View session room locations here.
Quick Jump to Tuesday / Wednesday/ Thursday

Tuesday, June 7, 2016

8:30 AM-5:00 PM

Fundamentals of Wire Manufacturing

The popular Fundamentals of Wire Manufacturing is a one-day, pre-conference course designed to give attendees a solid grounding in the essentials of wire and cable manufacturing. Scheduled for the day before the start of Interwire, it includes four general topics in the morning, and four each in a ferrous and nonferrous/electrical track during the afternoon. Lunch is included. It is valuable to those new to the industry, as well as a refresher for seasoned professionals. The course includes a 45-minute question-and-answer session following the end of the last class.

8:30 AM-9:15 AM

“Mechanics of Wiredrawing,” by Frank F. Kraft, Ohio University, USA

This course presents fundamental engineering principles and process calculations that are used to design, analyze, and improve metal rod and wiredrawing operations. Topics include a basic overview of wiredrawing mechanics with respect to material behavior and process parameters. Die angle and reduction will be addressed in light of the D-parameter and its practical application. Drawing limits, friction and lubrication, work-piece heating, and temperature effects are also discussed.

9:15 AM-10:00 AM

“Drawing Dies,” by Thomas Maxwell Jr., Die Quip Corp., USA

This presentation focuses on the die, the most important part of the drawing process. Without it, the best drawing machines, lubricant, and treatment systems cannot reduce the wire diameter. However, with a die, vice pliers, and a hammer, wire can be drawn, albeit slowly, as it has been for over 2,000 years. The intention of this course is to provide an understanding of what makes a die work, how it is designed, causes of failure, and problems with drawing larger sizes.

10:00 AM-10:15 AM


10:15 AM-11:00 AM

“Wiredrawing Lubricant Technology,” by David Gzesh, Blachford Corporation, USA

The wiredrawing process generates significant heat. This heat affects the lubricants’ ability to ensure quality wire production. The amount of generated heat is influenced by the interaction of factors that include the metal composition, surface preparation, and production equipment. This presentation will review basic wiredrawing lubrication principles and the lubricants’ chemistry. A review of basic issues will demonstrate the importance of understanding how the lubricant chemistry and physical properties interact with the drawing process.

11:00 AM-11:45 AM

“Wire Breaks & Surface Damage,” by Horace Pops, Horace Pops Consulting Inc., USA

This course presents a classification of wire breaks from a perspective that compares material defects to process-related problems. Rod defects will include both casting and rolling issues such as internal voids, foreign contaminants, rolled-in scale, hot cracks, and surface porosity. The effects of wiredrawing speed and lubrication will be discussed with respect to generation of fines, shaving, galling, and other surface defects.

12:00 PM-1:00 PM

Fundamentals Luncheon

Ferrous Track

1:00 PM-1:45 PM

“Fundamentals of Ferrous Metallurgy,” by Anand Bhagwat, Minova USA Inc., USA

This introductory course is designed to provide a general understanding of ferrous metallurgical concepts, including phase equilibrium, transformation, strengthening mechanisms, heat treatment, and an overview of steelmaking, and their relevance to the wire technology.

1:45 PM-2:30 PM

“Cleaning and Coating of Rod and Wire,” by Jack McAfee and Rudy Vey, Chemetall US, USA

This course presents the fundamentals of cleaning, pickling, and coating of ferrous wire and rod in preparation for drawing and processing. Proper control and handling in these areas ensures quality of the finished product. The design of these processes impacts the economics of the operation. It is imperative that rather than individual stages, this department should be viewed as a whole as it is critical to success. The course deals with zinc phosphate processes and the advantages and limitations as well as specialty coatings such as salt carriers, lubricants, dry film polymers, and new technologies on the horizon.

2:30 PM-2:45 PM


2:45 PM-3:30 PM

“Ferrous Testing and Properties,” by C. Richard Gordon, Gerdau Long Steel North America, USA

This course discusses tensile, coiling, wrap, reverse bend, torsion, fatigue, and hardness testing procedures. It illustrates interpretation of test results in terms of sample properties.

