One of the best parts of my job with the WVU Industrial Extension is getting to visit manufacturers across the Mountain State. Last year alone, I toured more than 50 different facilities and the variety is incredible.
Take Form Energy in Weirton, for example. Their 550,000-square-foot plant was completed in the summer of 2024, and it’s… well, let’s just say it’s nearly impossible to walk through without saying “shiny,” “new,” or “high-tech.” I dare you to try.
Now, drive twenty minutes down Route 2 and you’ll land at Warwood Tool in Wheeling. They were established in 1854, with some of their original machines still cranking out hammers and crowbars like it's 1910. Even with the technology they’ve recently added, it’s a masterclass in heritage craftsmanship.
Two wildly different companies, right? And yet, both are thriving. Both are solving problems every day. And that’s exactly where we come in.
At WVU Industrial Extension, we don’t shy away from variety. We embrace it. Whether you’re experimenting with cutting-edge tech or relying on century-old equipment, our team is built to meet manufacturers where they are. Our secret sauce is helping you solve problems, big or small, old-school or newfangled.
Sometimes that means implementing WWII-era solutions, like Training Within Industry (TWI) instructions. Believe it or not, this simple and effective training tool that helped “Rosie the Riveter” get up to speed still works wonders for today’s workforce. Other times, we partner with WVU’s School of Industrial Engineering to conduct tech assessments and recommend modern upgrades that reduce waste and risk.
Low-Cost and No-Cost Solutions
We have great relationships with folks who specialize in robotic and Internet of Things (IoT) solutions. Solving problems with new technology is always rewarding. Our value often comes from helping to find practical, low-cost, low-tech solutions. These solutions can be even more rewarding and, since they don’t break the bank, are more likely to get completed. For example, our friends at FLSmidth had a group of issues that could all be traced back to one culprit – lack of space. Randy Kowalczyk, our continuous improvement manager, helped them identify the problem and started the brainstorming session to fix it. They made some adjustments to their layout, got rid of a few things, and many of their issues were resolved without spending a dime. Even better, these changes were made in small increments, so there was no need to stop production to make the improvements.
Once there is a level of success and that mentality takes hold, it spreads through an organization. FLSmidth in Winfield, WV, has become the flagship for continuous improvement for their operations on six continents.
A West Virginia Manufacturer of Solutions
You probably know some manufacturers use “vending machines” to distribute things like PPE and essential supplies. What you may not know is that many of those machines are made in Kearneysville, WV, by Automated Merchandising Systems (AMS). It’s easy for places that don’t use systems for inventory management to have employees with 10 pairs of safety glasses riding shotgun in their truck. You can own an AMS machine for around the cost of a nice office cabinet (contact me for a list of amazing WV cabinet makers!), so it’s easy to see that these tracking systems can pay for themselves quickly.
Something I just learned is that AMS’s sister company, Seaga, makes machines that aren’t just for managing inventory. They can also help with asset management. Unlike a typical vending machine, where you can only get things out, with these “smart lockers”, you can also put things back in. If you have a problem with tools that disappear or scanners that are abused, this is the solution. There are even options to indicate that repair is needed when something is returned. When it comes to inventory and assessment management, data can be a powerful tool. These systems provide useful information to make your operation more efficient.
The Next Generation Gets It
Speaking of progress, I had the pleasure of judging this year’s SparkWV entrepreneurship competition, where students from across the state showcased some seriously clever ideas. And I say “students” only because that’s the rule to enter. These young innovators were as sharp and polished as any professionals I’ve met.
The winning idea from Bridgeport High School’s FFA program was a “Flood Release Emergency Exit” gate for livestock. No electronics. No fancy parts. Just a smart, simple design using a float and latch. Effective. Not just elegant, but “Farm-elegant”.
Then there was Mingo Medical Solutions from Mingo Central High School. These students repurposed retail anti-theft tags to track patients in care facilities. Off-the-shelf parts, creative thinking, and now they’re exploring custom electronics to take their idea even further.
It’s clear these students and their teachers, with big kudos to the EdVenture Group, are learning the most important lesson of all. Great problem-solving doesn’t require perfect tools. It requires the right mindset.
Let’s Solve Something Together
At the WVU Industrial Extension, we’re in the business of helping manufacturers do exactly that: solve problems. Whether it’s improving training, upgrading tech, or just having a fresh set of eyes on your processes, we’re here to help.
Want to see what that looks like for your business? I’d love to talk.
Jamie Cope can be reached at james.cope@mail.wvu.edu
## Media Inquiries: Tracy Straub, Strategic Marketing Manager WVU Industrial Extension tracy.straub@mail.wvu.edu
