Patti Perspective August 2017
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Hello there,
Our newsletter this month centers on a company you may well have worked with this summer- without even knowing it.
DMF Bait is the world's largest distributor of live bait, based in Waterford, Michigan. On a recent project there, a simple automation upgrade required a creative solution to meet space and budget constraints.
The spotlight this month is on DMF Bait's owner and CEO, Dan Beaudoin. Dan knows just about everything there is to know about the company. Read on to find out about his involvement and his plans for the future.
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A Custom Solution for a Worm Diverter
The project request from DMF Bait was straightforward: Automate a diverter that sorts paper and plastic bait cups.
The challenge in this project was to make it as small and as simple as possible. The customer wasn’t looking for $100k system to complete this simple task. Their warehouse space is also being well-used, and there wasn’t a lot of room to install large equipment.
DMF Bait is the world’s largest wholesale bait company, based in Waterford, Michigan. With a new product – bait to be sold in convenience stores – in growing demand, they wanted the ability to divert the different types of cups on the fly. This part of the process is after the cup is filled with dirt and just before it goes to be lidded. Different cups have different lids. Previously, every time they wanted to shift between cups, it would cost about 30 minutes to empty out the line and change over the machines. Therefore, they wanted to automate this process so that they could fill product as needed.
What made for a smooth solution was using a specialty sensor from Keyence that detects color (Keyence Full Spectrum Color Sensor). The cups are printed differently, so they were able to teach the system: If this part is white, it’s paper. If it’s orange, it’s plastic. The speed of the line can fluctuate and there is no set pattern, so detecting the color made for the simplest, most reliable way to divert the cups.
For the controls system, we used the Siemens S7-1200 and incorporated room for expansion, allowing the potential to add 1-2 more diverts. We also worked with Best Industrial Group, who specializes in the mechanical side of conveyors.
“We’re able to produce two products at the same time now, and can easily adjust the volume as needed,” said Dan Beaudoin, Co-Owner and CEO of DMF Bait. “As we hope to keep expanding, working with Patti Engineering has brought the opportunity of customized solutions. We don’t have to deal with making a standard machine fit.”
To read about more of our recent projects,
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Patti Perspective Spotlight: Dan Beaudoin
Dan Beaudoin started working at DMF Bait when he was about 8 years old. He would ride his bike after school and in the summer to the company that his father, Dan Sr., had started with his twin brother Mike, and their friend Fred.
Dan Sr., Mike, and Fred (DMF), were all high school teachers and began the bait business as a side hustle (before side hustles were a thing) in 1977. Mike taught English and Journalism, Fred taught math, and Dan taught technical classes like Shop, Electronics, and Computer Repairs. Their range of skills seemed to balance well in running the business. “Most businesses would have closed with the way that three teachers ran it,” Dan laughs. But the business got off the ground and gained traction.
In high school, Dan got on the pay roll and worked every job in the warehouse. Still, when he started college at Central Michigan, he intended to follow in his father’s original footsteps and majored in Education. “DMF was a business, but not a career,” he said of the time. However, in 1991, they landed Wal-Mart as a customer. The three original owners retired from teaching because things were starting to boom. Realizing the opportunity the company could afford, his junior year, Dan switched his major to business with a concentration in Product Operations and minor in Communication. He started working the day after graduation in 1997 because by May, the busy season is in full swing.
Now, the company is owned 100% by Dan, his aunt Mary Smith, and Fred’s son, Chris. They are the world’s largest distributor of packaged bait and have nearly tripled sales since 2000. While they have hundreds of competitors, the largest is only about 10-15% of their size. From that first Wal-Mart placement, they’re now in most of the big box stores including Meijer, Dunham’s Sports, Academy Sports, Dicks Sporting Goods, and Bass Pro Shops. They’re now venturing into convenience stores. The company employees 65 people full time, with 95 during peak season.
“I’m very fortunate; I enjoy coming to work. There’s always something here to challenge me mentally. We’re king as far as live bait goes but I don’t want to become complacent. I’m always wondering, ‘What can we do to improve?’ There’s always a new challenge,” Dan says. “I have a unique position, focusing on employees, sales, production, automation. etc. I wear all kinds of hats, but I try to keep the vision of the company in front.”
One of the current mental challenges for Dan is improving and growing within their limited space. Since 1997, they have implemented several automation solutions beginning with a lidding machine. Later, they added dirt dispensing which was more of a challenge to develop. They found a standard machine and made a lot of modifications. “Filling peat is difficult to dispense given the speed and amount,” Dan says. Their most recent project, of course, is the diverter featured in the article above. They would like to continue to improve with another diverter and possibly robotic packing soon.
This month, DMF Bait celebrated 40 years in business with an open house party for employees, customers, partners, and community officials. After 20 years “officially” in the business himself, what advice does Dan have? “You’ve got to have patience and you got to be open minded. If you pigeon-hole yourself in your own beliefs, you’re liable to get passed by. You got to be stubborn from a perseverance standpoint, but you got to be willing to listen. There’s no perfect business owner, and you got to listen to each other.”
Dan is the father of four: 1 boy and 3 girls between the ages of 8 and 16. As a family, they enjoy water-related hobbies like swimming and boating. They’ve taken cruises and took a trip to the Outer Banks this summer. Dan himself enjoys the fall – especially hunting and football, where he roots for the Lions. DMF Bait may well see a third generation as his oldest has expressed interest!
DMF FAQs
How long can you store the worms at the warehouse?
As long as we want.
How long do the worms live in a cup?
6-8 weeks
What are some of your more unusual products?
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We work as partners with our clients. When you need an expert to help solve automation challenges, we are here to add value to your solution - enhance efficiency, increase productivity, and work with your team as a trusted resource. Visit our website for more information on our areas of expertise, or call us (248)364-3200 for a free initial consultation.
Thank you for your interest in Patti Engineering.
Best regards,
Georgia H. Whalen Director of Marketing Patti Engineering
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