TAKING THE REINS: Women in leadership roles inspiring change. p. 12
CONNECTED SOLUTIONS
How the latest technologies are solving critical problems in manufacturing. p. 14
Your resource for Canada’s industrial automation news
CASE STUDY: Honda’s retooling strategy for future-proof facilities. p. 16
Automation technologies and solutions to consider this year p.8
From
Experts from the industrial automation space discuss technology trends that will impact manufacturers in 2023 and beyond.
Compiled by Sukanya Ray Ghosh
Women in leadership roles in the automation industry are taking charge of their own career paths to succeed. By
Sukanya Ray Ghosh
Connected factory technologies offer comprehensive solutions to address critical challenges in manufacturing.
Continuous improvements in efficiency, product quality and worker safety are all part of the bigger picture when Honda retools a plant.
By Jack Kazmierski
BY SUKANYA RAY GHOSH
Conscious technology adoption
The start to 2023 has been an interesting one, given the current economic climate globally. In Canada, the government is implementing measures to curb inflation and restore the country’s economic health. In 2022, the world as a whole returned to functioning at nearly normal pre-pandemic levels. However, with the Russia-Ukraine war playing havoc, 2023 seems to be the year when Canada and the rest of the world will have to deal with the full impact of the recent upheavals in global markets.
In his column for this issue, Paul Hogendoorn talks about how Canadian manufacturers this year are likely to take a more proactive approach to technology adoption instead of the reactive approach we witnessed in the last couple of years. If the attendance at Manufacturing AUTOMATION’s recent First Steps in Automation virtual event is any indication, that is indeed the direction that manufacturers are already considering. Our readers and audience are interested more than ever to learn how to make their automation projects successful from the very first step. They wish to learn not just from success stories but also from stories of initial failures and missteps.
Industry experts often highlight how being proactive can help businesses respond effectively in times of crisis. With high inflation, continued supply chain constraints, shortage of skilled labour and rising costs overall, manufacturers’ plates are already full trying to meet customer demands on time. The time is ripe for conscious technology adoption. But taking on too much at once might not be the best success strategy.
So where should manufacturers begin their journey? Right within their own processes, own products and own facilities,
according to the expert speakers at First Steps in Automation. No one is better equipped to understand your business, products and processes as well as you and your team. If the business is already a successful one, it indicates that every moving part within the company is functioning well. Technology adoption can take the business one step further, perhaps improving its competitive edge in a tough market. This is where manufacturers can help themselves by identifying specific areas of improvement for their automation projects. All experts at our virtual event agreed that incremental automation can bring more success than trying to tackle all issues at once.
According to a recent report published by the Association for Advancing Automation (A3), robot sales in North America set a new record in 2022, increasing by 11 percent. While the automotive industry purchased the highest percentage of robots, applications in other industries continued to emerge. The report points towards the general attitude towards technology adoption in the continent. As technology adoption becomes simpler, easier and more cost-effective, more and more small- and medium-sized manufacturers are likely to consciously implement automation.
Canadian manufacturing has already started the year on a positive note. S&P Global’s most recent survey data showed modest improvements in February. Stakeholders had more confidence in the health and future of the industry. It is not time yet to relax, however. This is the time to take the lessons learned in the past two years to plan for a stronger future.
If you are wondering what automation trends to watch out for this year, the cover story of this issue shares predictions about the same. | MA
JIM BERETTA, President, Customer Attraction and host of The Robot Industry Podcast
JONATHAN GROSS, Managaing Director, Pemeco Consulting
MIHAELA VLASEA, Associate Professor, Department of Mechanical and Mechatronics Engineering and Research Co-Director, Multi-Scale Additive Manufacturing Laboratory at the University of Waterloo
SHELLEY FELLOWS, Chair, Automate Canada
STEPHANIE HOLKO Director, Project Development at Next Generation Manufacturing Canada
WALTER GARRISON, Former Advanced Manufacturing Business Consultant for City of Mississauga
Your resource for Canada’s industrial automation news
Reader Service
Print and digital subscription inquiries or changes, please contact customer service
Angelita Potal
Tel: 416-510-5113
Fax: (416) 510-6875
email: apotal@annexbusinessmedia.com Mail: 111 Gordon Baker Rd., Suite 400 Toronto, ON M2H 3R1
EDITOR
Sukanya Ray Ghosh srayghosh@annexbusinessmedia.com Tel: 416-510-5225
Deloitte Canada’s new smart factory showcases interconnected ecosystem of solutions
Deloitte Canada’s recently opened “The Smart Factory @ Montreal.” The facility showcases an interconnected ecosystem of more than 20 digital transformation solutions and technologies for manufacturing and warehousing. Spanning over 9,000 square feet, the facility is designed to showcase the possibilities of automation to run production lines, efficiently store and move inventory, as well as track inbound and outbound shipments. In its first year of operation, the company expects the facility to draw national and global business leaders to expose them to revolutionary ways of working in order to maximize efficiencies. Using cutting-edge industry 4.0 technologies such as artificial intelligence (AI), sensors, robotics, internet of things (IoT), big data, cloud and edge applications,
AUTOMOTIVE
GM, Brightdrop inaugurate full-scale EV facility at retooled CAMI facility
General Motors (GM) and its subsidiary BrightDrop opened the doors to its newly retooled CAMI Assembly plant in Ingersoll, Ont., in December 2022. Marking the inauguration, the first BrightDrop Zevo 600 electric delivery van rolled off the assembly line at the first full-scale electric-vehicle manufacturing plant (according to GM). With investment support from the federal and provincial governments, GM retooled the CAMI facility for electric vehicle production. The retooling project kicked off on May 1, 2022, and in seven months, the team installed
entirely new production equipment covering two million square feet. The new assembly equipment includes more than 257 new robotic fixtures, 13 new autonomous guided vehicles (AGVs) to move parts from the body shop to the general assembly area and 325 truckloads of new equipment in total. The largest robot at CAMI is “Godzilla” which has a lifting capacity of 1,700 kg.
DEAL MAKERS
Sycodal named Flexiv Robotics’ first Canadian distribution partner
Flexiv Robotics, a manufacturer of general-purpose robotics solutions, entered into a distribution partnership with Quebec-based automation integrator Sycodal in the last quarter of 2022. This partnership allows Sycodal to offer Flexiv’s adaptive robotic technology in the Canadian market. The move is part of Flexiv’s continued expansion into North America. Created to address the shortcomings of collaborative robots, adaptive robots offer their users artificial intelligence, force control and computer vision integration to achieve precision. Flexiv granted Sycodal sole integrator rights for the entirety of Quebec as part of the distribution agreement.
ATS Automation receives second major EV order
ATS Automation Tooling Systems’s (ATS) industrial automation business recently secured an EV order worth approximately $231 million CAD. The company received the order booking from an existing global automotive customer towards expanding the capacity of its automated battery module and pack assembly systems for operations within North America. The booking is
valued at approximately US$167 million. ATS explained that this order booking is part of a previously disclosed multi-phase enterprise program that includes the design, build and installation of turnkey battery assembly systems. ATS expects to carry out the project execution over the next 15 months.
INVESTMENTS
De La Fontaine receives government investments of $4 million
The governments of Canada and Quebec are granting $4 million to window and door manufacturer De La Fontaine for automation and robotization. De La Fontaine will use the funds to acquire automated and
digital equipment to automate its full production line. The automation will focus on the folding and shaping steps and various cutting and gluing phases. To install the new equipment on the main floor, a second floor will be added to the current building for administrative offices. The aim of this investment project, valued at over $11.5 million, is to enable the business to increase production in order to meet market demand and solidify its position in this sector. As part of this project, the Government of Canada is granting $1 million under CED’s Regional Economic Growth through Innovation program. Quebec is granting $3 million through the Appui aux projets d’investissement favorisant la productivité et l’expansion des entreprises component of the ESSOR program.
SETTING UP FOR SUCCESS
At the First Steps in Automation virtual event, industry experts share crucial tips and resources for successful automation projects.
BY SUKANYA RAY GHOSH
Manufacturers today have access to automation technologies capable of achieving incredible efficiencies on their factory floors, positioning them for positive growth in a highly competitive market. The latest selection of products is available to anyone who is willing to invest in them.
