• • Phase 2 foundation pour
• • Exterior and interior metal framing
• • Roof, staircase, and mezzanine installation
• • Mechanical, electrical, and plumbing rough-in
• • A/C and fire sprinkler placement

Despite a slight delay in construction activities due to COVID-19, Phase 2 is in its final stages and we can see the substantial completion date in our sights.

Mid-March we saw the completion of the exterior metal framing, just in time for insulated metal panels that were lifted and placed into position. Each wall of Phase 2 had approximately 60 of these metal panels installed, which match the exterior paint of the Phase 1 tilt walls.

Just as we were making some major headway, the stay-at-home address came from Washington State Governor Inslee, temporarily shutting down both Tool Gauge and Washington Patriot Construction for two weeks.

Mid-April marked the first day of construction after the shutdown lifted and Washington Patriot immediately went to work with the help of Sound Glass installing windows, Alliance Steel installing our new metal canopy, and doors throughout the building.

If you’ve been keeping an eye on our time-lapse video from WorkZone Cam, you might have noticed the majority of exterior work has been completed. Construction activities for the remainder of April focused on the interior of the building, as Washington Patriot installed permanent power and drywall.

An infiltration trench to help collect rain water from adjacent surfaces was built in early May, where our new parking would soon be.

Throughout May, construction activities included installation of light fixtures, security cameras, and restroom tile. Long Painting came in and started giving the new walls a fresh coat of paint after all drywall was taped and textured. The last week in May, our second plastics parking lot was paved along with a smooth coat of asphalt on South Adams St.

We’re at the tail end of construction activities as we near the substantial completion date of June 26^th. Over the next couple of weeks, Washington Patriot will finalize interior paint, and restroom tiling, irrigation and new landscape, and floor installation. 

Tool Gauge employees will be able to move into Phase 2 beginning of July as we have new furniture delivered and the installation of Canteen Avenue C Micro Market. We’re also looking forward to our new paint equipment being delivered and installed in the upcoming months.

Once Phase 2 is complete, the new area with house an industry-leading paint line, new QA lab, training area/lunch room, employee lockers, offices and a customer lobby. All together, the Tool Gauge expansion project will include:

• • 80,000 sq ft in our plastics division
• • Expansion of our plastics press size range
• • Broadened secondary operations to improve flow and ergonomic assembly
• • Installation of industry-leading vertical paint system
• • New research and development center
• • Implementation of multiple collaborative robots (cobots)
• • 2,000 sq ft allocated for CNC machines and equipment within our metals division

Keep track of all the construction activities on our social media channels (LinkedIn, Twitter, Facebook, and Instagram) and through our live Workzone Camera.

The post Facility Expansion Update – Summer 2020 appeared first on Tool Gauge.

In case you’ve missed our previous expansion updates, we’ve hit some major milestones over the past few months including:

• • Taking occupancy in Phase 1
• • Receiving and installing 5 new Engel plastic injection machines
• • Evaluating new technology for plastics division
• • Demolishing the plastic legacy building
• • Beginning of Phase 2 construction

Despite the near 80 straight days of rain, Washington Patriot Construction was full steam ahead as the first few construction activities commenced. Much like Phase 1, construction started with site grading, footing and stem wall excavation and installation, underground plumbing and electrical placement.

Roughly 11 cement trucks visited the Tool Gauge construction site in early January to pour about 250 cubic yards of cement for the foundation of what will soon be offices, employee lunch and training rooms, QA and paint labs, and our lobby.

Soon after, the bones of the building were built as Washington Patriot installed steel beams, joists, and columns to complete the building structure by late January.

Exterior metal framing work started at the beginning of February along with the delivery and installation of two sets of steel staircases, sewer connection tie-in, and the build-out of the second-floor pan deck and mezzanine.

February 18^th marked the first day of roof construction and took Washington Patriot close to a week to complete – just in time for a second concrete for the mezzanine floor.

