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The Brad Pearson Story: A Problem Solver Defines the Future of Manufacturing

Michael Reader

On Saturday, October 10, 2015, Brad Pearson attended Blackhawk Technical College’s Gala and Grand Opening of the school’s new “Advanced Manufacturing Training Center” in Milton, Wisconsin. He was there with his parents, Lori and Don Pearson, and Precision Plus’ Administrative Assistant Luann Dall and her husband Dan. Wisconsin’s Lt. Governor Rebecca Kleefisch was the guest of honor at the function.

Brad is a straight A student at Blackhawk Technical College (BTC), where he is also the student representative for the CNC Technician Advisory Committee. In the afternoons, he drives from Milton to Precision Plus (PPI) in Elkhorn, where he works part-time.

On the night of the event, Lt. Governor Kleefisch approached Brad, and said, “I’ve heard about you and your story! Congratulations!”

 

As a youngster, Brad had always had an affinity for making things, building things, and working on things. He did well in school, and there was no question that after graduating from Elkhorn Area High School, he would probably enroll at U.W. Whitewater to pursue a business degree.

But for Brad, February 27, 2013, would prove to be a day filled with opportunities, as on that day, the First Manufacturing Career Panel would take place at Elkhorn Area High School (EAHS), organized by Mike Reader, President of Precision Plus and JoAnne Pella, CTE Coordinator at the school. Brad was one of nearly 180 students who came to the event to hear industry professionals talk about manufacturing and the highly rewarding careers available, especially for the younger generation.

Brad recalls, “I found Mike’s message amazing, and even thought I didn’t have a chance to meet him personally then, I talked with Mrs. Pella about my interest in meeting him. That request eventually resulted in  youth apprenticeship at Precision Plus in the fall.”

Mike Reader recalls,

It must have been the spring of 2013, when Elkhorn High School CTE Coordinator JoAnne Pella sent me three candidates to interview for the Youth Apprenticeship program Precision Plus was about to launch.

Our directive to Mrs. Pella was clear: We were looking for the “best and brightest” of the next generation, including exceptional character and the willingness to commit to about 3 hours of daily time, starting at 6:30 am–which could be a difficult feat, taking into consideration high school schedules that are jam-packed with coursework, and extracurricular activities.  

One of the candidates was a young man who although did not seem too enthusiastic during the initial interview, exuded with it the moment he stepped on the production floor. Yes, a light flickering in the eyes that proved we had now captured his attention.  I replied to Mrs. Pella that while I had some early reservations about Brad, he had shown a lot of interest on the shop floor, and that we wanted to offer Brad the opportunity to work with us during his senior year.

Brad started out the 2013-2015 PPI Youth Apprenticeship with two other students—one also from EAHS, and the other from Lake Geneva High School.  All three worked directly with Barry Butters, then Director of Education and Training, first covering all the basics in the classroom.  This included basic blue print reading, understanding Geometric Dimensioning & Tolerances (GD&T), measurement equipment and techniques, and machine shop vocabulary—no, not the swear words, but the manufacturing lingo. 

Each apprentice received clear instructions on how they would be introduced to all facets of manufacturing, and that while some activities would be extremely rewarding, others might challenge them with boredom through redundancy. 

After completing classroom instruction, the apprentices worked in a variety of support roles, reinforcing what they had learned, while exercising both body and mind through hands-on activities. These included working in the Secondary Department, where parts receive additional processing; the Finishing Department, where parts are washed/polished; and the Quality Assurance Department, where parts are given a second inspection.  Although sometimes tedious and/or boring, these experiences provide our apprentices with a foundation to draw from as they progressively move from basic platforms to much more complex responsibilities.

Once they had demonstrated an eye for detail and earned the confidence of their mentors, the apprentices were introduced to the Tornos Swiss-Screw machine platform, a mechanical machine used in the production of small, very close tolerance turned parts using custom-shaped cams mounted on a camshaft. Working on the machines helped the students understand the interaction between tools and material.  Once confident on this platform, the apprentices moved through different CNC Swiss platforms, and eventually onto the Miyano CNC turret lathe machines, which can cost up to $600,000 when all tooled up.  The students not only ran the machines, but also inspected them with different gauging equipment, made tooling offsets, and inserted changes.

We often refer to our apprenticeship program as “Karate Kid School,” as the apprentices must first learn all that it takes to get perfect product out the door for our customers.  Some tasks may not be exciting, but every task is as important and it must be considered the most important task in the world.   And every experience is a learning opportunity…even if just to learn why it is important to do it right the first time.

