Ma 2015novdec

GRIPPING POWER Ramping up robotic assembly line tasks

POWER SUPPLIES The power of keeping manufacturing productive

SENSOR OPPORTUNITIES LVIT technology offers more flexibility for less money

N O V E M B E R / D E C E M B E R 2 015

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M AC H I N E D E S I G N • S YS T E M S • T E C H N O L O G Y

STAYING STRONG the 2015 Canadian manufacturing study finds industry maintains strength during rocky times JUNE15 A&C Front Cover Banner (MA)_Manufacturing Automation Cover Banner 5/12/15 11:42 AM Page 1

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DEPARTMENTS 4 5

FEATURES

FROM THE EDITOR AUTOMATION UPFRONT

In brief Deal makers Movers and shakers

COLUMNS 9

MACHINE SAFETY

Machine safety isn’t what it used to be and thank goodness for that

10 INDUSTRY WATCH

Paul Hogendoorn highlights the difference between the grey beards and the blue plaids

12 LEAN INSIGHTS

Using lean times to become Lean

14

STAYING STRONG

The 2015 Canadian Manufacturing Study finds industry maintains strength during rocky times

By Alyssa Dalton

MOVEMENT 18 FLOOR Moving-floor assembly line streamlines production of large-scale farm equipment

By Patrick Roberts

30 BACKSTORY

A look back at the change in machinery

IN ACTION 20 AUTOMATION Ramping up robotic assembly line tasks with flexible gripping power

By Treena Hein

NEW PRODUCTS 25 26 26 27 28 28 29

Communications and Networking Motors and Drives Robotics Machine Safety Automation Software Material Handling Process Control

Murrelektronik MA Nov.indd 1

SUPPLIES 22 POWER The power of keeping manufacturing productive

By William Cisler and John Roeslein

OPPORTUNITIES 24 SENSOR LVIT technology offers more flexibility for less money in factory automation applications

By Edward E. Herceg

www.AutomationMag.com • November/December 2015 3 2015-10-23 10:04 AM

F R O M

T H e

e D I T O R www.automationmag.com • Vol. 30, No.7

inspiring youth on Manufacturing day and beyond

O

ctober 2 marked Manufacturing Day 2015, a day where a number of manufacturing industry players opened their doors to students and community members. This annual event aims to change the perception of today’s manufacturing environment by giving manufacturers an opportunity to “show, in a coordinated effort, what manufacturing is — and what it isn’t.”

And what an impressive showing this year’s initiative drew. More than 2,500 activities popped up across North America — from school visits and open houses, to presentations, plant tours and expos, these events continue the discussion on the viability of skilled trades careers for students, educators and industry alike.

The need to attract young workers into the skilled trades is not a new topic of conversation by any means... so why, after many years of discussion, haven’t we been successful at lessening that gap? What is wrong in our approach to tackling this ever-prevailing shortage and what solutions should we adopt?

A few ideas come to mind. Perhaps we should target students at a younger age, or maybe parents and other family members need to be more involved in these discussions. Another thought is that our educational system as a whole must understand the opportunities skilled trades can present to workers.

Just several days after Manufacturing Day 2015, the Canadian Apprenticeship Forum (CAF-FCA) published a very timely report. The study surveyed tradespeople at various stages of their career and found that 50 per cent of respondents reported making $80,000+ a year. It also indicated that many skilled trades careers transition into different fields, such as management, business ownership and teaching — busting the myth that skilled trades equal “dead-end jobs.” “We need to share that story with young people,” said Sarah Watts-Rynard, CAF-FCA executive director.

I couldn’t agree more. These success stories are just one element of this united movement for skilled trades careers we must continue to promote, both nationally and globally, to highlight the endless opportunities this vibrant industry offers. •

Canada’s leading publication providing industrial automation news and technology information aimed at the discrete and process industries. ediToR alyssa dalton adalton@annexweb.com

aCCoUnT Co-oRdinaToR Kathryn nyenhuis knyenhuis@annexweb.com

ViCe PResidenT and eXeCUTiVe PUBLisheR Tim dimopoulos tdimopoulos@annexbizmedia.com

CiRCULaTion ManaGeR Urzula Grzyb ugrzyb@annexbizmedia.com

GRoUP PUBLisheR Klaus B. Pirker kpirker@annexweb.com aRT diReCToR svetlana avrutin savrutin@annexweb.com

diReCToR oF soUL/Coo sue Fredericks sUBsCRiBeR CUsToMeR seRViCe 416-442-5600 ext. 3552

ConTRiBUTinG WRiTeRs William Cisler, Ryan Friesen, Treena Hein, Edward E. Herceg, Paul Hogendoorn, Nick Howard, John Martin, Patrick Roberts, John Roeslein ediToRiaL adVisoRY BoaRd Piero Cherubini, Dean, Faculty of Skilled Trades and Apprenticeship, Mohawk College of Applied Arts and Technology al diggins, President and General Manager, Excellence in Manufacturing Consortium, and Chairman and CEO, Canadian Manufacturing Network david Green, Technology and Business-to-Business Consultant sherman Lang, Industrial Technology Advisor, Industrial Research Assistance Program, National Research Council of Canada don McCrudden, Vice-President, Business Development, Festo david McPhail, President and CEO, Memex Automation nigel southway, Business Productivity Consultant and Author on Lean Thinking Bill Valedis, Vice-President, Precision Training, Products and Services Inc. Manufacturing AUTOMATION is published seven times a year

by Annex Publishing & Printing Inc. 222 Edward Street, Aurora, Ontario L4G 1W6 Tel: (905) 727–0077 • Fax: (905) 727–0017 • PM # 40065710 The contents of Manufacturing Automation are copyright ©2015 by Annex Publishing & Printing Inc. and may not be reproduced in whole or part without written consent. Annex Publishing & Printing Inc. disclaims any warranty as to the accuracy, completeness or currency of the contents of this publication and disclaims all liability in respect of the results of any action taken or not taken in reliance upon information in this publication. subscription rates: Canada — $40 per year. United States and Foreign — $60(US) per year.

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A U T O M A T I O N

U P F R O N T

GM Canada’s first renewable energy project saves 1.3 MW of energy

In brief • To mark the seven-millionth Honda vehicle built in Canada, the company will donate the grey 2015 Honda Civic EX sedan to the annual Rally For Kids with Cancer fundraiser for live auction. All proceeds from the auction will be donated to the Sick Kids Foundation.

• Keba AG has joined the Organization for Machine Automation and Control (OMAC), which works to address issues that confront global manufacturing and develop

General Motors says its St. Catharines, Ont., Powertrain plant is harnessing the energy of water to cool processes in its operations. Its new micro-hydro system marks GM Canada’s first use of renewable energy.

St. Catharines manufactures V6 and V8 engines and six-speed automatic transmissions for a variety of Buick, Chevrolet, Cadillac and GMC vehicles. The plant is located near the St. Lawrence Seaway and Niagara Escarpment, making raw canal water a “natural choice” to help cool the engine facility’s component machining, and to lower building temperatures in the summer, noted company officials.

Here’s how it works: St. Catharines taps into a penstock — similar to a large pipe — that runs parallel to the Welland Canal. The penstock delivers water from a higher elevation to a lower elevation, about a 140-ft. drop, using the force of gravity to feed water to the plant at approximately 40 lb. per sq. in. of pressure.

This micro-hydro system delivers the canal water that cools the plant’s refrigerated chilled water system.

This in turn provides cooling water to maintain the appropriate temperature of process equipment in the plant, according to the automaker.

Prior to the installation of this renewable energy project, the plant used refrigerated city water to cool building processes, then returned the warm water to a cooling tower to be cooled and used again.

GM says less electricity is now required to run pumps and fans because large volumes of canal water are cooling the refrigeration system.

In the winter, no refrigeration is needed at all, with desired cooling water temperatures achieved simply by using a heat exchanger, it says.

The facility also eliminated use of cooling towers and the chemicals needed to maintain them. Although St. Catharines’ version of the micro-hydro system does not generate electricity, it replaces processes that require electricity, giving it the distinction of a renewable energy project, adds GM. GM says during peak periods, cool water can save 2,000 kW of electricity, which amounts to 8,600 MW of electricity savings annually.

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• Alcoa has announced it will split into two independent companies — one focused on aluminum production and the other on engineered products for the automotive and aerospace industries.

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www.AutomationMag.com • November/December 2015 5 2015-10-20 10:00 AM

A U T O M A T I O N

U P F R O N T

DeaL Makers

skilled trades careers negate youth/parent perceptions

Though parents and youth say they believe career opportunities in the skilled trades to be limited, the Canadian Apprenticeship Forum (CAF-FCA) published a new national report today indicating the opposite is true.

With insights and observations from 754 certified journeypersons across Canada, The Benefits of a Skilled Trades Career: Journeyperson Perspectives and Experiences sheds light on career progression in the trades.

Journeypersons point to benefits including good pay, interesting work, full-time employment and the job satisfaction that comes with building or creating something.

Based on a national survey with tradespeople at various stages of their career, 50 per cent of respondents reported making more than $80,000 annually.

“In recent surveys to gauge parent and youth understanding of the skilled trades, we were disappointed with the perception that skilled trades careers are ‘dead end jobs,’” said Sarah Watts-Rynard, executive director of CAF-FCA. “This study reflects a much different reality, one of broad opportunity both in the trades and in related occupations. Tradespeople often transition into different fields, including teaching, training, management and business ownership. We need to share that story with young people.”

