Today on The Maintainers, David & Jake welcome Dave Zapata, the general supervisor of engineering and maintenance at Chicago Heights Steel (CHS). CHS is the largest special-market mill in the United States and has been running the same type of operation since its founding in 1893. 

Dave calls his time with CHS “his longest summer job” as he joined the company straight out of high school in 1994 as a summer laborer. He instead stayed on, working his way through departments and up the ladder from engineering to mechanical to electrical. 

You’ll hear all about CHS’s history and how they’ve evolved their operations over the years. Dave has been instrumental in leading the implementation of new technologies designed to make their processes safer and more efficient as they produce over 14m fence posts each year. He explains how they’ve managed to reduce downtime while maintaining a delicate balance of maintaining current equipment while replacing outdated machinery. In 2019, the company modernized its mill with a new OT network, virtual machines, and HMI systems, dramatically improving productivity. Dave also reveals exciting plans for further advancements, including new robotic lines for fence post production, underscoring CHS's commitment to staying at the forefront of manufacturing technology.

The trio also discuss Dave’s management philosophy, which centers around hands-on leadership and providing his workers with the same opportunities he had coming up at CHS. He stresses the importance of patience and practical learning for those just beginning in their careers and offers his view of the future of the workforce. 

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Guest Bio

Dave Zapata is the General Supervisor of Engineering and Maintenance at Chicago Heights Steel (CHS), the world's largest special market mill in the United States. Dave's journey with CHS began right out of high school in 1994, when he took what was initially intended to be a summer job. Over the next three decades, Dave transitioned through various roles within the company, gaining in-depth knowledge of mechanical and electrical maintenance.

Dave has been instrumental in modernizing CHS operations, focusing on increasing efficiency and safety. Notably, he spearheaded significant equipment upgrades, reducing the need for manual labor and increasing uptime. His leadership style emphasizes hands-on involvement and fostering a strong rapport with his team.

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Guest Quote

"We went from 1959 to 2020 technology. It was a learning process. My approach is: I take the time to learn. Analyze it, make sure l have all the information. And then come up with a solution, and then implement that solution." – Dave Zapata

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Time Stamps 

00:00 Episode Start 

02:00 Opening Icebreaker

03:40 Dave’s Background
04:30 Segment 01: The Maintainer Mashup

05:00 The operation at Chicago Heights Steel

06:40 Finding rail from 1893

08:40 How operations have evolved over the years

10:45 The importance of your team

11:55 Segment 02: What's in Your Toolkit?

12:35 Leading with a learner's mindset

15:15 Modernizing their manufacturing

18:30 Advice on leveling up in your career

19:50 Segment 03: The Future of Factories

20:40 Dave's recommendations for the future

22:25 Solving for a lack of workers

24:20 Ways to upskill your existing maintainers

26:00 Segment 04: Fix It Funnies

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Links

• Connect with Dave Zapata on LinkedIn
• Check out Chicago Heights Steel
• Connect with David Lee on LinkedIn
• Connect with Jake Hall on LinkedIn
• Learn more about Tractian