Park, IL ladder plant. Unique
circumstances existed:

  • The profiles, mix, and volumes were well known
  • Werner Co. had exceptional technical and IT staffs, data, and a progressive,
    technically oriented management
  • Their project manager had a extrusion knowledge and professional training in
    operational modeling
  • The Lotus 1-2-3 spreadsheet came to market, allowing structured analysis using
    personal computers
  • All extrusion systems and equipment considered were modeled with CAD
  • The model(s) answered extensive what if? questions to guide procurement
    decisions, ensuring Franklin Park’s immediate and long-term success, taking
    advantage of existing and projected extrusion process capabilities
  • The model(s) were fine tuned and extensively adapted to ensure that continuous
    improvements in results occurred at Franklin Park, and across multiple extrusion
    presses at all Werner facilities
  • Real data and results were verified over decades
  • This proven, systematic approach can, and should, be successfully implemented
    at other aluminum extruders to help optimize operations and provide competitive

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