When asked what a skilled trades career brought him, one respondent said, “Massive adventure. I bought

Machine that killed worker should have been guarded: MoL

Plastic bottle manufacturer CRS Plastics was fined $100,000 for a violation under the Occupational Health and Safety Act after a worker was killed by a machine that should have been guarded, according to the Ontario Ministry of Labour (MOL) investigation.

On March 29, 2014, a temporary worker was removing plastic bottles from the end of a blow mould machine at the CRS facility located at 140 Hanlan Road in Vaughan, Ont. The investigation found that the machine had a

moving part that should have been guarded, however that guard had broken and was missing while it underwent repairs. The worker came into contact with the moving part of the machine and was fatally injured.

CRS Plastics pleaded guilty to failing to ensure that a machine with a moving part that could endanger a worker was equipped with a guard to prevent access.

In addition to the fine, the court imposed a 25-percent victim fine surcharge as required by the Provincial Offences Act. The surcharge is credited to a special provincial government fund to assist victims of crime.

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my first house at 21 and had a successful business by 24. I travelled around the world, became a professor by age 30... [all while] my university buddies were still eating Kraft Dinner.”

Another respondent said, “I would question the notion that front-end programs, like degrees and diplomas, are equivalent or superior to an apprenticeship as they often lack the most critical component-social interaction in the context of the workplace. No one ever learned how to be a senior executive at school. They learned it at work.”

The survey found that the majority of journeypersons valued their Red Seal endorsement because it made them more employable and enhanced their labour mobility.

Many had also become mentors themselves, expressing satisfaction in becoming leaders who promote a positive work environment, model good safety practices and facilitate team collaboration.

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Omron acquisition adds robotics to industrial automation business Omron Corporation, a global provider of automation core sensing and control technology, has announced it will acquire U.S.-based Adept Technology, a provider of intelligent robots, autonomous mobile robot solutions and services. The transaction is expected to close by the end of October 2015.

By adding the robotics technology of Adept to its current offering, Omron says it will be very well positioned to provide manufacturers in the automotive, digital device, food and beverage, packaging, and other industries with solutions to these challenges, as well as engineering support.

“As global manufacturing comes under even more pressure to cut costs, shorten supply cycles and operate across global environments, production sites around the world strive to improve productivity. increased use of labour-saving robots is one of the solution,” noted Omron representatives. yutaka Miyanaga, Omron industrial Automation Business company president, said, “We are delighted Adept Technology, a world leader in robotics, has agreed to join Omron. This acquisition is part of our strategy to enhance our automation technology and position us for long term growth. Robotics will elevate our offering of advanced automation.”

“We are excited about the opportunity to join Omron, a global leader in automation,” said Rob Cain, president and CEO of Adept. “Together, our products will offer new innovative solutions to customers all around the globe.”

Following the transaction, Rob Cain will continue to lead Adept and will report to nigel Blakeway, chairman, CEO and president of Omron Management Center of America, Omron’s wholly owned United States subsidiary.

Pepperl+Fuchs acquires MACTek Pepperl+Fuchs, a global provider of process automation and applications, has acquired MACTek, a provider of HART protocol devices. The move is part of Pepperl+Fuchs’ strategy to further extend its integrated solutions offerings and strengthen its position in the WirelessHART market, according to company representatives.

“We are pleased to add the MACTek WirelessHART product line to our existing portfolio,” said Jim Bolin, Pepperl+Fuchs’ executive vice president of the Americas.

“This acquisition complements our current product lines well, and allows us to provide an even greater breadth of services to our customers.”

Founded in 1993, MACTek specializes in HART modems, including Viator HART interface modems. One of the company’s most recent innovations, the Bullet WirelessHART adapter, can be mounted on a device rated for hazardous areas.

November/December 2015 • Manufacturing AUTOMATION

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Movers & Shakers TM Robotics, partnered with Toshiba Machine, has hired Doug Dalgliesh as business development Doug Dalgliesh manager. Boasting more than 35 years of industrial robot experience, Dalgliesh will be responsible for cultivating the company’s distributor network while identifying and nurturing new markets.

According to the company, he intends on doubling TM Robotics’ number of partners by the end of 2015. As well, Dalgliesh has plans to build the sales and account management teams into double-digit growth.

Helix Linear Technologies is welcoming Dave Arguin as vice-president of business development to Dave Arguin help “expand a steadily growing list of national and international lead screw and linear actuator clients.” After spending 15 years with Kerk Motion Products and then seven years with Haydon Kerk Ametek, Arguin has established himself as a “knowledgeable and innovative leader” in the linear motion industry, noted company representatives.

Kingston chosen for Frulact’s Canadian home

Kingston, Ont., has been selected as the home for a new North American plant and research and development facility by Portuguese food processor Frulact Group. This announcement marks Frulact’s first presence in Canada.

Frulact Canada has acquired 15 acres of development land in the Cataraqui Estates Business Park in the city’s west end. The approximately 75,000-sq.-ft. fruit preparation and processing plant is slated to break ground later this year and open in fall 2016. The company also has an option for an additional 15-acre parcel adjacent to the purchased lot for potential future expansion.

About 50 employees will be hired when the facility opens with more jobs to be added.

“The capacity to attract foreign investment shown by the City of Kingston and Kingston Economic Development Corporation (KEDCO) played a crucial role in our decision to go to Ontario, allowing us to accelerate our growth and recognition as a global company,” said Joao Miranda, CEO of Frulact.

“Food and beverage processing plays a key role in helping grow Ontario’s economy,” continued Jeff

Leal, minister of agriculture, food and rural affairs. “This new operation will help Ontario’s agri-food industry continue to grow and contribute to the premier’s Agri-Food Growth Challenge of creating 120,000 new jobs by 2020. We welcome Frulact Canada to the Kingston community and look forward to their role in Ontario’s food and beverage processing sector.”

Established in 1987, Frulact offers custom-made fruit preparations for dairy, ice cream, pastry, and beverage industries.

Kruger Trois-Rivières Mill sees $250M boost

Kruger Packaging has announced an investment of $250 million to convert the No. 10 Newsprint Machine (PM10) at Kruger’s Trois-Rivières Mill in Quebec to manufacture 100 per cent recycled lightweight linerboard.

The modernization project will generate significant growth opportunities for the Trois-Rivières facility, says Kruger, “contributing to secure operations” and the 270 jobs at the mill. The project has received $190 million in support from the Quebec government, which includes an $84-million loan to finance the cost of the conversion and a $106-million participation, through Investissement

Québec, in a new company that now combines all of Kruger’s containerboard and packaging activities. As a result of this investment, the Quebec government will have 25 per cent ownership in this new company.

Over the coming 20 months, PM10 will be completely modernized to incorporate some of the “most advanced containerboard manufacturing technology,” says Kruger representatives. Once PM10 is up and running in 2017, it will produce 360,000 metric tonnes of 100 per cent recycled lightweight linerboard annually, a portion of which will be sold to Kruger Packaging’s box plants in LaSalle, Que., and Brampton, Ont., while the remainder will be sold on the market.

Kruger says the Trois-Rivières Mill will continue to produce newsprint on PM10 until two months before the end of the conversion project. Meanwhile, the mill’s other newsprint production line, PM7, will remain in operation into the future.

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www.AutomationMag.com • November/December 2015 7 2015-10-19 2:38 PM

A U T O M A T I O N

U P F R O N T

CMe, MssC work to harmonize Cdn-U.s. skill certifications

At the annual conference of the North American Strategy for Competitiveness (NASCO) in September, the Canadian Manufacturers and Exporters (CME) and the U.S. Manufacturing Skill Standards Council (MSSC) signed a Memorandum of Understanding to announce the harmonization of their respective standards and certifications for front-line manufacturing production workers.

According to the parties, CME and MSSC will also initiate communications to their respective manufacturing communities encouraging them to recognize both the MSSC Certified Production Technician (CPT) and CME Production Assemblers and Operators certifications as equivalent credentials that can: • • • •

Facilitate cross-border worker movement for job assignments; Promote equivalent hiring and promotion processes; Provide preferential consideration to individuals possessing these credentials; Create common performance metrics and consistent work practices for the front-line workforce in supply chain companies; and • Enhance the international recognition of both CME and MSSC credentials.

“Harmonization of skilled worker skills certification with our largest trading partner and closest ally is an important step for both countries that are facing skills shortages related to an aging population,” said Jayson Myers, CME president and CEO. “We look forward to continued cooperation with the MSSC on aligning standards on what has become a top priority on both sides of the border.”

“This harmonization should facilitate the development by manufacturers in both countries of world-class front-line workers with the skills needed able to meet the dual challenges of global economic competitiveness and accelerating technological change,” added MSSC chair and CEO Leo Reddy.

MarketsandMarkets: Mes market to be worth Us$12.6 billion by 2020

According to a recent market research report by MarketsandMarkets, the manufacturing execution system (MES) market is estimated to reach US$12.6 billion by 2020, at a CAGR of 10.85 per cent between 2015 and 2020.

A MES helps manage and automate the manufacturing processes on a production floor with the help of real-time data intelligence, all towards the goal of improving productivity.

MES is implemented in various process industry and discrete industry.

The market segmented on the basis of process industry includes oil and gas, chemicals, food and beverages, pulp and paper, lifesciences, power, water and wastewater management, and others. The food and beverages process industry

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aBB invests $70M in Technoparc facility

ABB has announced it will establish a $70 million, 300,000 sq. ft. facility in tech hub, Technoparc Montréal. The new ABB Saint-Laurent Campus will house the company’s corporate headquarters, as well as research and development, manufacturing, assembly and testing for ABB’s complete energy value chain in Quebec.