Every automation project has several moving parts, such as financing, getting approvals from key decision makers, planning the project and the actual implementation. At Manufacturing AUTOMATION’s First Steps in Automation virtual event held on February 15, industry experts shared strategies to approach an automation project and set it up for success right from the initial stages.
Financing the next automation project
Funding options available through the federal and provincial governments can offer manufacturers the required support to get automation projects off the ground. Sara Hipson, director of client services at Mentor
Works, a Ryan Company, shared the different options that manufacturers can take advantage of.
Hipson explained that a proper application increases the chances of receiving the necessary funds. Focussing on the fit is essential in this context. The first thing to remember is project timelines.
Another key piece of the application is understanding project impacts. Hipson explained that each funding program has an outline and evaluation criteria stating what it is looking for in terms of program ROI.
Here are some of the funding opportunities available to manufacturers. (Up-to-date application deadlines for the programs are available on the relevant program websites.)
Research and innovation: Under this broad category, the programs available include the following: Scientific Research and Experimental Development (SR&ED) tax incentive program; National Research Council’s Industrial Research Assistance Program (IRAP); programs offered by Next
Generation Manufacturing Canada (NGen); and programs offered by Southern Ontario Network for Advanced Manufacturing Innovation (SONAMI).
Commercialization and capital investment: Under this broad category, the programs available include the following: Federal 0%-Interest Loans for Innovative Expansion; Southwestern /Eastern Ontario Development Fund; Advanced Manufacturing and Innovation Competitiveness Stream; funding for digital system projects, such as Canada Digital Adoption Program (CDAP), Digital Modernization and Adoption Program (DMAP) and Technology Demonstration Program (TDP); and Ontario Automotive Modernization Program (O-AMP)
Hiring incentives and training development: Under this broad category, the programs available include the following: co-op student/ new apprentice funding; recent graduate or youth intern hiring; AIME Green – ON Manufacturer Training Program; and Canada Job Grant.
Seeking approvals
and following best practices
Ed Goffin, senior marketing manager at Pleora Technologies; Joshua Sese, senior technical sales representative at Pilz Canada; Joe Campbell, head of strategic marketing at Universal Robots USA; and Bob van den Berg, managing director at Murrelektronik discussed automation best practices and obtaining approvals from decision makers at an engaging roundtable session during the event.
Speakers shared that there is often a lack of connection between what the upper level management is facing and the actual situation on the plant floor. It is therefore, essential to understand the business problem and tailor the automation solutions accordingly.
Recommending risk reduction measures and drafting a comprehensive report for the manufacturer helps get the necessary approvals, shared Sese.
When there are issues on the plant floor, the challenge is creating a business proposition that outlines why the automation project is necessary. Speakers shared that upper level management is sometimes unaware of the workarounds that factory floor personnel implement to keep things moving.
Here are some best practices that the speakers shared from their years of experience working with manufacturers.
• Take a scalable approach to automation by picking one problem that can be fixed.
• Work with competitive professionals who are qualified through their knowledge, training and experience in their fields of expertise.
• Incremental automation is the key today. Select one process, one step, one station, one cell to solve a problem. Look for the “dull, dirty and dangerous.”
• Consider why the automation project is needed in the first place and what you wish to achieve with it.
Successful implementation
In a panel discussion at the event, Robert Almeida, business development manager at Advanced Motion & Controls; Rob Veldhuis, director of sales at Systematix and Calvin Kimura, automation specialist and co-founder of Ethos Automation, shared implementation strategies for automation projects.
Speakers shared that sometimes manufacturers do not understand their own products. When automation is implemented, product details become more evident. This lack of understanding of the finer details can create hurdles in the automation implementation process.
Another obstacle that systems integrators have encountered is that there is sometimes no clear definition of the problem that needs to be solved. It is essential that the end customer define what the issue is and communicate it to the team implementing the automation technologies. Another faux pas manufacturers might commit is not partnering with the right company to support the journey. Selecting the right partner for the project early on can help with its success.
The speakers shared the following implementation strategies.
• If the project is new or challenging, manufacturers should definitely consider doing a proof of principle before the actual implementation, said Kimura.
• Taking a look at the risks, such as commercial risks and technical risks, doing proof of principles and clear communication can lead to success, suggested Veldhuis.
• Selecting the right partner to go through the proof of concept process and ensuring that all stakeholders are on the same page regarding the project are key considerations, according to Almeida.
Helpful resources
Christy Michalak, director of advanced
manufacturing development programs at Next Generation Manufacturing Canada (NGen), shared information on the different automation resources available for manufacturers.
NGen, as an organization, is a major resource for funding and innovation collaborations for manufacturers. Michalak explained that often Canadian colleges work with the industry to
solve different problems and find innovative automation solutions. She added that manufacturers should also consider reaching out to the clusters that work with technologies and support automation projects. | MA
For more detailed information and session recordings of the event, visit automationmag.com/ virtual-events/first-steps-in-automation-virtual-event/
: Agile machines with adaptive automation
XPlanar enables new dimensions of freedom in product and material handling: Levitating planar movers fly over flexibly arranged planar tiles accommodating nearly any track layout and path planning.
Individual 2D transport at up to 2 m/s
Processing with up to 6 degrees of freedom
Transport and processing in one system
Wear-free, hygienic and easy to clean
Free arrangement of planar tiles enabling totally customized machine and process layouts
Multi-mover control enables parallel and individual product handling
Fully integrated into the powerful and standardized PC-based Beckhoff control system
(TwinCAT, PLC IEC 61131, Motion, Measurement, Machine Learning, Vision, Communication, HMI) For use across all industries: assembly, packaging, food/bev, pharma, laboratory, entertainment, …
Individual product transport
Free system layout
6D motion
Scalable payload kg
Levitating planar movers
Velocities up to 2 m/s
Flying 2D product transport with up to 6 degrees of freedom
Scan to experience XPlanar in action
TOP TRENDS IN 2023
Experts from the industrial automation space discuss technology trends that will impact manufacturers in 2023 and beyond.
COMPILED BY SUKANYA RAY GHOSH
Advances in automation technologies are transforming the industrial manufacturing landscape. Broadly termed “digital transformation,” these smart manufacturing initiatives bring physical and cyber systems together for greater performance, efficiency, sustainability and safety.
Automation experts share their predictions on trends that Canadian manufacturers need to watch out for in 2023 and respond to accordingly. To take a look at the predictions from previous years, check out the digital archives at automationmag.com.
Claire Fallon is executive director of the International Society of Automation (ISA).
A mechanical engineer by training, Fallon previously worked as a design engineer for Bechtel and served on the board of the American National Standards Institute (ANSI) and appeals board for Underwriters Laboratories (UL).
1. Industrial connectivity and security
According to a recent research from Nokia and ABI Research, 74 percent of manufacturing decision makers surveyed have plans to upgrade or enhance their communications networks. In 2023, it should be expected that a substantial number of manufacturers will see the benefits of investing in a private 5G network to advance digital transformation and Industry 4.0. One of the biggest challenges for these industrial connectivity upgrades, however, is the existence of operational technology (OT) legacy equipment that cannot easily be integrated, particularly at the state and municipal levels, or with smaller enterprises. This legacy equipment poses increased risk of cybersecurity threats. OT-specific security equipment and platforms are becoming increasingly prevalent in the market to address this challenge, but not all of these are created equal. For the greatest security and
interoperability, asset owners should look for equipment that is compliant with recognized international standards like ISA/IEC 62443.
2. Artificial intelligence and machine learning
If you’ve marvelled at how quickly TikTok got to know that you like content about pop culture and cooking, then you have an AI-driven algorithm to thank. But understanding customer and industry trends is just one piece of what AI can do. In the coming years, we will see more manufacturers leveraging AI and machine learning to better identify process bottlenecks and opportunities for cost savings through process automation.
Adding AI technology to industrial automation environments can increase system flexibility and functionality. Additionally, AI has the potential to make advancements in greater workplace safety and efficiency by mitigating repetitive and dangerous tasks or conducting preventive maintenance analysis. Manufacturers who adopt this technology stand to position themselves as next-gen leaders in data-driven manufacturing.
