Young Industries Manufacturing Facilities
Young Industries Inc. manufacturing area totals approximately 100,000 square feet. An on-site warehouse provides storage of finished goods when planned shipments are required to optimize construction schedules for major projects, or for containerized shipments of export machinery.
We manufacture our products using Carbon Steel, Aluminum, Stainless Steel, Hastelloy, Inconel, and Titanium materials. Young Industries has always been an innovator of developing fabrication techniques to meet the demanding requirements of our customers.
The progression of manufactured parts through our facility permits an efficient flow of materials from the start of fabrication to the shipment of finished goods. A brief description of each manufacturing department is as follows:
PRODUCTION PLANNING AND PURCHASING
All orders are processed by defining purchase requirements (allocations) for special ordered items and standard inventory materials. Each purchased item is identified by a unique inventory control number that insures production schedules and purchasing requests meet our delivery requirements. Manufactured parts are routed through our facility by means of a work order, which defines special requirements and includes detailed work procedures of manufacturing operations.
This permits our production planning and department managers to efficiently monitor manufacturing schedules by individual machine operation, or by total department capacity. Young Industries CNC (Computer Numeric Controls) Programming Department is located within our production planning offices, which permits timely availability of new programs. We utilize "Smart Cam" software (Point Control Corporation) for machine tool programming of our CNC machines. Our programming of sheet metal parts utilizes a customized version of "Parts 2 Plus" software (Shop Data Systems). This software includes standard HVAC parts information to permit efficient layout of customized parts.
CNC programming operations are DNC (Direct Networking Communication) connected to the machine operations which they service. Programs are transmitted from design stations or are directly entered at the machine tool work station.
Manufacturing capabilities for custom designed equipment
Young Industries capabilities include adapting our products to custom applications. Our design engineering, order processing, production planning, inventory control, and purchasing systems are equipped to facilitate special equipment efficiently. Our Fabrication equipment is selected for versatility of application to our products.
Some specific projects which Young industries has designed and manufactured include:
Design and manufacture of horizontal mixers weighing over 47,000 pounds and measuring 22 feet long, 10 feet wide, and 12 feet high, and producing 1200 cubic foot batch capacity.
Live bottom aluminum storage bin,1400 cubic foot capacity, designed and manufactured to store and discharge extremely light fluffy materials, complete with support structure and discharge conveyor.
Pneumatic conveying systems with components designed and manufactured with quick cleaning features for use in the pharmaceutical industry, with accessibility to filtering equipment by personnel wearing special protective clothing.
Rotary valves and diverter valves designed and manufactured of Inconel, Hastelloy, and Titanium.
CONTROLLED PRODUCTION SCHEDULES Young industries developed a customized Materials Requirement Planning (MRP) system which has been in operation since 1980 and is constantly being upgraded by our computer programming department. We believe our production scheduling system is capable of meeting the manufacturing requirements of today, with the following key characteristics:
Flexibility - Adapting to changes in product design and demand.
Controllability - Integrating critical control functions of quality control, production control, inventory control, and process reliability.
Efficiency - Minimizing waste of space, time, and materials.
Uniqueness - Developing and refining in-house manufacturing technology, which is the basis for a proprietary competitive edge.
Our system utilizes a database design and incorporates an "ORDER MASTER SCHEDULE" which is the complete listing of orders to be processed. From this listing, we develop the following information and/or reports:
ENGINEERING BACKLOG
A weekly report with important information regarding engineering approval, drawing schedules, and order release information stating the status of each item of an order.
MANUFACTURING SCHEDULES/REPORTS
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Shipping Schedule - a weekly report for the entire plant which gives the current status for manufactured items and outstanding purchased items (with scheduled acknowledgements from suppliers)
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Departmental Loading - a weekly schedule for each manufacturing department with the priority of work to be performed.
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Work Center - a report which is generated by request of manufacturing foremen, programmers, or the production manager to evaluate the current loading of any machine or departmental "Work Center".
INVENTORY REOUIREMENTS Young industries inventory materials requirement system is an "ON-LINE" system which provide current information regarding stock availability of parts and requirements of parts. Access by personnel from sales, engineering, manufacturing, and purchasing provides current demand for any inventory item, even if it is a one time, special item being manufactured.
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INVENTORY SCHEDULES/REPORTS
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Items Required to be Purchased - a weekly report that lists all items that are required to process an order.
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Expediting Reports
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By Supplier - a report generated by request which lists all oUtstanding purchased items from a supplier.
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By Shipping Schedule - a weekly report which lists all outstanding purchased items required for shipment for the next eight (8) week period.
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Order Status Report - a weekly report which states the manufacturing status of all items currently being processed. This report states the operations which have been performed and the operations and shop hours which still must be performed.