“This project, which is part of our 2020 global strategy, aims to promote greater collaboration, and increase efficiency and organizational synergy between teams,” said Nathalie Pilon, president and CEO of ABB Canada.

“The investment will allow us to continue improving our operational effectiveness and contribute to the development of cutting-edge technology in collaboration with our business partners, and with the academic and research sectors with whom we have long collaborated. It also underscores our ongoing commitment to the city of Montreal and to the local market.”

According to Pilon, the campus will include, among other things, spaces for technological demonstrations and for training clients on solutions and systems developed by ABB. It will be equipped with “ultra-modern equipment and boast advanced technologies and manufacturing processes.”

Founded in 1987, Technoparc Montréal strives to foster Montreal’s scientific and technological development by encouraging high value life sciences, aerospace, ICT and cleantech businesses and research centres to establish Canadian offices in Montreal.

“We’re so proud that ABB chose to establish its Canadian headquarters at Technoparc Montréal. This is a world-renowned company and a true leader in its field, so we know they will feel right at home in the midst of all the other high value, innovative companies that are now doing business in the heart of Montreal’s technology district,” added Mario Monette, president and CEO of Technoparc Montréal.

Construction began this fall and is set to be completed in February 2017.

Maple Leaf working to slash environmental footprint 50 per cent by 2025

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is expected to grow at a high CAGR of 14.35 per cent between 2015 and 2020, according to the report, while the discrete industry application includes automotive, medical device, aerospace and defence, and others. The automotive discrete industry holds the major share of the MES market, it notes.

The report includes a brief description of the factors driving and restraining the growth of the market as well as its opportunities and challenges. The factors driving the market include the growing impact of Cloud-based MES, growing demand for paperless operations, growing emphasis of real-time data analysis, and regulatory compliance. The high investment incurred by the adoption of MES and longer run update required in MES software is expected to add additional cost are the factor restraining the growth of the manufacturing execution system market.

Maple Leaf Foods unveiled its sustainability strategy and progress report, noting that it is working to reduce its environmental footprint by 50 per cent in 10 years, focusing on emissions, water and waste reduction.

In addition to its initiatives of sustainability and treatment of animals, Maple Leaf also launched a website highlighting the company’s efforts at sodium reduction, antibiotic use and sow housing.

“The enormous challenge our world faces is the urgent need to sustainably feed an estimated two billion more people by 2050,” said Michael H. McCain, president and CEO. “We are setting high standards for ourselves in areas where Maple Leaf can have the greatest impact, including animal care, nutrition, environmental impact and food security.

“Sustainability is a profound opportunity to create shared value by addressing critical issues that also deliver commercial opportunities,” he added. “The issues are daunting, but as Canada’s largest protein company, we want to be at the leading edge of change.” •

November/December 2015 • Manufacturing AUTOMATION

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M ach i n e

S afet y

Ye olde days

By John Martin

M

achine safety isn’t what it used to be — thank goodness for that.

I began working as a machinist in 1970. I turned aluminum dials for Hollywood motion picture cameras on Manhattan’s West Side.

I machined housings for Digital Equipment Corporation minicomputers in a job shop on Route 128, Boston’s “technology highway.” I refurbished parts for sewing machines in New York City’s garment district, and machined one-offs for faculty experiments in the Chemistry and Physics departments at New York University. I ran machining centres that tore up aluminum to make aerospace parts in Oakland, Calif.

I never saw a machine guard in seven years of work — everything was open to the touch (although to be fair to the OEMs, shop owners often removed guarding for easier access). In a Bronx, N.Y., job shop, on the first day of work, I reported to my lathe, reached in to open the chuck, and yanked my hands out when I realized it was spinning full tilt. Turns out the foreman, an old-school guy from what was then Yugoslavia, started the machines 10 minutes before each shift to mitigate temperature changes that might affect the precision work.

“I never saw a machine guard in seven years of work — everything was open to the touch (although to be fair to the OEMs, shop owners often removed guarding for easier access).”

As a tool-and-die apprentice at a manufacturer of electrical products, I had to do some surface grinding, something I hadn’t done before. When I saw something askew with the part held by the magnetic chuck as it fed toward the wheel, I reached in instinctively to make the adjustment and got caught by the abrasive disk. I was let off work for the day with a bandaged finger and a woozy feeling. I still have the scar where I almost lost the tip of my pinky.

Without guarding, we would reach in, insert stock into a lathe chuck, and tighten the chuck manually with a T-shaped key. The most critical part of the operation, besides rotating the part gently as you closed the jaws to ensure concentricity, was to remove the chuck key before starting the machine. One time I forgot, cranked up a lathe, and the metal key ejected like a missile from the whirling chuck, whistling past my head and across the shop.

The absence of machine guarding also intensified our exposure to cutting fluids. At the Oakland aerospace shop, the hot spot where the high-revving end mill met the metal was flooded with coolant. Blue-green liquid would splash all over me and I would inhale the mist. I broke out in a full-body rash; I was tingling, on fire everywhere. I went to the hospital for tests.

Today’s machinery is protected by mechanical guards, enclosures and interruption devices like light curtains and lockouts. Services and software pitch in too, as with all aspects of manufacturing. Various firms offer assessment, training and start-up services around machine safety. As members of the manufacturing industry, we must all play a part in promoting a culture of machine safety in the workplace. This brings to mind Machine Safety Management, a firm that was started by Jack Reiter, who as a kid saw his dad nearly lose his thumb trying to find the Off switch while tussling with a table saw. Reiter and his dad went on to design a hands-free emergency stop control, and his company now offers software to help businesses conduct, store, and manage machine safety audits and risk assessments for their equipment.

I still get a kick out of the scar on my finger — but only in retrospect.

I remember the terror at the time — thinking my hand was going to be dragged under the aluminum oxide wheel while I fumbled for the kill switch.

I remember sitting in the hospital being tested after the coolant exposure, wondering what was going to happen. My heart leapt into my throat when the chuck key was thrown from the lathe — at the exit velocity of a ball exploding off the bat of Jose Bautista and into the left-field seats at Rogers Centre.

Make sure you’ve got a good machine safety program. Give today’s machinists Tim Cards from Tim Hortons for their compliance, instead of scars. • John Martin is an ex-machinist who writes about manufacturing, software and IT from his base in Ithaca, N.Y. www.AutomationMag.com • November/December 2015 9 Hiwin_MA_Jan.indd 1

2014-12-17 3:17 PM

i n D U S T R y

W A T C H

Grey beards and blue plaid: how to keep from falling behind

BY PaUL hoGendooRn

W

alking through September’s Canadian Manufacturing and Technology Show (CMTS) gave me cause to realize how lucky we all are to live in these times, and made me pause to reflect on my own personal 35-year journey.

We (myself and other people approximately my age) straddle two great industrial generations; an older generation that brought the PLC into the mainstream, and a new generation that is doing the same thing with the Internet of Things (IoT).

Both generations started with a common attitude towards innovation. In each case, the incoming technology wasn’t a mere evolution, it was (and is) a revolution. Technology revolutions are disruptive, and disruption — in manufacturing especially — is always avoided. Both generations required more than a brand new technology, they each required a brand new way of thinking.

They both required persistence, determination and sometimes even a bit of arrogance and bravado. In my first go-round, I was often

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November/December 2015 • Manufacturing AUTOMATION

“Both generations started with a common attitude towards innovation. in each case, the incoming technology wasn’t a mere evolution, it was (and is) a revolution.” put in the position of “prove it,” which meant doing it for free to demonstrate to all the naysayers that it would work. And, there were a lot of naysayers. One of the problems we had then, which is exactly the same as the problem the new generation faces now, is that we were young and, in the industry’s eyes, inexperienced. To us, in our youthful confidence, “experienced” often meant “stuck and well-practiced in doing it the same old way.” But, we persisted, earning enough opportunities to eventually gain a solid foothold and start our businesses. And now we are the “grey beards,” looking suspiciously at what the young guns, wearing their blue plaid shirts, are heralding as the new way of doing IT on the plant floor.

As I was walking the show, these were some of the thoughts on my mind. A couple years ago, I helped launch a start-up company to help

bring IoT into manufacturing, and we hired some really bright young people to get it started.

Interestingly, blue plaid seemed to be their favourite fashion style, regardless of the occasion. The initial idea was that I would be a coach and mentor, but they soon convinced me that “every company needs a few grey beards.” This was a different attitude than the earlier revolution, certainly from my personal experience. But, I think it’s an excellent attitude, and an excellent idea: blue plaids and grey beards, all on the same team.

Manufacturers make trust-based decisions; their decisions are based largely on brand, on what they are familiar with, and on relationships — in other words, things they trust. New technology is instantly something they are not familiar with, and new technology brands are not yet unrecognizable to them.

(And, if they do recognize the

FOR THE MOST UP-TO-DATE NEWS, STORIES AND VIDEOS, CHECK US OUT AT

www.AutomationMag.com @AutomationMag brand, it’s likely that the company has an evolutionary technology and not really a revolutionary technology.) So, to even get a chance to present, requires having a long-term relationship, and a long-term relationship often comes with a grey beard (at least in manufacturing).

