Whether an automobile, a commercial airplane, a soda can, or an architectural roof, the metals used to make these products require cleaning, conditioning, and surface treatment to facilitate their transformation. For over 40 years, this plant has manufactured these enabling chemistries and continues to lead the market with innovative and sustainable solutions. Learn more in this segment of #AViewFrom: Warren, Michigan.
Did you know that Henkel North America employs over 8,000 employees in approximately 60 sites across the U.S., Canada and Puerto Rico? Collectively, these sites support two business units: Adhesive Technologies and Consumer Brands.
Our #AViewFrom series features select locations, sharing information and facts about our sites across Henkel North America.
Over 80 employees work at Henkel’s Warren, MI facility, a plant that runs 24 hours a day, five days a week to supply Bonderite® brand metal cleaning and surface treatment chemistries for use across multiple products within numerous markets. A workforce of production, logistics, maintenance, quality, engineering, and safety professionals that describes itself as family credits teamwork and an environment of inclusiveness, mutual respect, tenacity, and safety for its success.
Henkel’s team at the Warren, Michigan facility manufactures a variety of metal surface treatments under the Bonderite® brand. These products are used in automobiles, commercial airplanes, soda cans, metal roofing materials, and other metal coating applications.
Plant Director Dale Tuscany, who will soon celebrate 24 years at the Warren facility, says everyone takes ownership of product quality, employee wellbeing, and continuous improvement.
The employees at this facility keep me motivated. The chemistry we handle and produce is exceptionally challenging, and our team works together to do whatever it takes to deliver customer satisfaction while keeping health and safety always at the forefront. Agility and responsiveness to dynamic customer requirements set us apart.
Dale Tuscany, Plant Director, Warren Plant
The Warren, MI facility became part of the Henkel manufacturing network in 1991 when the company acquired Parker Amchem. Recently, the ISO 5001-certified plant has begun a multi-year initiative to further improve efficiency by implementing digital control tools, including a management operating system, upgrades to the packaging process, and investments in sustainability-enhancing technologies.
“We are a zero waste to landfill site,” says Safety, Health, and Environmental Specialist Ben Katan, explaining that any waste from the facility is converted to useful energy that will generate electricity. “In addition, our water conservation efforts are noteworthy. Recent investments in new reverse osmosis technology with digital control and oversight allow us to capture water that previously would have gone into the storm drain. Instead, we re-use it as process water in our production operation, which results in savings of over 1.4 million gallons of water per year.”
Warren’s new Reverse Osmosis process equipment is contributing to the site’s water conservation efforts.
AN INCLUSIVE ENVIRONMENT:
At Warren, an inclusiveness mindset is ingrained. Dominic Cocco, Production Specialist, came to this facility from another site and says, “I was welcomed right away and instantly observed that cooperation, teamwork, and pride in a job well done is the M.O. here.” 25-year Warren employee, Production Supervisor Keith Copeland, and his brother, Production Specialist Ed Copeland, credit this Henkel operation with establishing an atmosphere that fosters respect and professional excellence. Keith continued, “The tone is set at the leadership level and, at Warren, we all know that every voice matters because that is what our leaders model. Working for a company where you feel seen and heard is rewarding. It makes you want to come to work every day and perform at your absolute best.”
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A Production Specialist in the finished goods warehouse.
A Quality Specialist analyzes product samples in the Quality Lab.
A Logistics Specialist moves large totes of finished product in the warehouse and loads out-bound trucks for delivery.
A Production Specialist doses raw materials to a mix vessel from batch controller.
DID YOU KNOW?
“Cars – and a lot of other things -- would not be pretty without the chemistry we make in Warren,” shares Process Engineer Kathy Helmetag. “Our products prepare automobiles and household appliances for paint adhesion, support aluminum cans for safe food packaging, and prevent corrosion of architectural steel used for popular metal roofs.”
Warren’s sample shelf highlights the variety of products manufactured and the quality assurance process the facility undergoes to meet customer specifications.
Filled drums of product heading to the automatic palletizer.
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Finished products are shipped from the site in 55-gallon drums, pails, tanker-wagons and 330-gallon totes.
Finished products are shipped from the site in 55-gallon drums, pails, tanker-wagons and 330-gallon totes.
Finished products are shipped from the site in 55-gallon drums, pails, tanker-wagons and 330-gallon totes.