The last two weeks in February including mechanical, electrical, plumbing rough-ins and the installation of fire sprinklers throughout the Phase 2 building, along with the completion of the exterior metal framing.

The beginning of March will mark a busy month for Washington Patriot and the expansion project team as they complete framing for storefront windows and the interior, installing insulated metal panels and mechanical ductwork, and delivering our new A/C units.

March milestones that we’re looking forward to reaching is the completion of the building dry-in and permanent power.

Phase 2 is projected to be complete in the third week of May with a definite date slated for an open house on June 12^th.

Once completed, Phase 2 will house an industry-leading paint line, a new QA lab, employee lunch and training rooms, employee lockers, offices and a customer lobby. Other expansion details of the entire Tool Gauge expansion project include:

• • 80,000 sq ft in our plastics division
• • Expansion of our plastics press size range
• • Broadened secondary operations to improve flow and ergonomic assembly
• • Installation of industry-leading vertical paint system
• • New research and development center
• • Implementation of multiple collaborative robots (cobots)
• • 2,000 sq ft allocated for CNC machines and equipment within our metals division
  

Keep track of all the construction activities on our social media channels (LinkedIn, Twitter, Facebook, and Instagram) and through our live Workzone Camera [currently under construction].

The post Facility Expansion Update – Spring 2020 appeared first on Tool Gauge.

September proved to be one of the busier months with the remaining plastics departments moving from the old PMP building to the facility. Mold maintenance, CNC, and quality moved in the middle of the month, followed by the tool room and plastic injection molders.

With the help of Checkmate Industries, the plastic injection molders were moved swiftly to the new facility in just three days. Molders were then reconnected and calibrated to keep up with production schedules and to prepare for Boeing’s BAC5231 recertification.

Due to delays with a demolition permit, demo day was pushed back from early to mid-November but that didn’t slow Dickson Company from tearing down our old plastics building in less than a week. The final wall came down, marking the end of an era and the start of phase 2 construction with Washington Patriot Construction.

Construction began early December with site grading in preparation for footing and stem wall excavation, and footing forms installation.

Upcoming construction activities include concrete footing placement with 100+ yards of concrete being poured starting Dec. 13^th, stem wall form and rebar installation, underground plumbing and electrical installation, and slab on grade in early January.

Substantial completion of the Tool Gauge expansion project is scheduled for May 11, 2020 with an open house scheduled in June.

When completed, Phase 2 of the expansion project will include an industry leading paint line, QA lab, training and lunchroom area, employee lockers and restrooms, offices and facility lobby. Other important expansion details include:

• •An additional 80,000 sq. ft. in our plastics division
• •Expansion of our plastics press size range
• •Broadened secondary operations, improving flow and ergonomic assembly
• •Installation of a state-of-the-art vertical paint system
• •New research and development center
• •Implementation of multiple collaborative robots (cobots)
• •An additional 2,000 sq. ft. for CNC machines and equipment within our metals division

If you’ve been keeping up with our social media outlets and blog posts, you may have noticed we’ve already started taking action on expanding our plastic presses and evaluating new technology for the factory floor.

We’ve received one of our five new plastic injection molders, a bright green Engel 1250 equipped with a Viper 50 robot. Once up and running, this machine will be molding interior parts for Boeing’s 777x and 737 aircrafts. In the next coming week, we will be receiving four additional Engel 85-340 ton molders for the plastics factory floor.

Management and engineering teams have also evaluated new types cobots for the plastics division, including an autonomous mobile robot (amr) from Mobile Industrial Robots (Mir). Olympus Controls visited Tool Gauge in late November to demonstrate their MiR500, which is a prime candidate to autonomously transport material and finished goods from various departments in the new facility. Both teams will continue to evaluate MiR as they review proof of concepts and ROI before purchasing a model. Click here for more information on our automation strategy with MiR robots.

We invite you to follow along with the last leg of our expansion journey by watching our 24 hour Workzone Cam and on our social media handles.

The post Facility Expansion Update – Winter 2019 appeared first on Tool Gauge.