There’s another difference between “then” and “now.” Back then, I believe there were far more independent companies in Canada and far more autonomy for foreign controlled companies with operations here. The decades of having a currency advantage may have lulled a big chunk of our industry into complacency, perhaps stymying a more aggressive attitude towards adopting, or at least trying out, revolutionary technologies. Most seem satisfied with evolutionary r a t h e r t h a n r e v o l u t i o n a r y, unaware that simply keeping up is actually falling behind. Although our universities, colleges and innovation acceleration centres, all seem eager to marshal their energies to drive the sector into the new age, it will take more than that; it’ll take a new attitude and a collaboration of multiple generations — the grey beards supporting the ideas of the blue plaids, and the blue plaids willing to get their hands dirty, proving their ideas out on the shop floor.

At the end of the day, it’s not about manufacturing or machines or processes or even IT. It’s about people, just like it always has been, whether its people building it, using it, buying it, or just trying it. Our companies need people to drive innovation, to be imaginative, to be creative and to be sustainable, generation to generation.

Welcome to the new age of IT in manufacturing; it looks vaguely familiar. It’s a great industry to be in, and a great time to be in it. • Paul Hogendoorn (paulh@getfreepoint.com) is co-founder of FreePoint Technologies, “Measure. Analyze. Share.”

(Don’t forget to share!)

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www.AutomationMag.com • November/December 11 2015-10-192015 11:12 AM

L ea n

I n s i ghts

Using lean times to become Lean

By Ryan Friesen

O

urs is a story of growth, of building and most importantly, blessing. SteelTech Inc. started humbly, as most businesses do, in 2001 with the founders of the company as the only employees working out of a rented shop and some borrowed equipment building outdoor wood furnaces. In the first year, owners Ben Wall and Jake Friesen built and sold 80 units. By 2005, company growth called for the purchase of a newer, bigger shop and by the end of 2006, the neighbouring shop was also ours.

In 2008, demand for outdoor wood furnaces was at an all-time high and demand had to be met using satellite shops for welding and assembly. Times were good and making money was easy.

However after 2008, the effects of the recession hit home. At the time, we felt we needed a bigger shop to work in even though demand had decreased considerably and the value of the U.S. dollar was falling, significantly cutting into our margins. It was a tough decision, one that we wrestled with for a few months knowing it would have huge implications for the direction of our company in the future.

And then we went to a presentation that changed everything.

It was a presentation on Lean manufacturing. Lean manufacturing has been famously championed and pioneered by such companies as Honda and Toyota as keys to their success in becoming leaders in the automotive industry. At its heart, Lean manufacturing forces you to evaluate all of your activities and ask yourself: would my customer pay for this?

Are they willing to pay for that inventory sitting there?

Are they willing to pay for your employee to walk across

“At its heart, Lean manufacturing forces you to evaluate all of your activities and ask yourself: would my customer pay for this?” the room to get that tool or part? Are they willing to pay for the rework going through your shop? What about the scrap you throw away? Do they want to pay for that overengineering or extra feature?

In the end, we all build these forms of waste into our price but our customer isn’t paying for that, nor do they want to. And you can’t blame them. In the end, it’s about eliminating waste from your processes and delivering value to your customer.

We decided not to purchase a bigger shop and the high overhead costs that would undoubtedly come with it. Within the first year of our Lean journey, we had completely changed our shop to incorporate better product flow and eliminate time wasted from moving products and people around.

We also changed the way we purchased and batch manufactured our products. Instead of bringing 1,000 of this and a truckload of that, we bring in only what we need to make this batch of products.

Batch times went down 75 per cent, helping us to cut inventory in half. Meanwhile, lead times for our customers went down 75 per cent by cutting batch times.

The shipping/receiving position became

12

November/December 2015 • Manufacturing AUTOMATION

Micromo_MA_Nov.indd 1

2015-10-20 9:17 AM

a half-time position with the ability to do other things and support manufacturing activities by asking suppliers to deliver products to the point of use.

Our company became an employer of choice because the shop is clean, organized and safe for people to work in.

A Lean journey is never-ending — we still see things everyday that need to be improved.

However, taking the Lean manufacturing journey not only helped us survive the recession and the par Canadian dollar, it helped us build a higher quality unit, gain market share, become more profitable, and become a market leader by helping us keep our focus on providing value to our customers.

In 2014, our company set a record for sales and profits while keeping all manufacturing under one roof, reducing batch times to under three days and using 33 per cent less labour per furnace.

And so, the journey continues... • Ryan Friesen graduated from the University of Manitoba with a B.Comm. (Hons) degree. He has worked in manufacturing since 2005 and helped install Lean manufacturing processes at SteelTech Inc.

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STAYING

STRONG The 2015 Canadian Manufacturing Study finds industry maintains strength during rocky times BY aLYssa daLTon

I

n a year of fluctuating markets with some international powerhouses displaying months of economic decline (China, anyone?), Canada has managed to stay afloat. In fact, according to the data we collected from the 10th annual Canadian Manufacturing Study, very little of our economy has actually changed.

Conducted by Manufacturing AUTOMATION in conjunction with the Excellence in Manufacturing Consortium (EMC), the annual survey is designed to give insight into the Canadian manufacturing sector. And that it certainly did, providing segment snapshots and particular year-to-year comparisons of our economic performance.

The good news is that for the sixth consecutive year, production has increased for more than half (56.34 per cent) of respondents, though that number isn’t quite as strong as last year’s 59.4 per cent. In turn, nearly 70 per cent reported annual revenues below $49 million, this is a jump up from last year’s 63 per cent. Meanwhile, a number of respondents noted they plan to increase engineering/R&D, sales and service, and sourcing over the next three years. Where will this expansion take place? Nearly three-quarters of respondents say they plan to stay close to home and expand in Canada.

So what’s holding Canada’s competitiveness back? 52.3 per cent of respondents suggest it is the availability of skilled labour. This number is up from last year’s reported 51.4 per cent and 30.8 per cent in 2013.

While Canada maintained strong numbers in 2015, it’s important we proceed with caution, as survey data hints 2016 could be a year of change for many. While 22.9 per cent of respondents say they have already experienced a turnaround, 38.1 per cent say they expect to see improvements sometime in 2016, while 10.7 per cent say their year is 2017 and beyond. Alas, only time will tell what changes will occur, but I must say I’m already looking forward to next year’s data.

“Our owner is getting older, losing interest, but he does not want to relinquish any control — [it is] frustrating trying to move into the future with a leader who is bored of leading but won’t let anyone else step up to do it.”

14

“Just in the past few months, our customers have had bigger orders, more demanding timelines, and new customers have come in the door.”

November/December 2015 • Manufacturing AUTOMATION

HIGHLIGHTS:

The average hourly wage has just barely inched up over the last year, according to respondents. This year’s average hourly wage for workers on the plant floor is $22.41 — just 17 cents up from last year’s average of $22.24. nearly 70 per cent reported annual revenues below $49 million, this is up from last year’s 63 per cent.

58.11 per cent — more than half of this year’s respondents — say they do not use robotics in their manufacturing operations. nearly three-quarters of respondents listed Canada as the number-one location for expansion, followed by the United States. Canada is also the top spot respondents say they are interested in acquiring customers from. A number of respondents also listed Mexico, South America and Asia as their preferred location for expansion.

Just under 60 per cent anticipate their company will increase spending on capital equipment and technology over the next three years. This is down slightly from last year’s 61 per cent. Meanwhile, about 32 per cent noted no change at all, which is a touch higher than last year’s 31.7 per cent.

Production was the top area cited for expansion over the next three years by more than half — 60 per cent — of respondents, similar to the 61 per cent from last year.

Like previous years, the availability of skilled trades and labour cost rare the top two barriers to future competitiveness. increased competitive from Asia, low Canadian dollar, and poor oil price were suggested responses from respondents.

Lean manufacturing was the clear plant improvement strategy of choice, deployed by 51 per cent of respondents. This is down slightly from last year’s 52 per cent. What’s interesting to note is that the “none” category has decreased while the percentage of respondents who have implemented Six Sigma and software integration services has increased.

About 51.76 per cent of respondents have seen an increase in demands from current customers, but this is down from last year’s 58.5 per cent. Strangely enough, this is almost the exact same as the 51.8 per cent who saw an increase in 2013. •

“Without skilled labour, expansion is impossible. Just keeping at an even keel is difficult as no one from tech schools wants to do conventional machining.”

“The turnaround we have seen [has] more to do with an aggressive sales effort than the falling Canadian dollar or government policy.”

“The future for automotive manufacturing at Tier 2 level has poor prospects looking out 5-10 years. Responsibility is being pushed down further and further from the automotive OEMs and it will require some consolidation of companies through buy out or attrition in the Tier 2 stamping sectors to continue to compete. Where will the needed money to buy out competition come from with the tiny margins Tier 2 suppliers work from?”

company snapshot What is your current title?

Owner/partner

Senior manager/director

Senior executive (CEO, president, CFO, COO, VP, etc.)

18.96%

Manager/supervisor

14.22%

Salaried employee

Professional

26.64%

Hourly employee

15.80%

11.29%

4.74%

8.35%

What industry sectors do your products serve?

What type of manufacturing does your company engage in?

45.15%

27.09%

27.77%

Process

Discrete

Both

(Note: respondents were able to select more than one industry as their primary industry.)

What is the primary sector you serve?

What other sectors do you serve?

How long has your company been in business?

