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Haynes International is one of the world’s largest developers, manufacturers, and distributors of high-performance nickel- and cobalt-based alloys for use in high-temperature and corrosion applications. Standard product forms include sheet and plate, bar and billet, seamless and welded pipe and tubing, wire and welding consumables, fittings and flanges.

Haynes International has manufacturing facilities in Kokomo, Indiana; Arcadia, Louisiana; and Mountain Home, North Carolina. The Kokomo facility specializes in flat products, the Arcadia facility specializes in tubular products and the Mountain Home facility specializes in high-performance wire products. Our products are distributed primarily through our direct sales organization, which includes service and/or sales centers in the United States, Europe, and Asia. All of these centers are company-operated.

Situation:

In 2009, Purdue MEP assisted Haynes International with a grant-based pilot program focused on green manufacturing with the Department of Energy. This was our first project completed together. Through that engagement, Haynes realized the value of MEP’s offerings and sought more ways to incorporate resources from Purdue MEP into their operations. Their next engagement enlisted Ted Boehm, a consultant with Purdue MEP, to assist with ISO 50001 implementation and ongoing support, which quickly evolved into a long-term relationship between the two organizations.

Solution:  

Over the past 15 years, Ted has become an extension of the Haynes staff and assists with continual improvements within their management system to ensure they stay strong and sustainable. His expertise has helped the organization effectively implement several management system initiatives including ISO 50001 (energy management), ISO 14001 (environmental management), and ISO 45001 (occupational health and safety management) at their Kokomo facility.

Results:

Through this long-term engagement with Purdue MEP, Haynes has realized several positive impacts in their organization, including:

• Employee Awareness: Greater employee awareness of the management systems, goals for each initiative, and levels of achievement of those goals.
• Energy Conservation: Haynes has invested more than $4 million in energy conservation programs since FY10. The company now saves approximately $1.5 million in energy costs per year and continues to reduce the need for nonrenewable energy sources.
• Electricity Conservation: 7.1% of electricity consumption compared to FY18
• Natural Gas Conservation: 9.1% of natural gas consumption compared to FY18
• Improved Safety Metrics: 48% decrease in OSHA recordable injury rate since 2016
• Reduce Waste: In 2022, 90.3% of their byproducts were either reused onsite or sent offsite for recycling/reclamation.
• Successful Audits: Through efforts from both parties, the number of nonconformities in external audits has been dramatically reduced, turning some of their weaknesses into strengths.

“Our partnership with Purdue MEP has played a vital role in our continual improvement efforts. Purdue MEP is not simply a resource, but a valuable member of our team. With Purdue MEP’s assistance, we have transformed past weaknesses into management systems strengths.”  

- Greg Morrow, Director - EHS, Haynes International

 

“The relationship I’ve been fortunate to create with Haynes International truly showcases how MEP Centers operate best – providing long-term support through a partnership that benefits both parties. We are here to support manufacturers throughout their entire journey, and we can work with you for as long as it takes. It’s truly about long-term success for the entire team.” 

- Ted Boehm, Purdue MEP

 

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