3:30 PM-4:15 PM

“Ferrous Heat Treatment,” by C. Richard Gordon, Gerdau Long Steel North America, USA

This course focuses on heat treatment of ferrous metals. It includes basic heat treating principles applicable to many metals with specific examples related to heat treatment of steel rod and wire.

Nonferrous/Electrical Track

1:00 PM-1:45 PM

“Fundamentals of Electrical Testing”

This fundamentals course is geared to providing a general overview of electrical testing. The course highlights key terms, standards, and tests that are common to the wire and cable industry for conductors, insulations and, various product types.

1:45 PM-2:30 PM

“Extrusion, Part 1,” by Erik A. Macs, Wire & Plastic Machinery Corp., USA

Part 1 starts with a review of the basic polymers typically used in the wire and cable process and is followed by explanation of the basic design of a thermoplastic extruder—barrel and liners, feed section, drive system, gearbox and thrust bearing, heating/cooling system, and pellet feeding. Special emphasis is placed on the varieties of screw design.

2:30 PM-2:45 PM


2:45 PM-3:30 PM

“Extrusion, Part 2,” by Erik A. Macs, Wire & Plastic Machinery Corp., USA

Part 2 covers the design considerations of the remaining components of extrusion lines. Items discussed include payoffs, dancers and accumulators, preheaters, crossheads, cooling troughs, capstans, online measurement and testing, printing, take-ups, and control systems. A brief review of typical troubleshooting tips is included if time permits.

3:30 PM-4:15 PM


This presentation documents the stranding process of nonferrous materials, specifically bare copper and tinned wire. Different processes that are addressed include high-speed bunch, heavy bunch and cable constructions, silicone block stranding, and smooth bunch. Specific applications include industrial and energy sectors, electronics and data communications, the automotive industry, consumer products, and appliances.

4:15 PM-5:00 PM


All the instructors for the Fundamentals courses get together at the end of the program for an open session of questions and answers with the audience. The 45-minute session immediately follows the end of the last class.

Wednesday, June 8, 2016

SESSION – Opening Session

9:30 AM-10:15 AM

9:30 AM-10:15 AM

"USA Manufacturing: Open for Business!"

Frank A. McGrew IV, Raymond James & Associates Inc., USA

This presentation provides a macro-economic overview and outlook. It details why middle America is the new favorite emerging market and explains the key variables that are coming together to start the third industrial revolution.

SESSION – Workplace Organization (WPO): Maintenance Tools

10:30 AM-11:45 AM


10:30 AM-10:55 AM

"MRO Vending Machines in a Manufacturing Environment," by Mike Crouchley, Champlain Cable Corp., USA

This presentation focuses on the reasons Champlain Cable Corp. decided to implement supplier-managed, in-house vending machines for MRO-type (maintenance, repair, and operations) purchased items. The discussion centers on the thought process and research for implementing the vending machine program, the process for selecting the supplier that best met Champlain’s needs, the logistics of how the program works, and the potential caution areas that could impact the effectiveness of utilizing this type of program.

10:55 AM-11:20 AM

“Incremental Improvement to Maintenance Operations,” by Clay Li, CalemEAM Inc., USA

The presentation includes steps to streamline maintenance operations using CalemEAM, out-of-box procedures for incremental improvement, and performance indicators to measure operations and their improvement. Implementation strategies are also discussed including cloud service, on-premise deployment, and mobile solutions. CalemEAM is an enterprise asset management solution, a proven tool to drive the incremental improvement to maintenance operations by manufacturers across the world.

11:20 AM-11:45 AM

Nashville Wire Products, USA


SESSION – Health & Safety

10:30 AM-11:45 AM


10:30 AM-11:45 AM

“Health and Safety Panel”

Panelists: Portia Groff, Nexans, USA; Bart Persoone, Bekaert Engineering, Belgium

Join these wire and cable manufacturers and safety professionals as they share their experiences on important safety topics. A Q&A session and general discussion follows.