3.80%

4.99%

5 to 9 years

Less than 5 years

14.01%

77.20%

more than 20 years

10 to 20 years

31.60%

25 – 49 people

14.90%

50 – 99 people

17.16%

62.20%

37.80%

Aerospace

41.07%

58.93%

100 – 199 people

13.77%

Chemicals

45.16%

54.84%

200 – 500 people

11.51%

Computers/electronics

53.06%

46.94%

11.06%

Consumer goods

65.05%

34.95%

More than 500 people

Energy

36.36%

63.64%

Food/agriculture

55.79%

44.21%

Industrial equipment/machinery

65.96%

34.04%

Mining

42.11%

57.89%

Pharmaceuticals/medical

38.89%

61.11%

Plastics

42.86%

57.14%

Textiles

48.15%

51.85%

Wood products/furniture

54.17%

45.83%

27.54% 10.63% 3.38%

What is the average hourly wage (rounded to the nearest dollar) for your workers on the plant floor?

The average hourly wage for workers on the plant floor is $22.41. That’s just 17 cents up from last year’s average of $22.24.

$8-14

28

$15-19

121

$20-24

94

4.11% 2.90%

Power generation

5.41%

Moulding

8.11%

Welding/forming

20.81%

Material handling

27.30%

Assembling

28.92%

Production control

30.54%

Testing/inspection

29.46%

Packaging

14.59%

Extruding Less than $10 million

$50 million – $99 million

$10 million – $49 million

$250 million – $499 million

$100 million – $249 million

3.78%

Bending/forming

More than $1 billion

$500 million – $1 billion

$25+

117

For equipment purchases over the next year, which of the following production activities will be targeted? (multiple responses allowed)

41.30%

5.80%

Fewer than 25

Automotive

What is the approximate annual revenue for your firm?

4.35%

How many people work at your company?

N/A

12.97%

Stamping

6.49%

Sensing

8.11%

Mixing

3.51%

None

8.92%

Other

15.14%

Do you anticipate your company increasing or decreasing spending on capital equipment and technology over the next year?

Increase by more than 10%

19.73%

Increase by around 10%

Increase by around 5%

12.53%

26.93%

No change

32.00%

Decrease Decrease by around by more than Decrease by 10% 10% around 5%

3.73%

1.60%

3.47%

www.AutomationMag.com • November/December 2015 15

Strategies for growth What is your best estimate at a dollar amount for how much manufacturing technology, software and related capital equipment and services your firm will purchase over the next year?

What information technology applications is your company currently using? (multiple responses allowed) Enterprise resource planning (ERP)

38.26%

Product life cycle management (PLM)

8.97%

28.38%

Design (CAD, CAE, CAM)

68.34%

Product data management (PDM)

17.68%

$25,000 – $49,000

Customer relationship management (CRM)

26.39%

Asset management (CMMS)

12.66%

Warehouse management systems (WMS)

13.72%

RFID systems

8.18%

Financial management systems (FMS)

25.33%

Material requirements planning (MRP)

30.87%

Manufacturing execution systems (MES)

12.66%

7.84%

Mobile management (wireless systems)

10.29%

Supply chain management (SCM)

15.57%

More than $1 million

Demand planning/forecasting systems

17.15%

None

9.23%

Other

3.69%

Less than $25,000

16.49%

$50,000 – $199,000

22.43%

$200,000 – $499,000

14.59%

$500,000 – $1 million

10.27%

What strategic practices does your company use? (multiple responses allowed)

29.73%

45.14%

69.46%

Energy management

20.54%

Continuous improvement

21.62%

24.86%

Kaizen events

Quality certifications (ISO)

Benchmarking

Total productive maintenance

42.70%

Customer satisfaction initiatives

27.30% 14.86%

51.35%

Six Sigma Software integration services

Total Quality Management

Lean Manufacturing

5.95%

3.78%

Agile Manufacturing

42.70%

12.43%

Value stream mapping Supplier management programs

22.97%

Other

20.27%

Recycling program

7.30%

Quick None changeover/ single-minute exchange of die

0.81%

Other

How important is the use of robotics in your manufacturing operations?

What plant improvement strategies does your company employ? (multiple responses allowed)

25.14%

23.24%

None

58.11%

13.24%

17.84%

7.30%

Not at all important – we do not use robotics Somewhat unimportant – we use few robotics Somewhat important Very important – we strongly depend on the use of robotics Critical – robotics is integral to our operation

3.51%

Over the next three years, do you plan to expand Production

Where will this expansion take place?

Engineering/R&D

60.11%

38.52%

Sourcing

No expansion planned

15.85%

21.86%

Sales and service

What regions are you most interested in acquiring customers?

Decreased

16.80% 10.00%

16

Asia

United States Stayed the same

14.05%

16.53%

November/December 2015 • Manufacturing AUTOMATION

31.71%

4.17% Others

17.22% 51.76%

United Kingdom

61.16% 28.06%

1.37%

Has demand from your current customers Increased

2.22%

Canada

Other

45.90%

7.44%

68.87% 71.67%

No expansion planned

year-to-year comparisons

in the next 12 to 18 months, which is most likely to happen at your plant?

our company’s total production has:

2015 2014 2013 2012 2011 2010 2009 2008 2007 11.83%

14.7%

11.3%

17.0%

12.1%

16.3%

6.9%

17.3%

16.3%

20.85%

18.9%

21.7%

20.2%

22.9%

13.6%

10.9%

10.7%

13.6%

23.66%

25.8%

25.2%

20.6%

24.8%

22.8%

12.4%

20.0%

22.8%

25.35%

22.5%

24.3%

23.1%

22.1%

18.0%

19.8%

20.0%

18.0%

7.61%

9.0%

8.4%

9.4%

8.6%

12.9%

14.4%

12.0%

12.9%

6.20%

5.1%

4.6%

5.1%

5.4%

6.8%

6.9%

4.0%

6.8%

4.51%

3.9%

4.3%

4.7%

4.0%

9.5%

28.7%

16.0%

9.5%

increased more than 15%

Decreased less than 10%

increased 10 – 15%

Decreased 10 – 15%

increased less than 10%

Decreased more than 15%

no change

Merger/acquisition

49.58%

4.99%

Closure

Expansion

0.55%

39.61%

Contraction (layoffs)

5.26%

What do you see as the prime barrier to your company’s future competitiveness?

not changed

Availability of skilled labour

52.26%

the price of our product(s) has:

Government red tape

20.62%

2015 2014 2013 2012 2011 2010 2009 2008 2007 3.10%

2.1%

1.5%

1.4%

3.5%

2.7%

2.9%

5.3%

12.0%

11.27%

8.8%

7.3%

5.4%

9.2%

9.9%

7.3%

14.7%

12.0%

32.11%

31.4%

34.3%

37.2%

39.9%

31.5%

27.3%

50.7%

52.0%

46.76%

44.5%

46.3%

44.8%

36.9%

39.0%

40.5%

20.0%

17.3%

4.79%

10.4%

7.6%

9.4%

8.1%

12.0%

13.7%

9.3%

13.3%

0.85%

2.1%

1.2%

1.4%

1.6%

3.1%

4.4%

0.0%

5.3%

1.13%

0.6%

1.8%

0.4%

0.8%

1.7%

3.9%

0.0%

5.3%

increased more than 15%

Decreased less than 10%

increased 10 – 15%

Decreased 10 – 15%

increased less than 10%

Decreased more than 15%

not changed

Tax policy 12.99% Labour cost 42.37% Work rules11.30% Labour policy 9.60% High Canadian dollar

22.60% Other 13.56% What is your company’s status relative to implementing advanced safety technologies?

Have implemented and are fully compliant

34.90%

Have a plan and have begun implementation to comply

30.75% 8.59%

Don’t have funding to undertake implementation

our manufacturing costs have:

Don’t apply advanced safety technologies

25.76%

2015 2014 2013 2012 2011 2010 2009 2008 2007 reports indicate that manufacturers are optimistic about canada’s economic prospects over the next 12 months. When do you predict seeing improvements and/or a significant turnaround?

7.76%

5.9%

5.4%

8.1%

7.4%

9.8%

10.0%

30.7%

24.0%

18.28%

18.0%

14.4%

20.4%

22.8%

14.8%

12.9%

16.0%

24.0%

39.89%

42.6%

48.6%

40.7%

38.7%

34.7%

30.6%

20.0%

56%

23.27%

19.8%

22.0%

18.6%

17.2%

21.2%

20.6%

8.0%

6.7%

We have already experienced a turnaround

7.76%

10.9%

6.5%

8.8%

11.9%

13.1%

17.2%

14.7%

13.3%

22.88%

2.22%

2.4%

2.0%

2.8%

1.9%

4.0%

5.3%

4.0%

0.0%

0.83%

0.3%

1.1%

0.7%

0.0%

2.4%

3.3%

6.7%

0.0%

increased more than 15%

Decreased less than 10%

increased 10 – 15%

Decreased 10 – 15%

increased less than 10%

Decreased more than 15%

not changed

Beyond 2017

3.95%

We do not expect to see a significant turnaround

15.25%

By 2017

6.78%

By mid 2016

13.56%

By late 2016

10.17% A total of 443 respondents took the survey over a five-week period in August - September 2015.

The survey was emailed to our readers and the members of the Excellence in Manufacturing Consortium (EMC).

By the end of 2015

12.99%

By early 2016

14.41%

www.AutomationMag.com • November/December 2015 17

E ff i c i e n c y

Floor movement

Moving-floor assembly line streamlines production of large-scale farm equipment

By Patrick Roberts

L

ocated in the very heart of Canada’s Saskatchewan farm country in the small town of St. Brieux, is Bourgault Industries, which since 1974, has designed, manufactured and distributed farm equipment for seed planting and tillage. Recently, the company added 184,000 sq. ft. of production area to one of its several manufacturing facilities in St. Brieux. The main goal of the expansion was to consolidate its tillage product line into one manufacturing facility, and increase efficiency by reducing the handling and transporting of parts.