In the continued pursuit of implementing new technology and increasing automation throughout our plastics and metals division, Tool Gauge management and engineering are in the first phase of evaluating new cobots from Mobile Industrial Robots (MiR).

Robotic specialists from Olympus Controls were onsite in late November to demonstrate the capabilities of their MiR500, one of four MiR autonomous mobile robot (AMR) models.

The MiR cobot fleet is a cost-effective way to quickly automate internal transportation and logistics of goods throughout various industry facilities. These robots optimize workflow, freeing employees for more valuable tasks, ultimately increasing productivity and reducing costs.

Over the next few months, Tool Gauge management and engineers will continue to research and evaluate smaller models of the MiR fleet to determine which departments would best utilize the robot. Material staging at presses, kitting operations, and our future paint department are areas considered to receive MiR robots. After proof of concept (POC) and ROI has been assessed, we will add 3-5 more MiR robots over the next few years.

Factors to be assessed before the first robot is purchased will be size, how to successfully (and safely) integrate the robot into daily operations, ROI, and proof of concept. If the robot is successfully integrated into facility operations, 3-5 more MiR robots will be purchased over the span of a few years.

For more information on MiR and their autonomous mobile robots, click here. Check page continously on our blog page for more information on our automation strategy!

The post Tool Gauge Evaluates MiR for New Plastics Facility appeared first on Tool Gauge.

If you’ve been following along our social media pages and watching our Workzone Cam, you might have noticed some significant progress to the Tool Gauge facility expansion project. We’re excited to say, we have officially occupied Phase 1 of construction!

During July, Washington Patriot Construction wrapped up a few projects to get ready for our scheduled August move-in date along with receiving a very heavy delivery. Washington Crane and Hoist delivered and installed our shiny, new 5- and 15- ton overhead cranes which will assist employees in moving molds from tool storage to designated machines throughout the new facility.

August was one of the busier months as we finalized exterior and interior projects of our new facility in preparation for occupancy starting on the 23^rd. Exterior paint was completed earlier in the month as Washington Patriot Construction worked to install gutters, downspouts and bathroom sinks and partitions. Before the floors were sealed, the interior walls got a fresh, white coat of paint and two shiny blue air compressors were placed in the mechanical room.

As soon as the major items were built in, floors were sealed to get ready for final touches including air barrier testing. Tacoma based company, Nexus BEC, performed the air barrier test which measures how much air leaks through the building’s envelope. This type of test is required for all new heated buildings to receive a certificate of occupancy – we passed with flying colors!

August 23^rd marked the first day for our Plastics Secondary Operations and Shipping departments to move. Both areas worked throughout the weekend to move product, tools, equipment and work stations, enabling production and assembly to continue as scheduled the following Monday.

Both teams will continue to reorganize their departments to prepare for CNC machines and plastic injection molders to be moved from our current production facility in mid-September. Industrial racks have been built in two areas of the new facility, finished goods and mold maintenance, to better assist teams in their organizational processes. Management has incorporated new LEAN initiatives including designated hardware racks, which will allow for easier accessibility and movability of finished parts and molds through the facility.

As Phase 1 wraps up, we look forward to moving our CNC machines, tool room, and plastic injection molders starting on Sept 19^th – Oct. 2^nd. All machines will have to be disconnected, moved, then re-connected and calibrated over this specific time period. Once completed, Phase 2 demolition started on Monday, Oct. 7^th.

Phase 2 of the expansion is estimated to be completed late 2019. It will include the demolition of our current plastics facility to build our paint department, QA lab, training and lunchroom area, employee lockers and restrooms, offices and facility entrance/lobby. Other important expansion details include:

• •An additional 80,000 sq. ft. in our plastics division
• •Expansion of our plastics press size range
• •Broadened secondary operations, improving flow and ergonomic assembly
• •Installation of a state-of-the-art vertical paint system
• •New research and development center
• •Implementation of multiple collaborative robots (cobots)
• •An additional 2,000 sq. ft. for CNC machines and equipment within our metals division

As the expansion project concludes, we expect to create over 100 new jobs spanning over the next five years within the Tacoma-Pierce County region. The Work Start Grant from Governor Inslee’s Strategic Reserve Fund will assist in training of new employees and advance the skills of 50 incumbent employees. Employment opportunities are listed on our career page and are continually updated with positions ranging from full-time opportunities in machining, molding, assembly and engineering areas.