SESSION – WAI Member Rewards, Annual Meeting & Mordica Lecture

12:00 PM-1:30 PM


1:00 PM-1:30 PM

“2016 Mordica Lecture: The Encore Wire Formula—A Culture of Innovation and Collaboration,” by Daniel L. Jones, Encore Wire Corporation, USA

Innovation has always been a major key in the wire and cable industry, but for a company to be successful requires more than just that. It takes vision and leadership to develop and support a company’s mission, which is why it is fitting that Daniel Jones, president and CEO of Encore Wire Corporation, will present the Mordica Lecture, an accolade granted an individual for contributions that have furthered the industry. Jones’ presentation will be a blend of two worlds: innovation and the evolution of a company that enables those advances to become commercial realities.

SESSION – Workplace Organization (WPO): Processes

2:00 PM-3:15 PM


2:00 PM-2:35 PM

“Wildly Important Focus,” Jeremy Couey, General Cable Corporation, USA

Manufacturing facilities are fast paced, ever evolving, and never short on challenges. Despite the advancement of technology to help us manage through the endless barrage of work it can oftentimes be difficult for a team to focus on priorities and dedicate the necessary amount of time to improve them. In this session you will learn how a manufacturing plant adopted The Four Disciplines of Execution to help them gain traction for meaningful advancement on the critical aspects needed to drive their business to the next level.

2:35 PM-3:15 PM

“Managing Operational Change – Cleaning Technology Case Study,” by Dane Armendariz and Douglas Grover, Chemetall US, USA

This session highlights Management of Change (MOC) Procedures, in the context of Cleaning Technologies, to assure that the following considerations are addressed before any change is implemented: 1)The technical basis for the proposed change, 2) Impact of the change on safety and health, 3) Modifications to operating procedures, 4) Necessary period for the change (temporary changes), 5) Authorization requirements for the proposed change, 6) Training of any operations, maintenance, and personnel whose job tasks are affected by the change prior to implementation of the change, 7) Modifications to process safety information and performance requirements. The purpose of this procedure is to define the practices and other procedures that ensure all process changes are accomplished in an effective, controlled, and managed fashion after careful review and approval from the management team.

SESSION – Capital Expansion Projects

2:00 PM-3:15 PM


“Capital Expansion Projects Panel”

Panelists: John T. Johnson, Mid-South Wire Co. Inc., USA; Bill Reichert, Champlain Cable Corp., USA

Three industry executives describe major facility expansion projects, including steps taken, in an open discussion to include questions from the audience.

SESSION – Operational Excellence

3:30 PM-4:30 PM


3:30 PM-4:00 PM

“Understanding the Value Expectations of the Various Wire and Cable Market Channels,” by Bill Barrett, Nexans Energy USA

The electrical wire and cable historical customer base has evolved into various segments with distinct product and value-added service requirements. This presentation describes a few of the more common market channels’ value expectations, comparing the similarity, differences, and challenges each channel presents to the wire and cable industry. It discusses channel value expectations that include the traditional electrical distributor, the original equipment manufacturer, the electrical utility, and the EPC / large electrical contractor.

4:00 PM-4:30 PM

“Transforming and Managing Talent for an Operator-Led Culture,” by Ava Pogue, General Cable Corporation, USA

As process management transitions from traditional supervision to operator-led natural work teams, it is important to have a tool for creating and communicating expectations. That tool must be able to track individual and team performance against expectations easily. Active engagement and communication with and among direct labor high-performance teams can create a desirable culture shift. This session introduces a talent management approach that leaves no associate wondering about level of engagement and performance, as assessed by both management and peers, along with a software solution to facilitate a complete operator-led strategy.

