Manufacturing Assistance Center

Dynamic Business Magazine, July/August, 2001

Elizabeth Carbide Die Employees Complete Four-Year Apprentice Program in May 2001

By Bill Peduzzi

“It’s the best apprentice course I have ever seen. I could see the benefits of the training taking effect in our shop during the four years. I’d recommend the MAC apprentice program to anyone." – Phil Davies, manager of Personnel, Elizabeth Carbide Die Company.

SMC Member Elizabeth Carbide Die Company, Inc. is one of the Elizabeth Companies and is the largest manufacturer of rotary and single-station press tooling serving the pharmaceutical industry in North and South America, Europe, Asia, and Australia. The company is also a major source of quality tooling for hundreds of customers in the powdered metal, ceramic, chemical, electronics, and confectionery industries.

Located in McKeesport, PA, Elizabeth Carbide Die Company employs more than 150 machinists, engineers, quality control specialists, and management and support staff.

Elizabeth Carbide Die introduced the use of carbide punches and dies to the pharmaceutical industry in the United States. From a six-man shop in 1954, the company has grown to become a world leader not only in tooling for pharmaceutical tablets, but also for carbide indexable cutting tool inserts, powdered metal and ceramic parts, electrical contacts, battery parts, catalysts, and confectionery products.

Having access to the latest in computer-controlled equipment allows Elizabeth’s engineers, designers, and machinists to constantly achieve higher quality and delivery standards. Their goal is to combine technology with a well-trained team of machinists, that can provide customers with capabilities in conventional machining, electrical discharge machining, drilling, grinding, lapping, and polishing.

In February 1997, the management of Elizabeth Carbide Die asked how the Manufacturing Assistance Center (MAC) could help them bring the skill level of all of their machine shop employees up to a desired standard. After several visits to Elizabeth, the MAC staff prepared an outline for a four-year apprentice program tailored specifically to the needs of Elizabeth Carbide Die Company. The program began with a Machining Technical Skills Test. The test, covering 11 subjects critical to skilled shop personnel, established a skills profile across all 11 subjects for each student in the program.

Based on test results, the group was divided into subgroups. Lesson plans tailored to the needs of each subgroup were prepared. The MAC worked closely with Elizabeth Carbide as the testing and class preparation progressed. Tests and course outlines were complete by the end of July 1997 and classes began in September.

The subjects covered by year for all groups were:

1997-1998 Mathematics/Measurements; Print reading; manual machining.

1998-1999 Mathematics (geometry, trigonometry for CNC, statistics); Technical drawing and measurement; Machining; Manual machine projects and CNC.

1999-2000 Mathematics (algebra, trigonometry for CNC, statistics); Cutting theory; Print reading; CAD/CAM; CNC Mill and lathe; Heat treatment; Advanced tooling; Materials; Process planning; Quality control.

2000-2001 Mathematics (advanced algebra); Job planning and management; Geometric dimensions and tolerances; Advanced CNC machining; Coordinate Measuring Machine operation; Precision grinding; Electric Discharge Machining.

The MAC staff maintained close coordination with Elizabeth Carbide Die management throughout the program to assure them that the results would meet their needs. Student test grades and student feedback about the instructors and the class material were discussed with Elizabeth management throughout the four years of the program.

Phil Davies, manager of personnel at Elizabeth Carbide Die worked closely with the MAC staff during the planning, testing, and training phases of the apprentice program. Upon completion of the course this May, Phil stated how pleased he and the Elizabeth Carbide management are with the outcome of the course. Phil said that it worked so well because the entire course was “tailor made” for Elizabeth Carbide. What made it so effective was that the math and print reading courses were built around what Elizabeth uses in their own shop. Phil said, “It’s the best apprentice course I have ever seen. I could see the benefits of the training taking effect in our shop during the four years. I wouldn’t hesitate to send future employees to the MAC apprentice program. We got more than our money’s worth. I’d recommend the MAC apprentice program to anyone."