3. Digital twin and simulation
In the coming years, manufacturers looking to increase the productivity of their manufacturing systems will embrace the evolving opportunity of the digital twin. Similar to the previous example of using machine learning for preventive maintenance, the digital twin
is the notion of building a functional digital simulation version of a physical asset. Using the digital twin, a company can collect machine data and feed it into a model that can simulate future operations, determine failure limits, plan maintenance activities, and even calculate how much longer the machine will be operational – all without the physical machine being stopped. Adoption of digital twins opens the door for manufacturers to be flexible and adapt manufacturing processes to fluctuating supply chains, market demands, and more.
4. Virtualization technologies
You have probably heard of AR and VR in relation to video games, but in a manufacturing context, virtualization is no game. In the case of AR, or augmented reality, we expect to see an increase in the use of smart glasses to serve up machine and system information to operators. Using VR, or virtual reality, operators can prepare for dangerous situations or train on remote equipment and facilities. The two scenarios can even interoperate: imagine an operator in the field wearing smart glasses (AR), which transmit visualization and data to a remote technician working in a virtual environment (VR). Virtualization technologies unlock a new level of knowledge and innovation in the automation and manufacturing industries.
5. Cloud and edge computing
Cloud computing – where data is stored and processed remotely – is familiar to most manufacturers at this point. Edge computing refers to scenarios between the cloud and the device like real-time data processing for important smart factory applications like
predictive maintenance. Going into 2023, a stronger reliance upon the hybrid cloud model, where proprietary internal process information is stored locally by manufacturers, and resource-intensive applications like machine learning are moved to the public cloud will be trending.
Cloud-based operations, however, face omnipresent cybersecurity threats. Leveraging robust cybersecurity policies, such as the ISA/IEC 62443 standards, combined with regular audits and updates is key to maintaining a secure cloud or edge computing-based manufacturing operation.
Jim Beretta is president of Customer Attraction, an industrial marketing consultancy. He works with companies in robotics, automation, manufacturing, packaging and capital equipment on branding, marketing and search engine strategies. He attended the University of Western Ontario and is based in Cambridge, Ont. Jim can be reached at jim@customerattraction.com.
1. Labour has left the building People are leaving the workforce in droves. They are retiring or are working in places other than manufacturing plants. Manufacturers used to have a choice. “How much is a robot” they would have asked in the past? Now manufacturers don’t have a choice. Cost is not that important. Automation and robots are their last hope of keeping that automation line working. In fact, I believe that automation helps attract and retain
talent in today’s modern workforce. People (think Millennials and Gen Z) want to work for companies that invest in technology.
2. Humans will be part of the equation Collaborative technology, that is robotics from companies like Kinova Robotics in
Montreal, will grow and prosper. Cobots work well with humans and are a small part of the robotics market: less than five percent. But that market share is growing at a rapid pace. Collaborative technologies such as robots, conveyors and autonomous mobile robots, or AMRs, are simple and easy to use. Now they are plug and play, easy to
MEASURED VALUE + ADDED VALUE
•
• Verification of devices happens without process interruptions. It ensures high plant availability.
• Monitoring of all information enables predictive maintenance and process optimizations.
program, connected to your phone and fast to integrate into discrete manufacturing operations such as packaging and palletizing, sanding or even welding. They allow small and medium enterprises to be flexible and to compete with the big guys. Cobots too can be a bridge technology to investing in faster and more complex automation systems.
3. Independent automation integration companies are disappearing
Mergers and acquisitions in the automation industry are at a fevered pace everywhere in North America. We have seen several established automation companies get purchased by large global players: RAMP, Systematix and Eclipse Automation in Waterloo Region alone in 2022! I have many friends that are retiring – those who worked in the industry for 35-years-retiring. Our knowledge base is shrinking fast. This, however, will open the door to entrepreneurs who want to start new shops and that is a good thing as competition in any industry is always good.
4. Robots are easy, automation is still hard
In The Robot Industry Podcast, I hear the words “high mix, low volume” in almost every single episode. Manufacturers and ultimately consumers want flexibility: flexible feeding, flexible picking, flexible labelling, flexible vision and flexible packaging and end-of-line systems. They want to be able to adjust quickly and on the fly. This makes designing automation really hard.
5. I can’t hear you!
Interoperability is hurting our industry and we don’t talk about it nearly enough. This massive problem (Brand X robot system not being able to talk to Brand Y robot systems) is slowing the industry and the robot and automation industry is a little too busy to notice. There are a bunch of companies that are trying to solve communication challenges and MassRobotics in Boston is leading the charge, looking to create a standard, hopefully, the standard.
6. RaaS will rule
RaaS or Robots-as-a-Service will continue to grow and thrive. Manufacturers are excited about the prospect of protecting their CAPEX and transferring the manufacturing costs to an operational expense model. RaaS sellers take care of everything: maintenance,
advice, software upgrades and flexibility. A compelling concept is to expand the fleet at busy times, such as Christmas for distribution centres and shrink the fleet in January. Currently, autonomous robots (think Clearpath’s OTTO) and other brands such as Waypoint, MIR, Fetch and Locus are leading the way, but perhaps this model can move into Automation-Systems-as-a-Service or AaaS?
7. AI: Everywhere, all together, all at once.
Forgive me for (re) using the movie title but it really fits here. Artificial intelligence (AI) will be cheap; AI will be everywhere. AI will drive technologies like machine vision. This technology will be ubiquitous in a few years. Machines will be connected and will learn at a tremendous speed. Imagine if all the robots in all the Amazon plants shared data and were able to shave a fraction of a second off every pick, by sharing data and using AI. The manufacturers that are not collecting data will fall behind every year by just a few percentage points in key areas such as speed, quality, cost, uptime and waste.
8. Robots exploding into new sectors
Because labour has checked out, every other industry seems to have discovered or lost its fear of robots and automation. Construction, farming, consumer and food automation to name a few will be the new leaders in driving out cost and increasing quality and uptime by deploying robots and cobots.
9. Supply chain. Who knew?
Supply chain will still be a drag on the industry in 2023. Machine builders and customers will continue to scramble and force fit. They will change their design standards, they will overpay and will attempt to over-purchase, bulking up inventories like sensors and PLC devices. They will buy used robots and will continue to redesign mechanical systems to fit this new normal.
10. Cybersecurity
Sigh. We just aren’t moving quickly enough on protecting our data and we will continue to fall behind in implementing robust cybersecurity measures in manufacturing plants. Why? Because manufacturing wants to cut costs and the end customers will not pay for this overhead.
Jeff Burnstein is president of A3, the parent group of the Robotic Industries Association (RIA), AIA –Advancing Vision + Imaging, and the Motion Control and Motors Association (MCMA). Burnstein joined RIA in 1983 and has held a variety of senior positions, culminating in his promotion to president in 2007.
1. Overall robot sales slow slightly in Canada, but thrive in automotive and other key industries
In 2022, Canadian companies purchased 3455 industrial robots, according to the latest A3 report. This slight drop over 2021 is not alarming, as orders often fluctuate for any number of reasons. What is the most compelling finding is the significant jump in orders from automotive OEMS (up 113 percent), semiconductor and electronics (up 88 percent) and plastics and rubber (up 70 percent). While the automotive industry has traditionally been the leading purchaser of robotics and automation, other new industries had overtaken automotive over the last few years. However, the move to electric vehicles (EVs) has accelerated the need for robots in this market.
2. Labour shortages continue to lead growth of automation
In last year’s take on automation trends, we attributed much of the record robot orders in North America, including Canada, the United States and Mexico, to ongoing labour shortages across nearly every industry. 2022 was no different. According to the Canadian Manufacturers and Exporters’ (CME) annual labour survey, nearly two-thirds of manufacturers in Canada have lost or turned down contracts and experienced production delays because they didn’t have enough workers to complete the tasks. Deploying robots to take on the dull, dirty and dangerous jobs human workers do not want to do is helping, and will continue to help, manufacturers compete. Those that don’t automate are getting left behind.
