Neff-Perkins, Sealing the gap

Manufacturing in Action, Source : The Manufacturer US

Neff-Perkins is developing gasket technology for the automotive industry, as Colin Browning discovers

From the outside, an internal combustion engine reveals few of its secrets. Casual glances will not expose the incredible forces contained within or the power it unleashes which we take for granted. Over the years, designers have worked to reduce the weight of engines while getting them to produce more horsepower and higher revolution rates. But there are inherent weak points, normally where two metal components are bolted together. It is from here

that combustion gases seek to escape. So manufacturers insert gaskets between components to produce a perfect seal. One company which is improving the quality of these small but vital components is Neff-Perkins, a major part of the automotive supply chain.

As well as producing engine seals and gaskets, Neff-Perkins also designs and manufactures components for brake systems, medical, telecommunications, and sporting goods. But despite this impressive diversity, its major interest remains the automotive sector. In this area it works not only with the OEMs but also supplies the vast demand generated in the aftermarket sector. But to keep up with the rapidly advancing technologies associated with the big carmakers, Neff-Perkins has invested heavily in its R&D capabilities.

The company is based in Ohio where it has facilities at Austinburg, Middlefield, and Perry. It was first established in 1946, and from the outset its goal has been to excel in both quality and productivity. Today, it has grown to the point where it employs around 250 staff. Its focus on core technology means that it is able to work hand in hand with the customer. So as well as transforming vague concepts into working prototypes with the shortest possible lead-times, Neff-Perkins is called upon to provide advice about the latest developments in gasket performance.

It is able to offer this advice due to its possession of a full function laboratory, where the research staff are capable of assisting the customer in the selection and development of the most appropriate product material. Should the specification demand it, the laboratory is equipped to design and develop any polymer compound. This ensures that the final product performs exactly as expected and fulfills the role allocated to it in the finished engine. So entwined is Neff-Perkins with the automotive industry that staff from the lab are active members of the General Motors seals and gaskets sub-committee. The skills of the laboratory staff are regularly updated by monitoring new testing methodologies developed at the American Society for Testing and Materials (ASTM), which also provides a level of accreditation for the Neff-Perkins facility.

The laboratory is now equipped with the most modern and up to date state-of-the-art apparatus including a low temperature brittleness tester, an ozone chamber, four durometers, and a hot water bath for long-term testing. The company's plan is to increase the range of tests which can be performed and offer the facilities to a new generation of customers.

But R&D is just one element of the overall Neff-Perkins business strategy. Manufacturing is at the heart of the company, as is demonstrated by its 150,000-square-feet of production space.

Like the laboratory, the factory floor is fitted out with the latest tools and equipment. But in order to derive the maximum benefit from its investment in plant, Neff-Perkins has devoted a great deal of time to understanding lean manufacturing ideas and principles. These have transformed the working environment, so that it is now much more focused on the concept of production on demand.

But this method of working requires a coordinated approach across the whole business. So Neff-Perkins put a sophisticated MRP system in place which can control the workflow through the factory. This is enhanced by the use of a Kanban operation which not only guarantees that components reach the production line on time, but that they only do so in the quantities required. This reduces inventory levels and frees up space which would have been used as stores, for revenue generation.

But the culture of the company has also played a significant role in its success. Not only are its people attuned to the benefits of building a strong teamwork environment, they are also highly focused on quality. This attitude is especially prevalent in the customer service and post sales support functions.

Neff-Perkins has built its reputation by adopting the same attitudes as much bigger automotive suppliers. It proves once again, that adopting the correct approach is crucial for every manufacturer.

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