Editor’s note: Bill Peduzzi is the manager of the Manufacturing Assistance Center (MAC). For additional information, contact Mr. Peduzzi via phone (412.826.3536) or via E-Mail at bpeduzzi@engr.pitt.edu


		Case Study, Apprenticeship Progam
		Dynamic Business Magazine, July/August, 2001 Elizabeth Carbide Die Employees Complete Four-Year Apprentice Program in May 2001 By Bill Peduzzi “It’s the best apprentice course I have ever seen. I could see the benefits of the training taking effect in our shop during the four years. I’d recommend the MAC apprentice program to anyone." – Phil Davies, manager of Personnel, Elizabeth Carbide Die Company. SMC Member Elizabeth Carbide Die Company, Inc. is one of the Elizabeth Companies and is the largest manufacturer of rotary and single-station press tooling serving the pharmaceutical industry in North and South America, Europe, Asia, and Australia. The company is also a major source of quality tooling for hundreds of customers in the powdered metal, ceramic, chemical, electronics, and confectionery industries. Located in McKeesport, PA, Elizabeth Carbide Die Company employs more than 150 machinists, engineers, quality control specialists, and management and support staff. Elizabeth Carbide Die introduced the use of carbide punches and dies to the pharmaceutical industry in the United States. From a six-man shop in 1954, the company has grown to become a world leader not only in tooling for pharmaceutical tablets, but also for carbide indexable cutting tool inserts, powdered metal and ceramic parts, electrical contacts, battery parts, catalysts, and confectionery products. Having access to the latest in computer-controlled equipment allows Elizabeth’s engineers, designers, and machinists to constantly achieve higher quality and delivery standards. Their goal is to combine technology with a well-trained team of machinists, that can provide customers with capabilities in conventional machining, electrical discharge machining, drilling, grinding, lapping, and polishing. In February 1997, the management of Elizabeth Carbide Die asked how the Manufacturing Assistance Center (MAC) could help them bring the skill level of all of their machine shop employees up to a desired standard. After several visits to Elizabeth, the MAC staff prepared an outline for a four-year apprentice program tailored specifically to the needs of Elizabeth Carbide Die Company. The program began with a Machining Technical Skills Test. The test, covering 11 subjects critical to skilled shop personnel, established a skills profile across all 11 subjects for each student in the program. Based on test results, the group was divided into subgroups. Lesson plans tailored to the needs of each subgroup were prepared. The MAC worked closely with Elizabeth Carbide as the testing and class preparation progressed. Tests and course outlines were complete by the end of July 1997 and classes began in September. The subjects covered by year for all groups were: 1997-1998 Mathematics/Measurements; Print reading; manual machining. 1998-1999 Mathematics (geometry, trigonometry for CNC, statistics); Technical drawing and measurement; Machining; Manual machine projects and CNC. 1999-2000 Mathematics (algebra, trigonometry for CNC, statistics); Cutting theory; Print reading; CAD/CAM; CNC Mill and lathe; Heat treatment; Advanced tooling; Materials; Process planning; Quality control. 2000-2001 Mathematics (advanced algebra); Job planning and management; Geometric dimensions and tolerances; Advanced CNC machining; Coordinate Measuring Machine operation; Precision grinding; Electric Discharge Machining. The MAC staff maintained close coordination with Elizabeth Carbide Die management throughout the program to assure them that the results would meet their needs. Student test grades and student feedback about the instructors and the class material were discussed with Elizabeth management throughout the four years of the program. Phil Davies, manager of personnel at Elizabeth Carbide Die worked closely with the MAC staff during the planning, testing, and training phases of the apprentice program. Upon completion of the course this May, Phil stated how pleased he and the Elizabeth Carbide management are with the outcome of the course. Phil said that it worked so well because the entire course was “tailor made” for Elizabeth Carbide. What made it so effective was that the math and print reading courses were built around what Elizabeth uses in their own shop. Phil said, “It’s the best apprentice course I have ever seen. I could see the benefits of the training taking effect in our shop during the four years. I wouldn’t hesitate to send future employees to the MAC apprentice program. We got more than our money’s worth. I’d recommend the MAC apprentice program to anyone." Editor’s note: Bill Peduzzi is the manager of the Manufacturing Assistance Center (MAC). For additional information, contact Mr. Peduzzi via phone (412.826.3536) or via E-Mail at bpeduzzi@engr.pitt.edu