3. Robotics becoming easier to use, more collaborative
We’re increasingly seeing smarter and easier-to-use robots, some without any programming required from the user at all. As a
result, more organizations are able to automate, especially small- and medium-sized companies that are new to automation and often hesitated to automate at all because they did not have the in-house capabilities to handle complicated programming and set-up tasks. Without requiring coding, new robot deployment can often be achieved in hours or days. Robots are also becoming increasingly collaborative, flexible and more dexterous. Many robotics vendors also have developed a wide range of packaged solutions meaning a company can get everything it needs to automate a specific task with little or no extra engineering required.
4. Cybersecurity and sustainability emerge as new focus
With robots joining an increasingly connected world, some companies are concerned about the possibility of their solutions being hacked. While there is no one-size-fits-all prevention for manufacturers, they are tailoring their cybersecurity strategy to include robots. This requires more education and more collaboration among not just the IT and security teams but across the entire organization. And more vendors are creating tools and other solutions with cybersecurity built in, facilitating the process.
Sustainability is another trend moving front and centre in many areas of the world, including Canada. More companies are considering the impact of robots and automation on our environment, and many are now moving away from ground-based sources of materials and exploring the entire lifecycle of their products to discover which parts can be reused.
5. The mobile robot industry is booming
Manufacturers are increasingly recognizing the benefits of automating their material transport with mobile robots that can flexibly and safely move materials and any goods within their plants. A3 doesn’t track mobile robot orders, but in its latest report, Interact Analysis said mobile robot shipments grew by 53 percent in 2022 and forecasts “an installed base of over four million mobile robots by the end of 2027, 1.5 million of which will be installed in 2027 alone.”
6. New industries embracing automation
While the automotive industry re-emerged
as a big purchaser of robots in 2022, we continue to see new applications for robots such as drywall finishing, shelf-scanning, food preparation services, drink orders on cruise ships and busy hotels like Caesars Palace in Las Vegas, and even fruit picking. In Canada, these “other industries” were responsible for 14 percent more robot orders in 2022 over
2021. The new interest from these types of companies requires innovative solutions from robot vendors, and they’re answering with unique ways to automate tasks. We hear about new applications every day and can’t wait to see even more – along with other automation technologies – at Automate 2023 in Detroit this May 22-25. | MA
Safe radar sensor PSENradar
Safe protection zone monitoring in rugged conditions!
Women in the automation industry are taking charge of their own career paths to succeed.
BY SUKANYA RAY GHOSH
The automation and technology sectors have different types of opportunities for women who wish to pursue their careers here. Three women in leadership roles share their experiences of prospering in roles of their choice.
ALESSIA ALFIERI
Project Manager, Ethos Automation
Growing up, Alessia Alfieri always had an interest in understanding how things work. When the time came to choose a profession that would capture her interests, she opted to pursue Mechanical Engineering at McMaster University. To get some hands-on experience while still a student, Alfieri took up an opportunity to do a co-op stint with Magna International. That is where she met her current boss, the co-founder of Ethos Automation, Peter Botros. When Botros started the company with Calvin Kimura, he offered Alfieri a position as a project manager.
At Magna, Alfieri did not leave any stone unturned to learn about working in the industry. “I got my hands on a lot of different machines. I got a lot of good experience that I still use to this day in my current role,” she says.
As a project manager at Ethos, Alfieri
works with customers and the Ethos team to ensure that all automation project goals are met within the stipulated deadlines. She enjoys working with people from different disciplines, including millwrights, electricians, PLC programmers and robot programmers, to name a few. This, she says, allows for a tremendous amount of knowledge-sharing.
The dynamic tasks and challenging projects that come along the way keep Alfieri constantly motivated. “There is no redundant task. I travel to sites for installations. I’m often on the floor, meeting other integrators. And there is always so much to learn,” she says.
Alfieri took up this leadership opportunity when she was 24. As a young woman in a leadership role in automation, she had to work hard to prove herself, especially when working with more experienced people in the industry. “Once people worked with me, they accepted that although I am young, I am
competent and understand what is required for the jobs,” she shares.
Alfieri often spends time on the machine shop floor, wiring up panels, running electricals and so on. While the learning curve was steep in the beginning, the hands-on approach helped in doing her job successfully from the get-go.
At present, Alfieri is particularly excited about working on a major project for an automotive manufacturer. “With the compact timeline that the project has and the fact that we’ve been able to produce quality parts off the lines within seven months, makes me feel proud. This has probably been my biggest achievement so far,” she says.
ERIN BARRETT CEO, Eigen Innovations
Erin Barrett had never planned on pursuing a career in the automation and manufacturing sectors. In her previous roles, she worked in sales and marketing positions. However, Barrett spent considerable time working with engineers, something that worked as an advantage when she joined Eigen Innovations six years ago.
Barrett fell in love with the passion that Eigen’s founder Scott Everett has for the company and its products and solutions. Eigen Innovations offers smart vision solutions for smart factories. “It is game-changing technology. Once I made the decision to move to Eigen I didn’t look back even though I didn’t have an automation and manufacturing background,” shares Barrett.
Having joined when the company was newly established, Barrett worked with customers to help create the company’s product suite. She had a significant influence over product strategy, besides managing sales and marketing. Barrett also worked as the chief revenue officer at Eigen before taking charge as CEO in September 2022.
“As CEO, my mandate is to ensure that we have a team that is focused and we’re measuring success the right way. It is to ensure that we are all on the same page regarding the company’s vision and objectives,” says Barrett.
Not coming in from an automation background, Barrett worked hard to earn the trust of Eigen’s team and customers. She spent a lot of time listening to people and visiting factory floors to understand the technologies.
Barrett shares that her confidence in leading the company comes from the people that she works with. “In a leadership role, the key is to make sure you’re getting the right inputs
Alessia Alfieri Erin Barrett
Carolyn Garvey
with the right experience to make the right call at any given moment.”
Seeing Eigen’s technology solutions implemented in customers’ factories firsthand leaves Barrett with a sense of pride in the company and its work.
For women considering career paths similar to Barrett’s, she advises them to follow their passion and instincts and to step out of their comfort zones to gain fresh knowledge.
CAROLYN GARVEY
Co-president, OTTO Motors
Carolyn Garvey’s worked in an automation company at the beginning of her career. With her firm background in finance, she moved on to traditional CPA roles in different sectors. She worked in leadership positions in large firms, helping with risk management activities. When the current opportunity came up, Garvey was offered the chance to make a difference in a smaller company and help scale it up and grow.
“That excited me because it felt like I could take everything I learned over all those years and apply it operationally to help the company. I believe that accountants and engineers are close cousins. We are analytical and mathematical,” shares Garvey.
She felt an immediate affinity for the people she works with every day. “We speak the same language and the company I joined has a lot of potential, as well as talent. I was excited to come in and unlock that potential.”
Garvey is currently co-president of OTTO Motors, a division of ClearPath Robotics, as well as the CFO of the consolidated company. She shares that what she loves most about her role is mentoring young leaders.
“The Deloitte Best Match program talks about building the capacity and capabilities of teams, people and processes. That’s how I focus. I help the team members and team leaders develop their potential and expand their capabilities. That’s the best part of my job,” she explains.
Garvey shares that as a leader in an automation company, she has seen the company go through typical business challenges, such as supply chain disruptions, labour shortages and so on.
Looking back at projects that were particularly memorable for Garvey, she shares that many of them involved putting processes in place that were gamechangers for the business.
“We put in an ERP system at Prodomax and that set the company up for the next 10 years of positive growth and prosperity. We
took that same system and approach and put it in a facility in Michigan, and other companies. These were big projects with yearlong rollouts. I worked with the companies to get the buy-in. Our excellent team did the heavy lifting,” shares Garvey.
She adds that providing strategic direction to the company is a favourite aspect of her
role. At Prodomax, she was able to help take the company from delivering $2 million projects to up to $30 million projects.
To women considering a career in this industry, Garvey suggests taking up co-op opportunities at different companies and working in different departments to learn, grow and prosper. | MA
CONNECTED SOLUTIONS TO TODAY’S PROBLEMS
Connected factory technologies offer comprehensive solutions to address
critical challenges in manufacturing BY
In the increasingly data-driven and dataruled world of today, leveraging the right pieces of data can define the level of success for every manufacturer. Connected factory technologies available today can equip manufacturers with just the right amount of information to make the key decisions for optimizing and growing their businesses. With significant advancements in the technologies themselves in recent years, the endusers are now aware of what to implement to reap more rewards.