To receive more information on our expansion process and on-goings at Tool Gauge, sign up for our quarterly newsletter, here.

The post Facility Expansion Update – Summer 2019 Part 2 appeared first on Tool Gauge.

• • Roof flashings and gutters
• • Injection molder rack rough-in
• • Exterior Paint
• • Dock leveler install
• • Storefront installation
• • Bridge crane installation
• • Equipment relocation and startup
• • Asphalt prep and pave for employee and customer parking
• • Irrigation installation systems
• • Site furnishings installation

 


Projected finish date of Phase 1 construction for early September with Phase 2 right around the corner. Phase 2 of the expansion project includes demolition of our current plastics facility to build out our paint room, QA lab, training and lunchroom, employee lockers and restrooms, offices and facility entrance/lobby.

Construction is estimated to be completed late 2019 and will feature a customer lobby with the history of Tool Gauge in a storyboard format, two conference rooms, six offices, 14 work spaces, employee locker area, lunchroom and training area. Other important expansion details include:
 

• • An additional 80,000 sq. ft. in our plastics division
• • Expansion of our plastics press size range
• • Broadening of our secondary operations to improve flow and ergonomic assembly
• • Installation of a new, state-of-the-art vertical paint system
• • An additional 2,000 sq. ft. for CNC equipment within our metals division
• • Implementation of multiple collaborative robots (cobots)

Once the expansion project is completed, we expect to create over 100 new jobs spanning over the next five years within the Tacoma-Pierce County region. The grant from Governor Inslee’s Strategic Reserve Fund will assist in the training of new employees and advance the skills of 50 incumbent employees. Employee opportunities are on our career page and will include full-time, apprenticeship and internship positions in machining, molding, assembly and engineering areas.

To follow the Tool Gauge expansion project progress, visit out live WorkZone Cam or on our social media channels.

The post Facility Expansion Update – Summer 2019 appeared first on Tool Gauge.

Dickson Company broke ground with demolition in September 2018, demolishing 8 buildings including the original Tool Gauge PMP facility. After clean up was completed, Washington Patriot Construction came in and began installing underground utilities in preparation for approximately 1,000 – 1,050 cubic yards of concrete to be poured for the foundation. Another 906 cubic yards of concrete would be poured for the tilt walls.

With the help of a 550 ton crane, Washington Patriot lifted and installed the 55 walls in three days, taking the crew roughly 1,500 man hours to fabricate and lift the walls, some weighing up to 80,000 pounds.

Structural steel including steel columns, I beams, girders and joists have been delivered and are being erected through the end of March 2019. The beginning of April will mark the beginning of the roof installation (rood edge blocking, installing the roofing system and setting mechanical units) and vertical enclosures (installing windows, exterior door frames and doors, exterior painting and finishes).

Construction is estimated to be completed in late 2019 and will feature a customer lobby with the history of Tool Gauge in a storyboard format, two conference rooms, six offices, and 14 work spaces. Other important expansion details include:

• • Expansion of the plastics division press size range with implementation of multiple collaborative robots
• • Broadening of our secondary operations
• • Installation of a state-of-the-art vertical paint system
• • 2,000 sq. ft. for CNC equipment within our metals division

Once the facility is complete, we expect to create over 100 new jobs spanning over 5 years for the  Tacoma-Pierce County region. The grant from Governor Inslee’s Strategic Reserve Fund will assist in training new employees and advance the skills of 50 incumbent employees. Employee opportunities will include full-time, apprenticeship, and internship positions in machining, molding, assembly and engineering areas.