Like many farm equipment manufacturers, Bourgault’s equipment is not only built to be heavy-duty and durable, but very large in size. Its tillage equipment can vary in size up to 125 ft. in width, weighing in at over 75,000 lb. Assembly-line systems, conventionally employed for large equipment — such as drag-line conveyors that move products between stations or cells where specific tasks are performed — lose efficiency, productivity and safety when dealing with assembled-equipment requirements of such large size.

The manufacturing of Bourgault’s tillage equipment is segmented into two different sections. The 18

framework is welded together, powder coated, and then hydraulic cylinders are installed in one section of the plant. This assembly is then moved to another section of the plant where ground openers, fertilizer and seed dispensing systems, and other options specified by customers, are assembled and tested. It was in this assembly stage where Bourgault engineers confronted their biggest challenge in designing a more efficient and streamlined system to integrate into its newly-expanded facility.

Engineering an ultra-large-scale moving-floor assembly line

“We conducted considerable research on different systems for assembly of our tillage equipment,” said David Konopacki, lead engineer with Bourgault. “We consulted with a number of system manufactures, but none could provide a solution to meet our needs, because the sheer size and weight of our tillage equipment exceeded their systems’ capabilities.”

After assessing many different options, Bourgault’s internal engineering team, led by Konopacki, determined that a moving-floor assembly line would deliver the best throughput

November/December 2015 • Manufacturing AUTOMATION

volumes and cost efficiencies for the company’s needs. The idea was to have the moving floor not only support the tillage equipment during assembly, but to also have it support the kitting systems and parts to be assembled, as well as the workers doing the assembly. By the time the tillage equipment reached the end of the assembly line, it would be completely assembled and tested, and ready to be discharged from the moving assembly floor, and destined for warehousing or shipping.

To facilitate bringing this design concept to fruition, Bourgault brought in PFlow Industries to co-engineer and build the moving-floor assembly system. Working in tandem, the PFlow and Bourgault engineering teams came up with an ultralarge-scale moving-floor assembly system. The design utilizes a string of 25-ft. x 10-ft. wheeled carts, with a working surface of steel plates to support the tillage equipment and the workers performing the assembly functions. These 37 cart segments were designed to be queued end-toend to form a continuous 370-ft. long x 25-ft. wide floor, which would be pushed along on rails by hydraulic cylinders. As the carts reached the end of the line, the completed tillage equipment

would be rolled off from the assembly system.

The carts would then be lowered, and transported underneath the assembly system back to the front of the line to be reused.

“PFlow initially caught our interest because of the company’s existing product line of vertical lifts,” continued Konopacki. “We were looking for a solution on how to lower the carts down underneath the system once they had reached the end of the line, and how to raise the carts back up, after being transferred underneath to the front of the system where they could be reused. Not only was PFlow able to design a custom downlift and uplift solution that fit our needs, but the company also engineered the entire moving-floor assembly system, based on our initial design concept, then manufactured and installed it.”

Engineering on the project was started in July 2013, in tandem with the design of the building site. Since the assembly surface of the moving-floor system was designed to sit level with the manufacturing plant’s floor, virtually the entire system resides below floor level. A 496-ft. long x 32- ft. wide x 9-ft. deep concrete-lined pit had to be constructed when the foundation of the building was laid, to house the system. By February 2015, the moving-floor assembly system, consisting of almost a million pounds of fabricated steel, was fully installed and operational.

Mechanics of floor movement

The moving-floor system utilizes 37 wheeled carts at any given time on the working surface. The carts ride along on an underneath treble-rail system. An additional nine carts are simultaneously in transition at the ends of the floor, and being transported underneath the system.

The carts, which weigh in at 9,000 lb. each, are not propelled individually, but instead, the first cart is pushed using an innovative pair of servo-controlled hydraulic cylinders that propel the entire line of carts. Each pusher incorporates position feedback that is fed to a PID servo-hydraulic controller enabling precise control of position, velocity and acceleration of each pusher.

While the first pusher moves the string of carts at a constant speed, the second pusher extracts the next cart from a front-end vertical lift (which brings returning carts up from below the system), accelerating it to catch up to the moving line of carts. The second pusher smoothly matches the speed of the line, and ultimately takes over moving the entire line at the same established speed. Once the second pusher has control, the first pusher returns to the front end of the string of carts, and then smoothly takes over moving the string again. The second cylinder now moves to once again extract the next cart from the front-end vertical lift and accelerates it to catch up to the moving line of carts. This sequence of synchronized handoffs between the two hydraulic pushers is repeated over and over to continuously move the floor surface.

“This synchronized handoff of the hydraulic pushers is a key feature of the design,” said Mark Webster, vice-president of engineering at PFlow.

“We looked at many different ways of accomplishing the movement of the floor. The tillage machines impose multiple 20,000-lb. point loads to the moving surface. Because of this, and other unique characteristics, conventional assembly line systems such as tow conveyors or flat-top conveyors were quickly ruled out as options.”

“Each cart contacts adjacent carts at a single

contact point, mid-point of the width,” continued Webster. “This arrangement allows each individual cart to follow the rails in sequence, eliminating the need for highly accurate rail alignment and adjustment of contact points. The carts remain in contact entirely due to the backpressure created by the normal friction in the system. Deceleration of the moving floor is precisely controlled to be less than the normal deceleration due to friction, such that the carts never lose contact with each other during normal operation.”

The speed of the moving floor is user-selectable, ranging between 0.125 ft. and 3.25 ft. per minute, effectively taking between 1-3/4 hours and 45 hours for the floor to make a full transition.

Cart return

As a cart reaches the end of the moving-floor, it is pulled free of the line and discharged onto a vertical hydraulic downlift that lowers it to a unique return transport system, which transports the cart back to the front end of the system. The cart is then moved onto a vertical uplift, which raises it back up to infeed at the front of the moving floor, where it is positioned to be reinserted again onto the front of the moving floor.

“The cart return system must run at a much higher travel speed than the carts making up the working floor system,” explained Webster. “Many methods for transferring the carts from one zone to the next were considered, such as tow conveyors, slat conveyors and pushers, but none of these systems proved efficient enough for our needs.”

The engineering team did select a return-cart drive system which propels the cart along crane rails underneath the moving floor. The system’s technology, manufactured by OCS IntelliTrak, uses a spinning tube driven by a geared electric motor as the driving mechanism. Spring loaded elastomeric wheels on the bottom of the carts engage the spinning tube at a 45-degree angle, essentially operating as a friction screw to propel the carts along the rails.

Safety

“This moving floor was designed with stringent safety considerations in place,” added Konopacki.

“Deflection of the adjacent floor carts during maximum loading conditions is limited to no more than one-eight inch to avoid presenting a trip hazard to the workers. A safety latch system is incorporated that will prevent the carts from separating more than 1/4 in. in the event of an abnormal incident, and to protect personnel on the moving floor. There are no pinch points, chain lugs, hooks, or carts with exposed wheels. It simply consists of a flat moving surface.”

The entry and exit ends of the moving floor are protected by physical guards, preventing access to the transfer areas. A light grid warns the users if an object or person is getting close to the end of travel, and a safety light curtain, further downstream,

generates a system fault in the event of interruption, immediately shutting down all motion.

Controls

The control system incorporates an Allen Bradley Micrologix PLC for the control logic, and a Delta Computer Systems servo hydraulic controller to control the hydraulic pusher motion and synchronization. Ethernet IP is used for communication between the various controllers, and to communicate instructions to and from Bourgault’s production control system.

A virtual private network (VPN) router has been added to allow remote access by PFlow technicians for trouble shooting, adding program features, or updating the screens on the four human machine interface (HMI) touchscreens that provide user control. Password protection is provided to allow access to additional screens for maintenance, troubleshooting and manual control of individual motions. A detachable HMI is also supplied to be used in the lower pit area for maintenance, allowing technicians to control the various motions manually from within that area.

Performance

This system allows for the efficient assembly of Bourgault’s tillage equipment by providing a method for workers, tools, components and materials to move along with the assembly. Although the system has just gone into operation, Bourgault estimates a productivity increase of 30 per cent, due in large part to the ability to stage components and materials along the line at the specific point when they are needed, and to have them travel along with the tillage equipment.

“By any standard, Bourgault’s moving-floor assembly line is an extraordinary system,” said Webster. “Because of the simplicity of the servo hydraulic pusher system compared to conveyors or individual drives for each cart, this system offers significantly improved cost verses performance as compared to conventional methods of moving large machines during assembly. And because of the fewer moving parts compared to such systems, maintenance costs and downtime will be considerably reduced.”

The moving-floor system has the flexibility to add different Bourgault product lines, even with weight increases, if desired. And it has the ability to match the speed of the moving floor to the rate required for the assembly of different equipment.

“Our research shows that nobody has anything else like it,” said Konopacki. It is quite unique.

Although we have yet to integrate our full production processes with it, all indications are that the system is running as expected, and working out very well for us.” • Patrick Roberts writes on advances in material handling technology. www.AutomationMag.com • November/December 2015 19

A utomat i o n

i n

act i o n

The grip is key Ramping up robotic assembly line tasks

By Treena Hein

R

obotic grippers are an integral part of many manufacturing lines today, and for good reason. They provide, among other things, very different gripping strengths and extensive handling dexterity for handling objects of various sizes, weights and fragility levels. They also allow for quick setup and changeover from one complex assembly task to another, saving critical time and money.