Bob van den Berg, managing director at Murrelektronik Canada shares that manufacturers are currently requesting solutions that are scalable, modular and have the ability to connect to the cloud at some point.
“Many manufacturers think they need to do something with IIoT or Industry 4.0 but they haven’t really defined what that is yet. So, the ability to be able to do that at a future time is extremely important. If they need to increase or add functions to the machine, they should be able to do that,” he says.
Robotics, Industry 4.0, IIOT, artificial intelligence, machine learning and cybersecurity solutions are all in high demand. The specific asks vary according to the type of factory and the processes they run.
Robert Almeida, business development manager at Advanced Motion & Controls further adds that wireless technology is starting to take a firmer hold, whether it be
within the footprint of a particular machine (for example, a pneumatic valve manifold communicating wirelessly to the PLC) or throughout the manufacturing facility as a whole (example: calling for parts using AMRs or vibration/temperature sensors communicating data into a cloud data service). IO-Link is another technology that is taking root (RA-02162023).
“What these have in common is simplicity and speed of deployment. Cutting the cord and going wireless eliminates the need for time-consuming wiring, which is subject to mistakes resulting in troubleshooting,” explains Almeida.
Needs of the factory floor
The connected factory technologies of today are designed to achieve a number of goals on the factory floor.
Increased efficiency and productivity, improved quality control, better decision making, predictive maintenance and improved safety are some of the broad objectives that manufacturers target with these technologies, shares Warren Osak, CEO of Electromate.
The data collected from the technologies of today are actively used to analyze processes, and predict failing machine components or issues before it actually stops functioning.
Arshdeep Singh from Black Controls shares that remote accessibility has become a big part of every modern system for customer
SUKANYA RAY GHOSH
and OEM support. Cloud/ web-based HMIs are also being used increasingly due to their low cost and flexibility to display information that is not necessarily directly related to the machine they are situated at.
Reaping rewards with right implementation
Not every technology is suitable for every factory floor. To obtain the best results, it is essential to identify the specific issues that the manufacturer wishes to address.
Distributed IO provides a good example, according to Almeida. “There are many options to choose from, but which one to choose depends on the particular scenario. Where pneumatics are concerned it makes sense to use IO integrated on the manifold as oftentimes the actuators and sensors are located in close proximity to the valve manifold. Those sensors are connected to the IO blocks via M8 or M12 connections, then a single network cable is run back to a switch or the valve manifold communicates wirelessly back to the PLC. This makes deployment more efficient and keeps the technology under a single platform to minimize the need to manage handshakes between differing technologies from different manufacturers,” he explains.
Another example, he shares is technologies that overlay over existing legacy equipment already deployed onto the factory floor. “These technologies make older equipment Industry 4.0 ready without disrupting or redesigning the existing equipment. You use the same sensors, controllers and same PLC code. This overlay technology is connected in parallel and translates the existing signals into data formatted for enhanced use. This data is now used to measure and track the health of the equipment, providing similar visibility to what you would expect from a newer piece of automation.”
When making a choice, examples of successful implementation can offer better clarity regarding expectations.
Bon van den Berg shares an example of
a manufacturer customer that achieved success with the right technology choice.
“We had a customer with a part washing machine that had 32 sections. Depending on what parts they were washing, they needed to bring certain sections of the machine in and out. We were able to show them through one connection point to a PLC, how to be able to do that. If they need to remove a module from the machine, they can resection it. If they need to reattach it, they can. We also eliminated the need for them to use analog cards and devices, converting them over to IO-link for measuring devices. That allowed them then to simply connect and then replace these devices if they needed to as well. Overall savings for the customer was 25 percent in costs and 30 percent in installation labour.”
Manufacturers often have legacy systems on their plant floors. Replacing such equipment completely is a highly expensive and time-consuming process. This consideration often deters them from adding new technologies.
“While modern sensors come with
advanced IoT capabilities, not everything needs to be upgraded on legacy systems to start introducing connected factories,” says Singh. “Even with older hardware (PLCs), new sensing can be added that works with the legacy PLC and also has IoT capabilities. Connected factories can also simply start by adding a remote access device like an Ewon Industrial Gateway. Having remote access setup to your system allows for many capabilities including remote troubleshooting and diagnostics of devices like PLCs, HMIs, VFDs, servos, vision systems and sensors.”
He further adds that new technologies like AMRs can be integrated into older factories with legacy equipment with minimal impact. Black Controls, for example, assesses a production facility’s current state and provides a road map to implementing technologies like remote monitoring and AMRs.
Get more for less
As technology investments can be quite expensive, manufacturers expect to maximize ROI on every solution they implement. Osak
suggests the following tips that will help them achieve that goal.
Streamline operations: By improving processes, reducing waste and increasing efficiency, manufacturers can produce more with fewer resources.
Invest in technology: Implementing technology such as automation, artificial intelligence and machine learning can help manufacturers increase productivity, reduce errors and improve quality.
Utilize data analytics: Collecting and analyzing data on operations, customer behaviour and market trends can help manufacturers make informed decisions about production and reduce waste.
Collaborate with suppliers: Building strong relationships with suppliers and working together to reduce waste and improve supply chain efficiencies can help manufacturers get more for less. | MA
CONTROLS: Energy Meters • Current Transformers • Transducers • Power Supplies • Panel Meters • Time Delay Relays • Current-, Voltage- and Phase Monitoring Controls
CARLO GAVAZZI has the solution for your application needs, whether it’s our industry leading solid state relays, energy meters, contactors, motor controls, monitoring relays or sensors, now available with IO-Link communications.
Contact us today, and one of our field sales representatives will show you why we are one of the fastest growing automation companies worldwide. We’ll even provide a free evaluation sample to qualified customers.
FUTURE-PROOF FACILITIES
Continuous improvements in efficiency, product quality and worker safety are all part of the bigger picture when Honda retools a plant.
BY JACK KAZMIERSKI
Honda recently retooled part of its Alliston plant in order to manufacture the 2023 CR-V Hybrid. The plant will continue to build the Civic, the gas-powered CR-V, as well as Honda engines, but the addition of the Hybrid called for an upgrade to the assembly line at the plant.
“We don’t really retool in the sense of ripping everything out and putting in new equipment,” explains Ioan Buzdugan, engineering lead/equipment safety lead at Honda of Canada Mfg. “We basically try and reuse as much of our existing equipment as possible, and then we add and modify, as necessary.”
Buzdugan says that retooling for the new Hybrid model included new fixtures, new lift assists, as well as modifying existing automated cells, rearranging processes on the line, adding new robots to existing lines, extending conveyor lines and adding new conveyors for sub-assembly to accommodate new parts of the power unit.
The Alliston plant is highly automated, but Honda still employs thousands of workers. This means that all the processes needed to build the new Hybrid model had to be adjusted for the humans involved in the process.
In addition to retooling specifically for the new CR-V Hybrid model, Honda also implemented improvements to the plant as part of the company’s ongoing commitment to continuous improvements in efficiency, product quality and worker safety.
Man and machine
In order to improve the collaboration between man and machine, and to limit future expenses whenever the assembly line will need to be updated for a new model, Honda employed robots with power force limiting capabilities.
“We’re starting to look at where we can apply these robots to improve the flexibility of our lines,” Buzdugan adds. “If we don’t need to put up as many fences as we would on a
traditional robot line, that increases the flexibility. When we have to prepare the line for a new model, if we have to arrange processes around the robot, it’s easier and potentially less expensive to do so if we don’t have a lot of fences or light curtains to deal with.”
Honda is using these same types of robots to reduce the amount of non-value-added work employees have to do. “We want our associates to spend their time with their hands on the car, doing things that actually add value, and not walking around moving parts,” Buzdugan explains. “We’re looking at how we can use robots with power force limiting in the process area to do some simple sub-assembly work, and then present the finished part to an associate who wouldn’t have to walk to different part bins to get the parts himself.”
