“Our mission is to make sure quality is verifi ed at every product, every step and every workstation that we produce.”
— Henry Billingsley Vice President of Manufacturing Alto-Shaam
technology,” Carroll said. To that end, the manufacturer has also formalized its use of Design Failure Mode and Effects Analysis (DFMEA), a structured process that asks, “What could go wrong?” during product design. Engineers identify potential failure points and address them before manufacturing starts. When the refrigerants being used are fl ammable or toxic (or both), identifying potential failure points before production starts isn’t just good engineering practice; it’s a safety imperative.
“We want to be prepared as EPA
[Environmental Protection Agency] requirements around refrigerants continue to evolve,” Carroll said. “And we are.”
Building Quality Into
Every Station Some manufacturers test what they build, but Alto-Shaam tests while it builds. Based in Menomonee Falls, Wisconsin, the cooking, holding, and blast chilling equipment manufacturer folds quality verifi cation directly into its production stations, using technology to catch problems at the moment they happen rather than after the fact. “To own your quality, you have to understand why you’re doing something and what the impact is if it’s not done correctly,” said Henry Billingsley, vice president of manufacturing. “Our mission is to make sure quality is verifi ed at every product, every step and every workstation that we produce.” Alto-Shaam uses camera systems
and torque monitoring tools embedded directly in the assembly process. Take, for example, the placement of insulation in ovens, where proper installation is critical to performance. The manufacturer installed camera systems that verify insulation goes in correctly and in the right locations, then feeds that confi rmation back to the operator before the build moves forward. It’s not a spot check after the fact, Billingsley explained, but a verifi cation loop that’s built into the assembly itself.
36 FEDA News & Views Alto-Shaam uses a similar approach
with critical mechanical components. Torque monitoring tools verify that blower motors, fan motors, and other moving parts get tightened to spec and confi rm the joint wasn’t cross- threaded in the process. That data is trackable, Billingsley said, and Alto- Shaam is working toward tying it to individual serial numbers. That way, if an issue surfaces out in the fi eld, the manufacturer can trace exactly what happened during production. To further reinforce excellence
in its manufacturing, the company draws on Advanced Product Quality Planning (APQP), a disciplined process developed by the auto industry, along with DFMEA to prioritize where those investments go. ISO 9001 certifi cation and standards like UL underpin all of this and provide a documented framework for continuous improvement. For distributors, Billingsley says that kind of built-in verifi cation changes the sales conversation. “If safety comes fi rst and quality second, delivery and cost usually follow,” he adds. “Doing it right the fi rst time prevents problems in the fi eld and controls cost better than reacting later.” As equipment becomes more
complex and regulatory requirements more demanding, the ability to point to documented performance will only grow in importance. Distributors that understand how products are tested — and use that knowledge in the sales process — will discover fewer surprises in the fi eld and more confi dence at the point of sale.
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