This type of gripping technology is exactly what Robotiq of Levis, Que., specializes in. Founded in 2008, the company has steadily grown the markets for its grippers, which can be found in factories worldwide. Robotiq grippers are used for three main tasks: general universal assembly, machine tending (feeding machines and also placing the completed part for the next step), and product testing. About half of Robotiq’s sales are in North America, with a quarter in Europe and another quarter in Asia. The most common sectors using Robotiq grippers are SME contract manufacturers, general industry component manufacturers, automotive tier, and electronics.

“The common need in all these companies, no matter what the sector, is flexibility,” explains Robotiq president Samuel Bouchard. “Companies generally manufacture a lot of different parts and need to adapt their production continuously.”

How they work

Robotiq makes two versions of its standard 2-Finger products as well as a 3-Finger universal Adaptive Robot Gripper. All of the grippers ensure that both the grip is correct and that the object continues to be held — intelligent gripping if you will, notes Bouchard. The feedback system for gripping pressure and detecting object presence employs a combination of motor current monitoring and encoder data.

In addition, the grippers are electric, which means cycle times can be slashed compared to situations where other grippers are used, according to Bouchard.

He says this is because electric grippers only open and close as much as needed, unlike pneumatic grippers which operate only from fully open to fully closed.

The electric aspect also allows adjustment of speed, force and finger position.

20

November/December 2015 • Manufacturing AUTOMATION

“So, our grippers give more options to the computation software by being able to pick a part from different orientations,” Bouchard notes. “This is a very important aspect in making efficient unstructured picking [bin picking] a reality.”

Case studies

Before we look at two companies where Robotiq grippers have helped boost automated manufacturing speed and efficiency, let’s check in on the typical scenario. “Usually companies who go with our grippers install it on a robot for a new cell,” says Bouchard. “Considering the high frequency of changeovers and the high mix of parts, it would be impossible to have an adequate ROI for their robotic cell using the traditional custom tooling approach.

Said another way, the use of a flexible Robotiq gripper really leverages the flexibility of the whole cell and makes it really worthwhile.”

Genesis Systems Group, a firm that specializes in the integration of robotic cells, needed a solution for an aerospace customer with a machine-tending task where different parts were being produced with an Okuma double spindle lathe.

One of the goals was to run the system unattended for the shift — lights-out manufacturing — and a big challenge was the wide range of parts that needed

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to be produced, parts from less than 1 in. to 6 in. in diameter.

Another major challenge was the fragility of some of the finished parts. The feeding gripper needed to be able to pick up blocks weighing as much as 25 lb., but the finished parts could deform with as little as 2 lb. of gripper force and be easily scratched. A gripper that could handle both challenges would be ideal.

Genesis designed a series of fingers resident on one Robotiq gripper, with some fingers being used for loading and some for unloading tasks — allowing a single gripper to do everything with no changeover required. The finger position and force could be selected by the robot and automatically controlled during the cycle. While the initial cost of this complex gripper was high, it was quickly offset by the reduction in tool changer complexity that would have otherwise been required, says Bouchard, adding that it also provides Genesis with great flexibility for future tasks.

Inertia Switch is another manufacturer that recently chose a Robotiq solution. The firm produces many types of switches for aerospace, mechanical and electrical products. Bouchard notes that at the time Inertia started to automate the process in question, they decided to create a conventional work cell that is fully guarded and cannot be easily reprogrammed. “The grippers they had were pneumatic and limited to a few parts, and since Inertia Switch makes over 1,000 different parts, they needed a more flexible solution to optimize their machine tending production process,” he notes. “Optimizing this process also meant that any machinist should be able to easily manage the robot system and the gripper with minimum setup time.”

Inertia chose the Robotiq 2-Finger Adaptive Gripper because it was the only solution that fits with most of their parts. Bouchard says ROI was achieved in less than a year and provides new application opportunities going forward.

After the installation, Slobodan Todoric, a machinist and programmer at Inertia Switch (pictured left), described the gripper as a “game changer.”

“The gripper is very flexible, it can pick up the small parts that we make at Inertia… it’s flexible. You can grab onto many different surfaces, round, square, whatever you want. It’s durable.” Todoric continues, “We got the software and we just loaded it up on the universal robot and it started working and it’s perfect, just plug and play.”

Although Bouchard and his team have accomplished a great deal and taken manufacturing automation to the next level, he believes we have only begun to see what robots can do on assembly lines and beyond. “For many years, we have moved so much information into the digital world, and now robots can use this information and act back on the tangible world. There are very exciting things to come.” • Treena Hein (treenahein.wordpress.com) is an award-winning Ontario freelance science and tech writer.

www.AutomationMag.com • November/December 2015 21 Asco_MA_Nov.indd 1

2015-10-19 2:32 PM

P ower

suppl i es

No interruptions here The power of keeping manufacturing productive

By William Cisler and John Roeslein

A

ccording to the U.S. Bureau of Labor Statistics, manufacturing sector labour productivity increased 2.3 per cent in the second quarter of 2015, as output increased 1.3 per cent. Meanwhile, productivity increased 2.8 per cent in the durable manufacturing sector and 1.2 per cent in the nondurable goods sector.

In order to ensure this productivity, these manufacturing plants need a constant feed of electricity — which can be a big appetite to feed. It is estimated that industrial operations consume about one half of all electricity generated worldwide, largely due to the massive, and constantly moving, mechanical operations such as industrial motors, pumps and production equipment.

When the power goes out, productivity suffers. Industry analysts estimate that downtime costs factories at least 5 per cent of their productive capacity, with some factories losing as much as 20 per cent of their productivity. Oracle Corporation has also underscored this fact by estimating that equipment downtime can cost large businesses an average of $100,000 or more per hour.

However, the power does not have to completely go out to wreak havoc on manufacturing plants. Fluctuations take all types of forms such as surges, brownouts and even overages. Consider this: a single voltage dip lasting only 100 milliseconds can have the same effect on an industrial process as a power outage lasting several minutes or more. Given the facts and figures, there is no doubt that power is one of the most critical concerns for the manufacturing sector.

The power of positive action

Although the aforementioned facts and figures paint a dim scenario for power outages, advances in power management technology have greatly enhanced the ability for manufacturing plants to continue operations in the event of a power issue.

To help ensure uninterrupted power, many manufacturing plants are now seeking a more efficient method to ensure operations continue in the event of a power interruption. Facility operators now realize that generators take time to get power to the critical equipment and this means interruptions in manufacturing process will prevail. And while smaller static uninterruptible power supply (UPS) systems have been implemented to support small, non-motor production loads, many facilities are starting to look toward rotary UPS technology to help prevent the specter of downtime and fully support entire portions of the production chain.

Understanding a UPS system’s value-add

UPS systems offer the best value-add for any manufacturing organization, because they fulfill the critical need for 24/7 electricity supply. The traditional option manufacturing organizations are moving away from is the high price tag of static-based battery systems that continually consume capital expenditures (CAPEX) funds with their continued maintenance and regularly required system updates.

In addition, plant managers look at every square inch of the floor space to find opportunities to maximize productivity. A significant amount of productivity space is typically consumed by hundreds of square feet of behemoth batteries. For instance, an estimated five minutes of battery of 400kW translate into nearly 200 sq. ft. of floor space. This is a significant amount of real estate that could be allocated towards revenue-producing manufacturing, but pillars of static power are consuming it.

Not only are these docile giants squatting on needed real estate; their lifespan is a short one. The typical lifespan of batteries in these static UPS systems is no more than five years. This translates into multiple removals, replacements and maintenance cycles — all of which cause a further drain on the plant’s checkbook.

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November/December 2015 • Manufacturing AUTOMATION

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2015-10-19 11:04 AM

A better choice to static battery behemoths A new portfolio of power options for the manufacturing sector can be found within a next-generation, diesel rotary-based system (DRUPS), which is an environmentally-friendly alternative to static battery UPS. Here’s why: • They integrate the traditional backup components into a single system.

When utility power is lost, the system retrieves kinetic energy from its induction coupling to support the critical load until the diesel engine takes over.

• This next-generation option lasts approximately 30 years, saving any manufacturing plant considerable cost compared to the five-year replacement option of traditional UPS systems.

• With no toxic battery chemicals to dispose of, DRUPS system is far more environmentally friendly.

• A DRUPS system produces clean voltage, which also carries the distinct advantage of being more reliable.

What’s nice about this option is that DRUPS systems replace all of the battery-backed static UPS equipment required to support critical IT loads, and the standby diesel generating equipment required for continuous power supply. By combining these two functions within a single, compact concept, DRUPS system provides tangible environmental benefits.

This latest advancement in technology also uses a power backup that is three per cent more efficient than typical UPS systems. While this may not seem like much, for a manufacturing plant operating 24 hours at anywhere from 7 to 11.5 cents per kilowatt-hour, this could mean millions of dollars of savings over the life cycle of a DRUPS unit.

As well, these systems are far greener than their predecessors because they do not use standby batteries for energy storage. A DRUPS system does not require components with significant environmentally damaging chemicals such as lead acid, nickel and cadmium.

A long-term solution

As stated at the beginning of this article, manufacturing plants are always concerned with efficiency and production. These new rotary UPS systems

achieve efficiency levels up to 97 per cent. Compare this to the overall efficiency level of static UPS systems using advanced, expensive IGBT inverters, move reach around 94 per cent at best.