In their quest for constant improvement, Honda is looking at ways to use 3D cameras and machine vision to automate inspections, especially when a part may not have been installed in the exact same location, every single
A major challenge when retooling a plant is minimizing the impact any changes will have on assembly line workers.
time, on a vehicle by a worker. Furthermore, the company is harnessing the power of the Internet-of-Things in order to predict the failure of certain parts used in the manufacturing process, and replace those parts before they fail, thereby reducing downtime.
Retooling process
Buzdugan says that Honda has over 300 engineers and technicians working at their plants. When a new car model needs to be built, it’s their job to figure out what needs to happen to make that possible. “When we receive the design for a new model, our team analyzes the changes, analyzes the current situation of our equipment, and then they identity the gap to determine what has to be changed or added,” he explains. “We try to reuse as much of the current line as possible, instead of just ripping it out and putting a new one in. So, their job is to analyze the existing automation, determine what we have to change, as well as look for opportunities to automate, where possible.”
Honda employs both internal and external integrators to get a line ready for a new vehicle. “We prepare specifications for what we need, determine the cycle time, what quality inspections are needed, and what the safety requirements will be,” Buzdugan says. “Our engineers do a layout, and then we get either external integrators or our internal integration group to build that equipment and test it. Then our on-site engineers commission it and get it running.”
Although Honda’s engineering team will often design and build the equipment necessary for retooling, sometimes the company will recruit outside help. “If there is a piece of equipment that’s very specialized, that an outside company makes, then we’ll buy it from them,” Buzdugan explains, “but we’ll have our engineers integrate it into our existing line, and test it to make sure it meets our standards.”
The process of retooling a plant can take years. It’s often a longer process for a brand new model, than for a vehicle like the CR-V Hybrid, which is based on the current CR-V model.
Worker training
One of the major challenges when retooling a plant is minimizing the impact any changes will have on the assembly line workers and other associates. “We try to keep the way they interface with the automation as consistent as possible,” Buzdugan explains. “We consider everything, including how they will interact with things like the touchscreens.
We can change the automation, but if we make the interface similar to what they’re used to, that helps.”
Training assembly line associates can take weeks. “There’s a significant process that production associates go through to train for new models, because of all the process changes,” Buzdugan adds. “But then there’s all the technical training for our equipment, services and maintenance associates. We have an internal technical training centre, inside our facility, where we have experienced associates going through courses on technical topics like robots, PLCs and more.”
Planning for the future, Honda also brings training to schools, with the aim of teaching the next generation of technicians. “Our goal is to be proactive,” Buzdugan says, “so we work with universities and colleges where the faculty, along with mentors from Honda Canada Manufacturing train students on the automation technologies we use in our plant. When we hire candidates, we’d like them to already know a lot about the technologies we use.”
Whenever an upgrade or an update to a plant is needed, Honda plans the retooling process with the future in mind. Continuous improvement is a key concern, as is future-proofing the facility. “We like to set ourselves up for future success,” Buzdugan concludes. “Within reason, we want to assure that we have the flexibility to take on future models, or future variation of existing models while staying focused on key elements like efficiency, product quality and worker safety.” | MA
The addition of the CR-V Hybrid to Honda’s Alliston plant called for an upgrade to the assembly line.
ACROSS THE ENTERPRISE
BY JONATHAN GROSS
Jonathan Gross is managing director at Pemeco Consulting, a vendor-neutral consulting firm. He leads clients through the entire digital transformation lifecycle, including: technology architecture and planning, technology vendor selection, technology procurement, implementation, and ongoing optimization.
Digital transformation trends shaping Canadian manufacturing
We’re squarely into 2023 and are slowly putting a few major shocks behind us. COVID-19 restrictions are (hopefully) a relic of the past. And global supply chain bottlenecks seem to be easing.
Even though there’s continued volatility, we’re seeing positive signs that the economy might land more softly than many have recently predicted. Inflation is still increasing, but the pace is slowing. The January Canadian Manufacturing Purchasing Manager’s Index climbed back above 50, indicating expansion. And the Canadian economy added 150,000 jobs in January – the most in 11 months.
Meanwhile, politicians aren’t blindly trusting the invisible hand to continue working in the economy’s favour. Various levels of government are stepping in to prime the pump with funding programs to help Canadian manufacturers adopt digital technologies and improve operational efficiencies. For example, my firm has several nationwide clients tapping into the federal CDAP program to fund business process improvement, ERP software acquisition and implementation and Industry 4.0 projects.
A question we’re often asked is: “Which digital projects should we pursue?” Should companies pursue a full-scale ERP implementation or a more narrowly focused business process optimization project? Where do connected factory and Industry 4.0 projects fit in? And, with all of the data being collected, should businesses pursue a business intelligence initiative?
The answer, of course, depends on a company’s circumstances. Does it have strong fundamental data, processes and systems? Given limited financial and human capital resources, which projects will deliver the most business bang-for-buck?
As you build your business case, it’s important to consider marketplace trends and best practices. Here are a few notable emerging trends in 2023.
Conversational artificial intelligence
Until recently, executives I’ve spoken to have had a hard time conceptualizing how to practically deploy artificial intelligence. With the overnight success of ChatGPT, they’re starting
to see strong use cases. Here are three enterprise areas ripe for conversational AI:
• User experience: Enterprise software systems are hard to use. AI offers opportunities to improve the user experience, break down adoption barriers, and reduce employee training costs. Instead of entering data into 30 fields to create a sales order, for example, expect users to soon be able to ask the system to create an order in plain language.
• Analytics: With data residing in multiple systems, businesses still need expensive data scientists, architects, and consultants. In the not-too-distant future, AI should make analytics more consumable. Already, certain systems support conversational queries (“show me material variances in the past 24 hours on work centers 1 to 5”). We’re hoping to see vendors extend conversational AI capabilities to support the development of the underlying data models.
• Technical development: ChatGPT has already demonstrated its ability to develop and audit software code. Vendors will soon figure out how to deploy AI tools into their development platforms to give users an easier ability to build, test, and connect applications.
Data governance
Businesses have insatiable appetites for more timely and refined analytics. Also, companies are under increasing pressure to formalize procedures to comply with rapidly evolving data privacy and security regulatory frameworks. As a result, business leaders are moving data governance from the back burner to the front. Fundamentally, they’re prioritizing organizational, procedural, and technical initiatives to ensure that data is complete,
accurate and controlled. Organizationally, they’re establishing data competency centres to develop and oversee corporate policies and procedures. Functionally, they’re formalizing key data records ownership and are implementing systematic controls and workflows to manage access and security.
Disciplined approach to ERP and digital transformation projects
Until recently, companies were jumping headfirst (arguably blindfolded) into digital projects. From 2019 to 2022, we saw companies greenlight speculative technology projects, premature Industry 4.0 projects, and excessively scoped rip-and-replace ERP projects. As businesses applied a shoot-readyaim approach to their technology initiatives, the tech vendors and their services partners were more than happy to oblige.
The goldrush seems to be over. Canadian manufacturers are now generally taking a more disciplined approach. Though many still need to replace ageing end-of-life systems, we’re seeing others laser-focus their investments on optimizing existing systems. And, in most cases, executives are demanding that proposed projects be supported by a proper business case and return-on-investment analysis.
Strong focus on implementation readiness
Historically, digital transformation projects have had notoriously low success rates. We’re seeing signs that the trend might be reversing.
For starters, manufacturers are more willing to hire experienced client-side advisors and digital transformation consultants to help them get organized. Here are four tangible steps companies are taking before project kickoff to assure readiness:
• They’re establishing project teams, building strong governance, and backfilling project core team members in their day jobs.
• They’re tightly defining project scope and are implementing formal change control procedures.
• They’re making key decisions on future state design options.
• They’re rearchitecting and cleaning key data, such as items, BOMs, routings, vendors, customers and chart of accounts.
Composable ERP
Composable ERP refers to an ERP application environment built from loosely coupled systems.
Companies pursue this strategy when certain business functions are better supported by best-of-breed peripheral systems and not monolithic ERP systems. For example, we have several industrial automation manufacturing clients who have bolted best-of-breed field service management systems onto their core ERP systems because of better capabilities for equipment installation, commissioning, and maintenance processes. Although an attractive option, composable ERP isn’t always the right choice. It can shift requirements and costs from the business onto IT to develop and support an integration strategy. Sometimes, those costs outweigh the benefits. Also, multiple systems might not be the right choice if that architecture severs an important cross-functional business process.