Over the course of the fall semester, Brad was learning quickly and embracing what manufacturing had to offer. He was particularly intrigued by the nuances and the challenges of the manufacturing process and the problem-solving skills required to bring the part from drawing to reality. “Just checking on a part’s tolerance,” mentions Brad, “requires problem-solving skills. If it’s off, I need to offset the problem by making the necessary adjustments.”

Brad was excited about manufacturing and regularly shared his excitement at home. However, there was obvious resistance from his parents, who did not believe manufacturing should be part of the options for Brad’s future.

However, at Mike Reader’s request, they agreed to come to the plant to see what Brad was learning as a youth apprentice. Brad’s parents and sister spent one and a half hours touring the plant, talking with Mike and Barry, observing the type of technology Brad was utilizing, and the skills and knowledge required to properly use the equipment. At the end of the tour, Brad’s parents understood what they saw was not “vintage” manufacturing, but 21st century technology, and have since become Brad’s greatest supporters in his decision to pursue a career in manufacturing.

Upon his high school graduation in the spring of 2014, Brad rolled into PPI’s summer internship program, where he continued his journey. “And it’s been a journey ever since,” reiterates Brad, “Precision Plus and manufacturing are very special to me. One day I may even want to have my own manufacturing business!”

As the beginning of the 2014-2015 academic year was approaching, Brad had to make a final decision as to his next step. He had three options: he could continue with his on-the-job training while working full time, he could enroll in a technical college to pursue a machining degree, or he could pursue a 4-year degree. “Barry and Mike took me around to different technical schools, but I fell in love with Blackhawk Technical College in Milton and with its state-of-the-art CNC training facilities.” And that was his final choice.

Mike continues,

Between Brad, Barry and myself, we set a plan in place where Brad would take classes during the day and work about 4 hours in the evening to reinforce what he was learning in the classroom.  We also had set up a reimbursement plan whereby we would refund him 100% for As, 50% for Bs and nothing for Cs.  Some would say this is a tall order, but the goal is clear: We want to nurture the “best and brightest.” Average does not cut it these days. 

Brad continued his school/work efforts through both the fall and spring semesters, and then brought his transcripts in for Barry and me to review.  It was with great delight that we saw nothing but straight As in every class, both semesters.  A check was drafted and presented to Brad for his full year tuition expenses.  It was a great day for Precision Plus, Brad and his parents. 

Brad is now in his third of the four-semester program and leading his class in all aspects.  BTC and his instructors have done a great job furthering Brad’s education, while we reinforce and focus his energies on how both must go hand in hand.  He is still considering his options for after graduation.

Brad is thoroughly enjoying his experience at Blackhawk Technical College, including being the liaison between his fellow students and the CNC Technician Advisory Committee, serving as a communication bridge between the two groups.

At Precision Plus, he currently operates a Miyano lathe and loves the process involved in solving problems. He thanks his mentors, Ryan Landreman, Sam Kirkland, Victor Moreno and Curt Hibl.

Whenever he can, Brad also shares his message with others as he promotes manufacturing as a career, and a not job.  As a matter of fact, a year after he first heard Mike at EAHS, Brad talked about his manufacturing experience to 200 attendees at the Second Annual Manufacturing Career Panel. He has also talked to students at Delavan High School, has been to the Capitol, was interviewed by the Lake Geneva News, and by the office of Secretary Reggie Newson of the Wisconsin Department of Workforce Development, just to name a few.

As far as the future is concerned, Brad will continue to look at all opportunities, but hone in on his own hope to make a difference and change the world. After all, he is a problem solver.

At Precision Plus, we are grateful for that snowy day in February of 2013, not only for Brad, but also for everyone who has shared in his enthusiasm for the industry ever since.

It is clear why so many people, including Lt. Governor Kleefisch, already know Brad Pearson, his story and his love for and commitment to manufacturing. And there is no question that given the opportunity to change the world, he will.

 

Gateway Technical College Elkhorn Campus Launches First Midwest Micro Machining Advanced Manufacturing Lab

Michael Reader

By Dana Runimas-Plazyk
Reporting for Precision Plus

Recently, I had the pleasure of talking with Dr. Bryan Albrecht, President of Gateway Technical College (GTC), about the launch of a micro machining (Swiss screw machining) advanced manufacturing facility at the school’s Elkhorn, WI Campus.

When Albrecht joined GTC as its president in 2006, he was charged with creating curricula that directly responded to the need for a highly skilled workforce by Southeast Wisconsin employers, imperative to have in place in order to grow the local economy. He began his tenure by holding “listening sessions,” with local businesses, to enable GTC to understand that need.