Thursday, June 9, 2016
SESSION – Keynote

9:00 AM-9:45 AM


9:00 AM-9:45 AM

Mark Horstman, Manager Tools

Mark Horstman, host of the popular podcast “Manager Tools,” delivers the keynote address. Manager Tools is a management consulting and training firm owned by Horstman and Michael Auzenne. It regularly consults and trains Fortune 1,000 companies throughout the world. Clients served by the owners include AT&T; MCI; Apple; Procter & Gamble; General Electric; Spacex; the U.S. Departments of Defense, Justice, and Commerce; Royal Dutch Shell;; General Motors; Daimler Mexico & NA Trucks; Cisco; and Manager Tools also produces the most successful business/management podcast in the world. “Manager Tools” won Best Business Podcast in 2006, 2007, 2008, and in 2012 as well as winning 2008 Best Podcast (overall, in all categories). Their free podcasts are currently being downloaded over 1,500,000 times per month.

SESSION – Manufacturing Management Seminar

10:00 AM-12:00 PM


10:00 AM-12:00 PM

“Manufacturing Management Seminar,” by Mark Horstman, Manager Tools

Immediately following his keynote address, Mark Horstman leads a two-hour manufacturing management seminar to explore the Manager Tools philosophy more deeply. Manager Tools is a management consulting and training firm owned by Horstman and Michael Auzenne. It regularly consults and trains Fortune 1,000 companies throughout the world. Clients served by the owners include AT&T; MCI; Apple; Procter & Gamble; General Electric; Spacex; the U.S. Departments of Defense, Justice, and Commerce; Royal Dutch Shell;; General Motors; Daimler Mexico & NA Trucks; Cisco; and Manager Tools also produces the most successful business/management podcast in the world. At the core of the Manager Tools philosophy is the notion that management is a workplace discipline that can be learned by anyone—regardless of personality—who is willing to engage in effective behaviors wherever delivering results and retention are critical. The key elements of their training approach focus on developing routine management behaviors that enhance one-on-one relationships with directs, delegation of work tasks to develop talent and enhance productivity both for managers and their reports, and performance feedback that encourages future effective behaviors and actions.

SESSION – Mobile Classroom

10:00 AM-1:00 PM


Davis-Standard LLC

This program combines an on-site tour of Davis-Standard's Pawcatuck, Connecticut, facility and classroom discussion of screw technology for wire and cable applications. Topics will include screw design (materials and coatings, barrier/metering, distributive mixing, and dispersive mixing), groove feed technology (types, benefits, and tradeoffs), and applications (high temperature, foam, HFFR/LS0H, crosslinked materials, and rubber).

SESSION - Production Solutions

10:30 AM-12:00 PM


10:30 AM-11:00 AM

T&T Marketing Inc., USA


11:00 AM-11:30 A

“Marking, Printing, and Guiding of Insulated Wire,” by Mark Spencer, W. Gillies Technologies LLC, USA

This presentation and hands-on demonstration features equipment for marking, printing, and guiding insulated wire and cable in addition to precise positioning of wire and cable relative to processing and gauging equipment. It includes flexible turn-key designs suitable for a variety of applications on a product range from 28 gauge up to a 6-in. diameter. Equipment can be located in-line during extrusion, off-line during take-up and payoff, barrel-fed for wire and harness processing, and used for short runs for wire and cable distribution. Many of the parts used in the construction of this equipment are modular. This means that components used for guiding and positioning are often interchangeable with those used for printing and marking. This reduces inventory of spare parts and allows the product to be repurposed should the end users’ requirements change. Universal bracket mounts allow a variety of CIJ ink jet markers to be incorporated directly into this equipment.


11:30 AM-12:00 PM

“Wire Breaks,” by Horace Pops, Horace Pops Consulting Inc., USA

How do you identify possible causes of wire breaks? Is it the process or the material? Learn to distinguish between both issues that can result in wire breaks. A detailed analysis of central bursting (cuppy wire) will include both causes, prevention, and correction.

Go back to schedule