Getting to Know Ava
Q: What made you interested in this internship?
A: I toured part of the facility last January and was fascinated by all the different processes that take place here. The ability to manipulate such a strong, heavy piece of material so precisely, down to such small tolerances, is something that I thought was really cool. In one of my classes last year, my professor also brought up the importance of quality assurance within my field of study, which made me want to explore what quality looks like in the steel industry.
Q: What did you know about manufacturing or steel before starting here?
A: Very little, honestly. Most of what I knew came from hearing my dad talk about it over the years, since he worked in steel his whole life. Outside of that, I had no prior knowledge or hands-on experience, just a genuine interest in learning more.
Q: What surprised you most about working in a manufacturing environment?
A: What surprised me most was the sheer number of people it takes to make everything happen. From the employees working in the mill and on the plant floor to everybody working inside, each person plays a critical role in getting the customer what they need. I had the opportunity to shadow several different people and learn what their day-to-day looks like, which was really eye-opening and helped me understand the bigger picture of how everything operates here.
Q: What was your favorite project or task this summer?
A: My favorite project this summer was working on improving the calibration process within the Quality Department. One project that I am especially proud of was converting our physical calibration records into a digital system that is easy to access, maintain, and track. To help prevent gaps in calibration records, I developed automated email reminders that notify the Quality Department before equipment is due for calibration. I also programmed the tracking system to automatically update future due dates based on each piece of equipment's required calibration frequency, saving time and keeping calibrations on schedule. In addition, I had the opportunity to visit calibration labs and spend time on the plant floor and tube mill verifying that precision measuring tools, such as micrometers and calipers, remain within tolerance.
Q: What is one skill you learned or improved during your internship?
A: One skill I improved during my internship was professional communication. Whether I was coordinating with coworkers to locate materials or communicating with customers and building relationships, I practiced professional communication daily. Because opportunities to practice these skills are limited in a classroom setting, this experience was especially valuable.
Q: How has this internship helped you think about your future career?
A: This internship has given me a foundational understanding of the steel industry that I can carry into my future career. My long-term interest is in the agricultural sector, and because many agricultural companies rely heavily on steel, gaining hands-on experience in steel manufacturing has given me a stronger understanding of those processes from the ground up. More broadly, this experience has shown me the importance of a positive workplace culture, and that's something I will definitely look for as I pursue full-time opportunities after graduation.
Quality Tools & Processes
Q: What does "quality" mean to you after working in this role?
A: Quality means consistently meeting customer expectations through attention to detail, accuracy, and accountability. I've learned that quality is about more than just inspecting finished products; it involves maintaining accurate equipment, following processes, investigating issues, and continuously working to prevent problems before they occur.
Q: What quality tools, processes, or inspections did you get to learn about?
A: I learned how to use a variety of precision measuring tools, including micrometers, calipers, and a Rockwell hardness tester, as well as how to verify that they are properly calibrated. I also gained experience identifying different types of steel defects and learned how quality personnel use collected data and inspection results to determine the appropriate course of action.
Q: What was the most interesting part of seeing how parts and materials are checked?
A: The most interesting part of the inspection process was seeing the level of investigation and attention to detail involved in identifying defects. I enjoyed learning how quality professionals determine when, where, and why an issue occurred so they can make informed decisions about the best path forward.
Projects & Takeaways
Q: What was a project or inspection task you helped with?
A: One inspection-related project I helped with involved analyzing bowed tubes at the tube mill. I assisted in developing a method to measure bow to determine whether the tube is within tolerance and to identify issues before the productreaches the customer. To help identify the root cause, I reviewed and logged past occurrences of bowed tubing, notingfactors such as gauge, size, and length, which allowed us to look for trends and narrow our focus for further investigation.
Q: What surprised you about how much goes into making sure material meets specifications?
A: What surprised me most was the level of precision required to ensure materials meet specifications. I learned that tools such as calipers and micrometers must be calibrated to very tight tolerances because even small measurement errors can significantly impact product quality. I was also surprised by how often these tools are used on the plant floor.
Q: What is one thing you will take with you from working in Quality?
A: One thing I will take with me from working in Quality is the value of thorough problem solving. I learned that solving issues isn't just about finding a quick solution; it's about gathering data, investigating the root cause, and making decisions based on that evidence. This mindset is something I can apply throughout my career, regardless of the industry.
Thank you, Ava, for a great summer in Quality — we're excited to see where your career takes you next!
About Alliance Steel
Alliance Steel is a flat-rolled steel supplier, coil processor, and material distributor dedicated to supporting various manufacturing needs across many industrial sectors for over 20 years. We provide unmatched service and supply chain solutions to large OEM's and fabricators on a regional and national basis.
In May 2020, we relocated to Gary, Indiana, strategically placing ourselves near significant highways, mills, and ports. We are headquartered in Northwest, Indiana, with two additional locations in Atlanta and Memphis.
Our temperature-controlled 500,000 square foot facility is equipped with full rail service, multiple slitters, including a heavy-gauge line, numerous fiber lasers, multi–blanking, cut-to-length, stretcher leveling, and metallurgical capabilities. We are prepared to support your specific physical market needs with client-tailored solutions in futures hedging, index pricing, and spot buys.
Alliance Steel has an extensive inventory of flat-rolled sheet and coil products. We maintain a selection of hot-rolled steel, hot-rolled pickled and oiled, hot-rolled pickled dry, cold-rolled steel, and coated steel products. For more information, please call 219-427-5400 or send us a contact form.
About Alliance Family of Companies
The Alliance Family of Companies brings together Alliance Steel, Alliance Fabrication & Manufacturing, and Alliance Tubular Products, three divisions united on a single campus.
Located in Gary, Indiana, our three divisions share a centralized, rail-accessible campus strategically positioned near major mills, ports, and highways, enabling seamless coordination and efficient logistics between steel, tubing, and fabrication operations.
Alliance Steel specializes in coil processing and distribution, including coil slitting, multi-blanking, cut-to-length processing, stretcher leveling, and toll processing.
Alliance Fabrication & Manufacturing (AFM) delivers precision fabrication and value-added metal manufacturing, including laser cutting, forming, press-brake bending, robotic and manual welding, and assembly. AFM’s engineering team also provides expertise in geometric dimensioning and tolerancing (GD&T) to ensure quality and efficiency at every stage.
Alliance Tubular Products (ATP) produces mechanical and structural tubing through direct forming in various sizes and gauges. ATP offers ASTM A500 and A513.
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