The requests were vast and included a ready workforce need for manufacturing, HVAC, IT, health sciences, aeronautic, automotive, hospitality, law enforcement and everything in between. Over the last nine years, many programs have been developed and are successfully in place, addressing the needs of the local business community. Today, Gateway Technical College operates from three campuses in Racine, Kenosha and Walworth counties, and offers advance technical certificates, associate degrees, technical diplomas, and certificates, some online classes, and dual enrollment options with the University of Wisconsin, Parkside.

“On an annual basis, 23,000 students attend Gateway,” says Albrecht. “We currently offer 100 certificate programs and 65 degree programs. Last week alone, we graduated EMS technicians, certified police officers, and SharePoint developers. Additionally, we are working with primary and secondary schools on K12 articulation.”

However, Albrecht points out that in as much as the workforce needs of manufacturers in Kenosha and Racine counties had been met, GTC “couldn’t wrap up” their thoughts for the needs of manufacturers in Walworth County.

He recalls meeting Mike Reader, President of Precision Plus, in 2012 at a career and technical education advisory committee meeting. “Mike’s concern about the lack of a qualified workforce to address the requirements of Walworth County manufacturers struck a chord,” says Albrecht. “Mike and Precision Plus were adamant about changing the situation, and had launched, single-handedly, an educational initiative geared to correct this issue, while bringing attention to–and gaining the support of–educators, organizations and legislators.”

“Changing the situation would also require higher-level technical education,” reflects Albrecht. “Both the Racine and Kenosha Campuses offered associate degrees in manufacturing and machine tool, as well as CNC programs. None was available in Walworth County.” Albrecht recalls Reader’s words: “We have to get this done, Bryan.”

Albrecht considers Mike Reader “a true champion,” who enlisted the help of fellow manufacturers, vendors, customers, legislators, educators, students, and organizations to “get things rolling.” A preliminary study conducted by GTC indicated Walworth County was one of two national hubs (the other being Kosciusko County, IN) for Swiss-type precision manufacturers (micromachining), and that the absence of technically skilled employees to run the specialized equipment, made it hard to grow the local economy.

Albrecht presented Gateway’s Board of Trustees with a plan: To expand the Walworth Campus to include a state-of-art manufacturing center, offering the traditional manufacturing programs already in place at the other two campuses, plus a unique Swiss screw (micromachining) advanced manufacturing program. The latter, would make Gateway Technical College the first institution in the Midwest to offer this specialized training, also contributing to better position Wisconsin in the overall global market.

The current plans for the new manufacturing center include remodeling of the the Elkhorn Campus South Building and an expansion which will bring the total area dedicated to the center to 4,000 sq. ft. The center (yet to be named) will house welding, fabrication, rapid prototype, computer aided design (CAD), engineering, and full-scale precision machining labs. The footprint construction will start in November with an estimated Spring of 2016 completion date.

GTC’s Manufacturing Center officially opened over the summer by offering a Youth CNC Boot Camp, a program designed for high school seniors to finish the school year with a high school degree and a CNC operator certificate.

The CNC adult programs will begin to be offered at the Elkhorn Campus in September.   “We have recently added two new instructors, as all CNC classes at all three campuses are fully enrolled,” adds Albrecht.

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Equipment has been steadily arriving to the new manufacturing center over the last couple of months, and Albrecht reiterates that the total endeavor would not have been possible without Mike Reader’s resolve, his ability to see the big picture, and his talent to simultaneously engage all the pieces that were needed to make the center a reality.

Thus far, four brand new Haas ST-10 lathes, one Tsugami S205 CNC Swiss machine, and an MTA barfeeder are already in place thanks to the tremendous help from Brad Morris of The Morris Group, and Jamie Schwartz of CNC Indexing & Feeding Technologies. Precision Plus not only assisted with the equipment installation, but also with a generous donation of $50,000, which facilitated the purchase of the equipment. Plans are to have at least eight Haas machines, 4 turning and 4 vertical machining centers, when the center is in full operation.

Industry support for GTC’s manufacturing center has been unprecedented, notably, a long-term agreement reached by GTC with Hanan Fishman of PartMaker who will provide computer aided manufacturing (CAM) software for students in the center. Also, a recent $2,500 tool donation by Grainger for the CNC Boot Camp, will contribute to the student experience.

On August 15, 2015, Mike Reader and Mark Beilman, Director of Education and Training at Precision Plus, toured the repurposed space housing the equipment. “We met with Dean of Students Michael O’Donnell and instructor JD Jones,” mentions Reader. “We had a great meeting and everyone is excited about the new equipment rolling in.”

The next few months promise to be exciting for the Elkhorn Campus of Gateway Technical College, and for the local industry, community, and economy. Precision Plus thanks Dr. Albrecht for his time to conduct this interview, and looks forward to continue to report on the progress of Gateway Technical College Elkhorn Campus’s new manufacturing center.