Technology contract rationalization and renegotiation
With North American companies spending between five percent and 10 percent of revenues on IT, many are taking a hard look at their tech contracts for cost-saving opportunities.
First, IT leaders are triaging the lowest-hanging fruit by cancelling contracts for seldom-used technologies. Next, with tech markets softening, many are renegotiating existing agreements before they automatically renew. We have a client that’s currently auditing its 400 ERP user licenses to see if any can be deactivated or downgraded. And, when our client approaches the vendor with updated license counts, it’ll use pricing benchmarks to try to negotiate more favourable rates.
Applying the trends to your business
Ultimately, you can distill these 2023 digital transformation trends into three broad categories: governance, discipline, and innovation.
• Governance: Whether your business is embarking on a major ERP implementation, a business intelligence project, or a process improvement initiative, your project’s success hinges on having the right organizational structures, enabled teams, and effective change control.
• Discipline: Making the right digital investments takes thought. It’s important to support your recommendations and
decisions with a strong business case anchored by a return-on-investment analysis. And, over time, it’s important to revisit your technology contracts to make sure they’re delivering maximum value.
• Innovation: Composable ERP and conversational AI are two of the big trends. There are others. Spend time studying the
marketplace to learn about potentially value-driving new technologies.
By building the right governance models and focusing on value-driving technologies, you’ll be on your way to building a methodology you can trust to deliver meaningful digital transformation. | MA
Innovate today for a new tomorrow
Realize your vision with Festo’s approach to smart automation. Partner with Festo today.
INDUSTRY WATCH
BY PAUL HOGENDOORN
Paul Hogendoorn co-founded FreePoint Technologies with the goal of giving manufacturers the benefit of information technologies that inform, empower and motivate their most critical asset – their people. He can be reached at hogendoorn.paul@gmail.com or linkedin.com/in/paulhogendoorn.
From a reactive 2022 to a proactive 2023
Good riddance to 2022. What a crazy year it was. But will 2023 be any different?
It will be the same as it will be a year of many changes. But it will be different as while the changes in 2022 were mostly reactionary, most of the changes in 2023 will be prescribed, intentional or proactive.
Manufacturers did an admirable (amazing) job throughout the pandemic, keeping their plants open, their people employed, and their customers supplied with the products they required or wanted. Throughout that period, they adapted by having “nonhands-on” personnel work from home and realigning shift schedules to optimize the time for when there were workers in-plant.
Many of my customers found it was possible to get all the production done each week in two shifts and five days rather than needing extra hours during the week and a half shift or more on weekends. This led more than one of them to quip: “see what happens when management gets out of the way?” It was a time of adjustment and learning, and refinement for many of them.
Then came the supply chain challenges. As most manufacturers know, there is no such thing as 95 percent complete. You are either 100 percent on time or 100 percent late. One missing part and you are not shipping a product, but instead, managing and working around a growing inventory of work in process, tying up space and capital. The reshoring sentiment of the years before the pandemic became a reshoring objective and mandate to mitigate supply chain concerns caused by the pandemic.
On top of everything else, the manufacturing industry lost a large part of its workforce. This was anticipated to some extent with the last of the baby boomer generation reaching retirement age. However, the pandemic years caused a lot of younger people to rethink how they felt about work and how they wanted to spend their time. The manufacturing workforce was shrinking at the same time our industries were reshoring.
In 2022, like they always do, manufacturers adapted, adopted and prevailed. (It’s why I love manufacturing – no waiting for someone else to figure it out and come up with a program or plan to fix it for you. Just figure it out along the way and get ‘er done!) That’s a
In 2023, manufacturers will use lessons learned to intentionally make changes by adding more agility through effective selection and deployment of technology.
manufacturer’s world. It’s not done until it’s shipped, not shipped unless it’s done and not invoiced until it’s done and shipped. This is the system week in and week out for 52 weeks a year – regardless of circumstance.
Here’s how things will be different in 2023. Manufacturers did what they had to do just to get through each of the last few tumultuous years. However, in 2023, they will take the lessons they learned ad-hoc, along the way and intentionally make changes to build on their resilience by adding more agility through effective selection and deployment of technology. For at least the last 10 years, people have been “interested in” or are “talking about” Industry 4.0, the Industrial Internet of Things (IIoT), MES systems and digital transformation. In 2023, many are going to be intentional and actually do it. The reason most manufacturers haven’t started in these directions is that these things are all indirect to what they do or know. They are comfortable spending hundreds of thousands of dollars on a new, high-speed milling machine, or new automated workstations, because they know what those things do
for them and understand the value those things deliver to the product they produce. Technology or software that improves their operations indirectly was not something they were as comfortable with, because it’s not what they innately knew.
Now, that ice has been broken. Many manufacturers had no choice in the last few years but to begin experiencing what new digital technology could bring and what immediate problems it could solve. It let them have engineers and management work effectively from home. It let them move information around on the plant floor without moving pieces of paper. It let them dynamically make changes to their production schedule as daily (and even hourly) circumstances changed. In short, they started seeing and experiencing these technologies as effective tools that helped them get their product out the door rather than just the next new fad that they were expected to adopt sometime in the future. The benefits became real, tactile and tangible because they experienced them.
In 2023, I sense a very strong difference in attitude towards Industry 4.0, the IIoT, MES and digitization than previous years. In previous years, it was something companies aspired to, or felt compelled to think about, and maybe even start to plan for. In 2023, however, there is a strong intentionality to do it. It is no longer a reactive change but a proactive one.
Here’s to a productive and proactive 2023! | MA
HMI & OPERATOR
Integrated web server
Exor’s newly released eX707M Web industrial HMI offers an integrated web server and is suitable for use in modern factory automation systems, according to the company. The eX707M Web features a highresolution 7-inch colour TFT display, with a 800x480 pixels resolution. It is equipped with a powerful and fast CPU, with a Cortex-A8 600 MHz processor and a RAM of 512MB. It also includes a built-in web server that allows users to access the HMI through a web browser from any device connected to the same network. The eX707M Web also offers a wide range of connectivity options, including Ethernet, USB, and serial ports. It supports various protocols such as Modbus TCP, EtherNet/ IP, and Profinet. It also includes a built-in SD card slot for data storage and firmware updates. electromate.com
ENCLOSURES & WORKSTATIONS
Mounting flange solution
Stahlin Enclosures released new mounting flanges designed to add a robust mounting option to its polycarbonate enclosures. These new mounting flanges provide a durable alternative
to mounting feet and will meet customer requirements and preferences for a full flange. They can be used in a variety of applications and surface types, or in combination with user-added mounting materials and hardware such as Stahlin pole mount kits or channel. Available with the enclosure or as an accessory kit, the new Stahlin mounting flange is ideal for any installation. A built-in water-shedding design features a radius that prevents accumulation of water and provides a mounting “cross” which allows for multiple screw positions and adds flexibility during installation. stahlin.com
SENSORS
Miniature inductive linear position sensor
Alliance Sensors Group’s LZ-9.5 series of miniature linear position sensors uses LVIT technology. The LZ-9.5 series LVITs are contactless devices for use by OEMs and in factory automation or assembly machinery applications, where sensor space is at a premium. These miniature LVITs are available in full scale ranges from 6.4 to 150 mm (0.25 to 6 inches) with DCV in / DCV out electronics built into the sensor. The sensor has a 9.5 mm (0.375 inch) outside diameter stainless steel body with a 1-m long axial cable for I/O connections. The 4.75 mm (0.187 inch) diameter through-bore of an LZ-13 provides clearance for its 2.4 mm (0.096 inch) diameter stainless steel target rod. alliancesensors.com
MOTORS & DRIVES
Metric and imperial dimensioned linear voice coil servo actuators
Moticont’s new, compact 25.4 mm (1.000 in.) stroke SDLM-025095-01-01M and SDLM-025-09501-01 linear DC servo actuators feature high repeatability, high acceleration/deceleration and no cogging. These electric cylinders have linear encoders mounted internally for closed loop servo operation. The fully enclosed servo actuators are 25.4 mm (1.000 in.) in diameter, the housing is 95.3 mm (3.750 in.) long and the total length of the housings and shafts are 139.7 mm (5.500 in.).