Young Industries maintains the flexibility to store and access all information necessary to provide an efficient, productive, and employee creative environment to serve our customers, utilizing our mainframe database system.
The following graphs provide order processing information to our engineering managers. As you will notice, we evaluate our engineering load by product division, manufacturing department, and by monthly schedule.
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Engineering Backlog BY MONTH
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TOTAL BACKLOG HOURS BY MONTH
Our production department utilizes the graphs above to evaluate the accumulated manufacturing hours committed, and develops a six month plan based on our current "MASTER SCHEDULE OF ORDERS". This plan compares the required manufacturing hours with the available hours of our labor force. Realizing that communications are critical for maintaining production schedules, Young Industries submits a detailed status report to our customers on a regular basis throughout the phases of a project.
RAW MATERIAL STORAGE AND CUTTING
Both ferrous and non-ferrous materials are stored in this area. This building is equipped with the necessary cranes for manufacturing.
We utilize a model.6 MG Industries Apollo HSG CNC Thermal Cutting System for our sheet metal preparation. This machine is equipped with an oxy acetylene torch, plasma cutting torch, and pneumatic punch marker Our cutting table will accommodate materials up to 3" thick with a 96" by 144" cutting area.
SHEET METAL LAYOUT - FORMING
Although most parts are programmed and cut by our CNC process, we also utilize manual band saws, gang punching, shears, rolls, and press brake operations to shape and form parts in materials from 22 8a. up to 5/8" thick. Our layout department utilizes some of our most skilled craftsmen, working from equipment detail drawings to perform the actual layout, cutting, forming, and fit-up of pieces to be welded. We utilize a "work cell" concept to provide for high quality products.
WELDING AND CLEAN-UP
Our welding department is equipped with automatic and semi-automatic welding equipment, and is equipped to perform all welding procedures. Such processes include MIG, TIG, STICK, and PTA (Plasma Transferred Arc). The PTA process is an automatic welding system which is primarily utilized to inlay weldments of Stellite hard surfacing materials. All welders, welding procedures, and processes utilized in production of weldments are certified according to ASME Section IX standards.
Young utilizes inert environmental facilities for welding of exotic alloys such as titanium and Hastelloy. The grinding (clean-up) department is well equipped with grinding and polishing tools which permit us to provide finished welds from minimal clean-up to sanitary weld polishes for pharmaceutical applications. Grinding equipment and supplies are carefully controlled to prevent cross contamination of materials. Young maintains facilities for performing glass bead blasting, shot peening or conventional sand blasting.
Young Industries has in house capability for both Thermal Stress Relief and Vibratory Stress Relief of parts. This permits us to choose the most practical means of stress relieving for the part being manufactured. Special heat treating requirements are achieved by sub-contracting of services to heat treating specialists.
MACHINE DEPARTMENT
The modern machining department, which is equipped with three CNC machining centers, are utilized to machine approximately 90 percent of all parts. Our Giddings & Lewis machine tools are capable of turning parts up to 18" diameter, 96" between centers, and for vertical boring of parts up to 48" diameter by 50" long.
Our G&L 3-axis model 15HSP Horizontal Machining Center, complete with automatic tool sequencing, is capable of machining in a work area of 48" by 60". It's automatic work piece system incorporates four (4) 40" pallet type work stations for shuttling parts, and a transporter to load and unload parts to the actual machining area. This machining center is also capable of machining contoured parts. The parts shuttling system allows improved productivity by allowing set-up to be accomplished while others are being machined.
The machining center is complemented by digitally instrumented and operated dual machines, capable of keying, slotting, milling and boring. An engine lathe with turning capacity of 54" diameter by 22 feet long highlights this department.
ASSEMBLY/SHIPPING
Our assembly area is a spacious two (2) bay area serviced by three (3) overhead bridge cranes, each with 8,000 pound lifting capacity. This layout provides for adequate room to perform smaller "bench work" assembly while permitting ample floor space for larger assemblies such as vessels, mixers, filters, and conveyors.
We are equipped to perform vibration testing, and static and dynamic balancing of component parts (IRD). We can run tests on equipment up to 300 HP, do sound level testing, perform soap bubble tests for fabricated vessels, or hydro pressure tests for ASME code vessels and steam jackets. Young maintains air and airless painting facilities for the application of conventional and special coatings.
After the final inspection of equipment is completed, the product is then crated for immediate shipment or sent to the warehouse for storage.
SPECIAL FABRICATION AREA
Young Industries has implemented a special fabrication area for contaminant-free products. These products require minimal contact with carbon contaminants, therefore they are formed and machined by normal sheet metal and machine shop equipment. All welding, clean-up, and assembly is performed in our isolated fabrication area to minimize possible contact with carbon contaminants.