Follow the live expansion updates

To keep up with the Tool Gauge construction progress, visit our live workzone cam or our social media channels.

Contact Us

To discuss your plastic and metal assembly manufacturing needs, please email our General Manager, Jim Lee. If you are attending AIX 2019, from April 2-4 in Hamburg, Germany, please visit our booth under the Washington State umbrella at booth 6E80 / J.

The post Facility Expansion Update – Spring 2019 appeared first on Tool Gauge.

Originally from Utah, Steven and his family moved to Sammamish, Wash., at a very young age. He attended Western Washington University, majoring in Manufacturing Engineering.

“I pretty much got hired as soon as I graduated at Tool Gauge,” said Steven. “This is my first career job. I’ve done internships at other plastics companies through summers in college, but this is my first real job.”

Starting his career in June of 2018, some of Steven’s daily tasks and projects as an ME includes supporting production and making sure it all runs smoothly.

“If there is a problem that arises that inhibits assembly or manufacturing of some item, we tackle that problem and see how to fix it,” says Steven. “Usually, it’s about designing fixtures. If we need to drill holes in something, we’ll have to design a fixture that goes into a drill press to get accurate hole placement every time.”

Some of Steven’s projects include decorative ceiling panels for the new Boeing 777x and decorative plastic pieces that are placed around the storage bins of airplanes. But his favorite project to date that he’s worked on are edge supports manufactured for Zodiac Aerospace.

“There is one long edge support part that can be cut down in to four other part numbers,” stated Steven. “That was fun for me because it was the first project that I tackled from start to finish, where I felt confident in how to approach the situation and was able to build my own fixture for production use that can accurately cut down those parts to length. We still use it and it was a really cool experience.”

Tool Gauge is in the midst of expanding their plastics division to an 80,000 sq. ft. facility. When asked about the expansion and what he hopes to work on in the new facility, he answered pretty quickly with robotics.

“We’re expected to get some assembly robots in,” says Steven. “I haven’t got to touch that [sprue pickers] yet but I’d really like to be involved with the new robots.”

As a new engineer himself, his main goals are keep improving and learning every day. For aspiring engineers, his main advice is to do things the correct way.

“Always do things the correct way, don’t take short cuts. You could risk creating bigger problems for yourself.”

The post Interview with Steven Ouzts, Manufacturing Engineer appeared first on Tool Gauge.

• • An additional 80,000 sq. ft. in our plastics division
• • Expansion of our plastics press size range
• • Broadening of our secondary operations to improve flow and ergonomic assembly
• • Installation of a new, state-of-the-art vertical paint system
• • An additional 2,000 sq. ft. for CNC equipment within our metals division
• • Implementation of multiple collaborative robots (cobots)

Once our new facility is complete, we expect to create between 100 and 150 new jobs over the next five years for the Tacoma-Pierce County region. We will grow from 135 employees currently to approximately 235 by 2024, adding full-time, apprenticeship, and internship positions in machining, molding, assembly, and engineering.

Just like many businesses going through such an extensive company expansion, we have learned a few lessons along the way, including:

• • We visited other local peer aerospace companies to verify best practices.
• • We found out that plans take longer than projected.
• • We learned to not delay – we need to hire now for the future.
• • We need to continuously think automation and LEAN practices.
• • We created new benefits package to attract new talent.
• • We implemented key performance indicators (KPIs) measuring safety, quality, delivery, cost, and training – measure, report, share in Plastics and Metals Operations, Tool Maintenance, and Secondary Operations.
• • We immediately integrated change into our evolving culture.

Estimated expansion timeline

• • June 2019: Phase 1 of construction complete
• • Late 2019: Phase 2 of construction complete
• • Fall 2019: Inauguration of new manufacturing facility

Follow live expansion updates

We invite you to follow our construction progress on our live workzone cam at https://bit.ly/2NpvscM.

To discuss your plastic and metal assembly manufacturing needs, please email our General Manager Jim Lee.

The post Facility expansion update – Fall 2018 appeared first on Tool Gauge.