The 3.2 mm (0.125 in.) nonrotating shafts have M2.2X0.45 x 5.1 min DP or 2-56 UNC-28 x 0.20 min DP threaded holes, for direct, zero backlash connections to a load at either end. The shafts are supported at both ends by plain linear bearings and can tolerate side loads up to 2.0 N (7.2 oz.). moticont.com
ROBOTICS
End-of-arm tooling components
AutomationDirect now offers Schmalz end-of-arm tooling components for robot arm vacuum pick-and-place applications. Components can be purchased individually or in kits that include everything needed to create a single-beam or dual-beam end-of-arm tool. The kits include structural rails (which support optional internal vacuum), connectors, cup mounts, vacuum tubing, vacuum cups, fittings, a basic ejector, a flange for Universal robot, and a blank robot flange. Just cut the structural rails to the desired lengths, determine the location of the suction cups, assemble the unit and add the robot interface flange for specific brand of robot or drill your own using the included blank robot flange, explains AutomationDirect. automationdirect.ca
BY STEPHANIE HOLKO
Stephanie Holko is the director of project development at Next Generation Manufacturing Canada (NGen). She loves connecting emerging technologies with existing manufacturing problems and believes the future of manufacturing is in the adoption of new ways of working. Stephanie is a licensed Professional Engineer in Ontario.
Women in automation: The past, present and future
What comes to mind when you think of women in automation?
Do you picture students working in a lab? Or the lone woman you remember from days on the shop floor? Or something else? I picture a legacy that stretches back generations, brilliant women solving the problems of today, and I picture a hopeful future.
The story of women in automation could start with Ada Lovelace and her computer algorithm in 1843. The Countess of Lovelace saw potential in the technological designs of an analytical engine and created the first computer program meant to calculate Bernoulli sequence numbers. Fast forward to the hundreds of thousands of women who worked in factories during the World Wars running power machinery in munitions plants, with the rallying icon of Rosie the Riveter. Jump to the hidden figures of the National Advisory Committee for Aeronautics (NACA) and NASA that helped put men on the moon using slide rulers, pencils and sharp minds. From that generation came the generation of women just before mine, in the 1970s and 80s. These women opened the doors further, providing the groundwork for modern generations to work shoulder-to-shoulder with men in our factories. These women developed the first energy models created on modern computers to help plants run more efficiently or the first quality programs connected to production. When I think of women in automation, I look back on a history of bright minds and stubborn women who were (and are) grit and grace incarnate. When we look at women in automation today, we see women founding and running automation
When I think of the future of automation, I think of the creativity and boldness of young girls and women who want to make the world a better place.
companies. We see new problems being solved with the latest technologies and a burgeoning FemTech sector. There are First Robotics teams that are all girls, with women mentors who have long careers in industry. All these signs point in the right direction, but there is still a gender imbalance. Girls and women in STEM programs are ubiquitous, and the percentage of women graduating from engineering and trades schools in Canada is slowly increasing. Engineers Canada has a 30 by 30 challenge that seeks to have women as 30 percent of newly licenced engineers by 2030. The entire pipeline still needs work. Early interest in STEM, training and recruitment practices are all essential parts of the equation. The one item that seems to be underserved is the retention of women in these fields. This is one way Diversity, Equity and Inclusion work serves business objectives. If we agree there is a skilled labour shortage, how do we make the automation sector a place where women want to stay? How do we invest in the professional development of the workers in automation and manufacturing to grow capabilities and retain top talent?
One way to retain women is to connect the work they are doing with a larger purpose – what problems are identified and how they are solved changes when women are the decision makers. The focus on environmental, social and governance as a good business strategy is in large part being led by women. Strides in the automation world are happening to support these business decisions. New businesses are created to address needs uncovered in the market. The aptitude for multidisciplinary approaches and creativity coupled with a different perspective makes investing in women, and other groups, a strategic necessity. None of these attributes are solely the purview of women, but the odds of having a broader problem-solving creative team are greater when you have different voices around the table. When I think of the future of automation, I think of the creativity and boldness of young girls and women who want to make the world a better place. The confidence of up-and-coming students and graduates and their ideas give me hope for the future.
The history of automation is using technology to make work easier, faster and better. The factories that women worked in a century ago are vastly different from the technology-rich environments of today. Whether a factory is retrofitted or greenfield, automation has made making stuff safer and more interesting. Women have always played a role in automation and the big goals and heady solutions of the 21st century will be led by women. If you are interested in learning more about the careers of the future and what skills are needed to take on the problems of today and tomorrow, check out careersofthefuture.ca. | MA
Have company news, case studies, events or story ideas to share? Send to srayghosh@annexbusinessmedia.com and you could be featured in Manufacturing AUTOMATION!
Cut your costs, Bulk up on savings
Order your cut-to-length and bulk cables today and save with AutomationDirect’s affordable pricing - No gimmicks. No hidden charges.
Cut-to-Length
Cables with NO Hidden Fees
All AutomationDirect multi-conductor cable can be ordered cut to your speci ed lengths without the added cutting charges, hidden fees, and in ated shipping costs found with other suppliers.
With AutomationDirect you get:
• UL certified re-spooling facility - ensures that our cut-to-length cables maintain the UL certifications
• Low price per foot Starting at $0.24 (PLTC3-20-1S-1)
• Free, fast shipping (typically 2-day delivery)*
Multi-Conductor Cables
• Easy online, phone or email ordering
• 30-day money-back guarantee*
(yes, even custom cut cable)
• Low minimum cut lengths
NEW! Quabbin continuous flexing industrial Ethernet Cat5e, Cat6/6a, and Profinet communication cables now have more options.
• 26 and 24 AWG sizes (Cat5e & Cat6/6a)
• 22 AWG size (Profinet)
• Shielded versions (All)
• Unshielded versions (Cat5e)
• 2-twisted pairs (Cat5e & Profinet)
• 4-twisted pairs (Cat5e & Cat6/6a)
Starting at $0.78/ft (Q5772-1)
• 4-conductors (Profinet)
• TPE jacket (All)
• ZHFR jacket (Cat5e & Cat6/6a)
• FR-TPE jacket (Cat5e)
• PLTC or PLTC-ER jackets (Profinet)
Other multi-conductor cable types available:
• Power cables
• Tray-rated cables
• Control and signal cables
• Instrumentation cables
• Data communications cables
• Food and beverage cables
• Variable frequency drive (VFD) and servo motor cables
• Thermocouple and RTD extension wire/cable
Bulk Electrical Hook-up/Building Wire
AutomationDirect has a large selection of quality MTW, THHN, and TFFN electrical wire in pre-spooled lengths that meets all NFPA and NEC requirements at great prices.
Over 35 types of cable available in bulk or cut-to-length sizes and shipped fast!
Orders over $49 get FAST FREE SHIPPING
Our shipping policies make it easier than ever to order direct from the U.S.!
Fast free standard shipping* is available for most orders over $49 U.S., and that includes the brokerage fees (when using an AutomationDirect nominated broker). Using our choice of carrier, we can reach most Canadian destinations within 2 to 3 days.
*Free shipping does not apply to items requiring LTL transport, but those shipments can take advantage of our negotiated super-low at rates (based on weight) that include brokerage fees.
See Web site for details and restrictions at: www.automationdirect.com/canada
MISUMI
MANUFACTURER & DISTRIBUTOR
MISUMI OFFERS CONFIGURABLE COMPONENT SOLUTIONS: A COST-EFFECTIVE, RELIABLE, AND FAST ALTERNATIVE TO OFF THE SHELF AND CUSTOM OPTIONS.
CUSTOM
Design a custom part to meet design specifications when speed and cost isn’t a factor.
• High Quality
• Fully Custom
• Uncompromised Design
OFF THE SHELF
Choose stock components when you need a part fast at the lowest cost.
• Lowest Cost
• Fast
• Convenient
CONFIGURABLE
Configure the materials, dimensions, features and finishes you need online FAST!
