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Assembly required: Students tour Savanna plant

West Carroll students learn about auto parts plant for National Manufacturing Day

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SAVANNA – If a North American-made truck rolls by, there’s a good chance its wheel fasteners were made in Carroll County.

That was among the things a group of about 45 West Carroll High School students learned Thursday as they toured the MacLean-Fogg Component Solutions plant, also known as Metform, south of Savanna. The visit was part of National Manufacturing Day activities through Tri-County Economic Development Alliance of Northwest Illinois.

The company also has two additional Savanna sites, and one in Mount Carroll, employing about 390 people locally, and has operations worldwide.

Metform production manager Jake Bellich gave the students an overview of Metform’s products and operations. The company produces transmission gears, fasteners, and many other automotive parts for major automotive and farm equipment companies.

Bellich said many loads of steel are delivered by semi to the hot form plant every day. The steel is heated and shaped at the hot form plant, with some parts finished there and others at a second building on the plant grounds. Ten Hatebur presses made in Switzerland operate at the hot forming plant, often heating the steel to more than 2,000 degrees Fahrenheit, with a part coming off the press every second.

Bellich said as of this month, the company this year has 71 percent of production in the automotive field, 23 percent in heavy technology, and 6 percent in other fields. One example of the company’s product volume are the millions of Surex brand wheel nuts made annually.

“it’s a good likeihood that on any North American-made truck, the wheel fasteners were made in Savanna,” Bellich said.

After the presentation, the students broke into groups, with one touring the hot form plant and another touring the other plant. Large fans helped keep the air moving in the hot form plant, with still-red-hot parts coming off a roller and into a bin.

Quality control is critical to Metform’s processes. Bellich said the company examines parts at both buildings, and metallurgist Taylor Grieve examines materials under a microscope to ensure they meet customers’ requirements.

“Customers may want it soft so they can machine it, or hard for durability,” Grieve said.

Engineer Kyle Johnson led tours of the other plant, where a great deal of work for companies like Chrysler is done. A number of the assembly machines use robots, which require computer programming skills to operate properly.

The other plant also houses Metform’s shipping department, headed by Bryan Ranchino.

“We have 25 trucks a day, moving about $750,000 to $1 million worth of parts,” Ranchino said.

The morning ended with a pizza lunch at the hot form plant’s cafeteria. Students shared their impressions of the tour.

“I liked it. It seems pretty neat for summer work,” Carlos Rodriguez, 17, of Savanna, said.

Ashlynn Rahn, 15, of Savanna, thought the tour was really cool.

“I’d like to go into art, but I do like engineering, math, and science,” Rahn said.

Cheyanne Moreland, 17, of Savanna, said she learned a lot, and that she’d like to go into a technical field.

“I like computers and fixing them,” she said.

Brandon Byrne, 18, of Mount Carroll, said the tour was very informative. Metform’s products also may affect his career path.

“I’m going to school for race car technician,” Byrne said.

The tour was one of nine programs sponsored for National Manufacturing Day across Carroll and JoDaviess counties to promote business opportunities in Carroll, JoDaviess, Whiteside, and other northwestern Illinois counties.

“It’s not just limited to those three. Anyone can be a member,” said Vicky Trager, Thomson’s village president and TCEDA board member.