METALSTAR SOLUTIONS

ALUMINUM EXTRUSION EXCELLENCE

Johnny Pangborn

Johnny has over 20 years of experience in applied aluminum extrusion metallurgy. His professional work includes leading various training, extrusion process auditing, department management and process engineering.

He has worked with industry leaders to reduce scrap, increase revenue and develop training procedures. His background as an Extrusion Manager, Process Engineer and Quality Manager provides a broad perspective on the aluminum industry.

First, Johnny has a passion for helping employees become the best they can be. He feels strongly that people make it happen and no improvement activity will ever be effective and lasting without starting with people.

Johnny has a Master’s in Materials Science from Michigan Tech University and extensive extrusion metallurgy training. He is a certified Six Sigma Green Belt and a voting member of ASTM Subcommittee B07 and E01.04.

Publications

Pangborn, et al., The Future of 6xxx Medium Strength Structural Applications, Proceedings of the 9th International Aluminum Extrusion Technology Seminar, 2008 (Jointly presented May 2008)

Pangborn, et al., 6005A: Practical evidence of advantages for extruders and their customers, Proceedings of the 10th International Aluminum Extrusion Technology Seminar, 2012 (Presented May 2012)

Pangborn, et al., Simple temperature measurement techniques for extruders: Straightforward solutions in a tough market, Proceedings of the 10th International Aluminum Extrusion Technology Seminar, 2012 (Presented May 2012)

Past project results

  • Major scrap reduction initiative resulted in > 3M pounds saved annually

  • Productivity turnaround for struggling press line – stabilized and increased productivity 30% +

  • Key extrusion die design upgrades at multiple plants

  • Change culture to follow credible recipes for aluminum production

  • Extrusion process audit activities across the United States

  • Multiple 6xxx aluminum alloy implementations including press qualifications

  • Working with quality department to reduce scrap and defects (reduced 1.5%)

  • Cross tooled 10” and 8” press for operational flexibility, while improving die/container interface stability

  • Materials lab analysis of aluminum extrusion defects

  • In-depth training sessions for plant personnel and management focused on process control, quality, extrusion metallurgy, best practices