In conclusion, as manufacturers look to reduce unwanted and unnecessary capital costs, they will continue to pursue next-generation technology in more efficient means to ensure productivity levels. The ROI for a DRUPS system is a much better option than the traditional UPS solution. This can actually be proven by determining the cost of a power outage to the entire manufacturing facility and dividing it by the total kilowatt load needed to be protected. If an outage costs the operation $200 per kilowatt load, an upgrade to a rotary system would pay for itself in just a matter of five power outages. As manufacturers begin to understand and evaluate these facts, it’s clear that selecting next-generation technology will improve productivity and decrease expenses. • William Cisler is vice-president, U.S.A. Engineering for Hitec Power Protection, a global technology company of UPS systems for the supply of uninterruptible, continuous and conditioned power to mission critical applications. John Roeslein is president of Robotic Systems & Automation (RSA). He has 35 years of experience in global manufacturing automation, working with large system integrators and the implementation of operational cost reductions in manufacturing facilities worldwide.

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www.AutomationMag.com • November/December 2015 23 2015-10-20 9:11 AM

S e nsors

Sensor

opportunities LVIT technology offers more flexibility for less money in factory automation applications

By Edward E. Herceg

A snapshot of an LVIT cutaway.

W

hat is an LVIT and where is it used? LVITs — Linear Variable Inductive Transducers — which have been around for more than 30 years, are relatively low cost, contactless position sensing devices that utilize eddy currents developed by an inductor in the surface of a conductive movable element that is mechanically coupled to the moving object whose position is being measured. The common form of an LVIT uses a small diameter inductive probe surrounded by a conductive tube called a spoiler. Typical LVITs have full ranges from fractions of an inch to 30 or more inches. Modern electronics utilizing microprocessors make possible outstanding performance, achieving linearity errors of less than ±0.15 per cent of FSO and temperature coefficients of 50 ppm/ºF, along with either analogue or digital outputs. See Figure 1 for a cutaway view.

LVITs are used in many factory automation applications, including packaging and material handling equipment, die platen position in plastic molding machines, roller positioning and web tension controls in paper mills or converting facilities, and robotic spray painting systems. Being contactless, the basic measurement mechanism of an LVIT does not wear out over time due to rapid cycling or dithering like a resistive device. LVITs also offer a much lower installed cost than that of most other contactless technologies.

While Figure 1 shows an LVIT that is intended to be attached to the part it is measuring, LVITs can also be spring-loaded, as shown in Figure 2.

The natural question is: where does one use a spring-loaded LVIT sensor versus another spring-loaded technology, such as an LVDT (Linear Variable Differential Transformer) gage head?

In fact, LVITs can be used in place of traditional gage heads primarily because, electrically, an LVIT offers the same resolution and repeatability, and mechanically, the same outer diameter and an external mounting thread but with about half of the length of the gage head —making the stroke-to-length 24

November/December 2015 • Manufacturing AUTOMATION

An LRS-18 sensor installed in the measuring slide position.

ratio of an LVIT substantially better. And all of these features come at a markedly lower cost. Why utilize a 9-in. long sensor to measure 1 in. of travel when the same performance can be achieved with a 4-in. long LVIT sensor?

LVIT-based gaging applications in factory automation typically mirror those for traditional gage heads, as shown here.

When compared to LVDT pencil gaging probes, a spring-loaded LVIT can satisfy many of the same applications: automotive, medical and mil/aero test stands, robotic arms, part placement, and shop floor dimensional gaging applications, to name a few. Pencil probes are typically selected for one of two reasons: resolution and repeatability, or size. Pencil probes are smaller (either 8 mm or 0.375-in. OD) than LVITs and have resolution and repeatability of four millionths of an inch. However a pencil probe requires a separate LVDT signal conditioner, making the cost per channel typically double the cost of an LVIT. If an application does not require the specific features of a pencil probe, a spring-loaded LVIT is a much lower cost alternative.

Some factory automation applications that have been solved by proximity sensors can be better satisfied with LVIT technology, which offers a proportional analogue output, giving greater control flexibility than merely an NPN or PNP TTL switching signal. The spring-loaded LVIT shown in Figure 2 has an 18-mm thread on its housing, matching a thread commonly used by proximity sensor manufacturers. With an LVIT’s short body length, the sensor can fit in places or mountings where there previously was a proximity probe. • Edward E. Herceg is currently vice president and chief technology officer of Alliance Sensors Group, a division of H. G. Schaevitz LLC. With a career in the sensors industry spanning more than half a century, he is highly regarded both for his applications engineering expertise and for his technical innovations.

P R O D U C T S

C OMMUNIC AT I O N S MTConnect FDI monitors machine tool performance

AN D

N E T W O R K IN G

and support. Using the Rockwell Software Studio 5000 design environment, engineers can leverage FactoryTalk View faceplates from Rockwell Automation and add-on profiles to simplify switch configuration and monitoring, notes Rockwell. www.rockwellautomation.com

Controller demo/evaluation kit

The Omega CNPT-DEMO PID controller boasts a fully integrated temperature control system suitable as a platform to investigate the use of closed loop (PID) and On/Off temperature control in heating and cooling applications. Its features include

“smart” menu flow, panel-mounted USB and Ethernet connectivity, an alarm indicator, a 4 to 20 mA remote set-point potentiometer, a pushbutton digital input, and an aluminum plate so the user can feel the temperature response. www.omega.ca

5ME says its Freedom Digital Interface (FDI) with integral MTConnect adapter allows shops with legacy equipment to monitor machine tool performance using the company’s Freedom eLOG or other MTConnect monitoring software. The FDI has eight digital inputs (24VDC or 120VAC) and two analogue inputs (0-10VDC), and each input is user-configurable based on specific use. An onboard adapter outputs a Simple Hierarchical Data Representation (SHDR) signal to the user’s MTConnect agent. 5ME’s Freedom eLOG software suite extracts manufacturing data to produce webbased reports and analytics on asset utilization, availability, performance, quality and OEE. It is brand, asset and process agnostic, says 5ME. The software also integrates with ERP, MES, maintenance and quality business systems, and can be accessed anytime via smartphone or tablet device, it adds.

5me.com

Industrial distribution switch

Rockwell Automation has expanded its portfolio of industrial Ethernet switches with the Allen-Bradley Stratix 5410 industrial distribution switch. With four 10-gigabit Ethernet ports, the switch claims to provide a high-performance connection to the rest of a facility’s network architecture. It can be used as a Layer 2 switch or a Layer 3 routing switch, which allows engineers to use it in various applications. With a 19-in. rack-mount design, the switch gives end users a centralized point of network distribution and increased port density, says Rockwell. It is ideal for heavy industry applications and has a rugged exterior to help withstand harsh environmental conditions, it adds. With embedded Cisco technology, the Stratix 5410 switch promises to help ease network configuration, management Yaskawa_MA_Nov.indd 1

www.AutomationMag.com • November/December 2015 25 2015-10-19 11:01 AM

P R O D U C T S

MOTORS

A N D

D R I V ES

Stepper motors

Additional frame sizes for waterproof AC induction motors

Empire Magnetics is offering stainless steel AC induction motors for frequent wetting and washdown environments, available in horsepower ranging from .5 to 20 HP.

Kollmorgen says its next generation of stepper motors, the PMX series, adds 8, 11 and 14 frame sizes to the traditional 17, 23 and 34 frame size offering. Users can also between several stack length and winding options for each frame size. According to the company, each frame size is built with “high quality construction which translates to reliability in the field and long service life.” Kollmorgen says the PMX stepper motors offer “Kollmorgen quality, co-engineering and support with short lead times and competitive pricing.” As well, the stepper motors boast high torque/ dollar ratio, options for 1.8 and 0.9 degree step angles, and localized technical support. www.kollmorgen.com

Users can choose between nine frame sizes: 56, 143, 145, 182, 184, 213, 215, 254 and 256. According to the company, typical applications include food processing, chemical and drug manufacturing, machine tools, paper making and film processing. Additional features of the AC induction motors include integrated design and solution, highly corrosion resistant, integral housing seals and double-sealed cable entry, notes Empire Magnetics. www.empiremagnetics.com

Variable frequency drive series

Mitsubishi Electric Automation has released the F800 series variable frequency drive (VFD) for “precise motor speed control with maximum energy-savings,” adding that it is specifically designed to improve efficiency of air movement through HVAC systems.

The F800 controls and supports various motor types, including AC induction and permanent magnet motors, which the company says eliminates the need to implement multiple VFDs for different motor control needs. An optional LCD display provides time-stamped logging and real-time clock scheduling functions, and captures and displays energy usage. The F800 comes in traditional chassis style, large system/ component style and is also available as a true turnkey bypass control solution. It is available in 200V and 400V classes. us.mitsubishielectric.com

Networking for brushless DC motors

Crouzet Motors has introduced CANopen technology for its brushless DC motors, which it says allows design engineers to connect multiple brushless motors to the various components in the system. According to the company, the technology reduces wiring and installation costs while increasing system communications and integrity. The CANopen interface permits connection of up to 127 brushless DC motors with a single, shielded two-wire cable. Data

may be transmitted at speeds up to 125 kBd at distances over 550 yards, notes the company. Embedded fieldbus control promises “integral protection for maximum life in severe environments, excellent reliability of data transmission, and immunity to external noise and vibration.” www.crouzet.com

ROBOTICS Robotic lance blasting system

separate cyclone separator, classifier and pressure pot for each. www.guyson.com

Automation catalogue

Robot with double yoke design

Guyson says it has designed and built a robotic blast system with an extended lance nozzle for precision grit blasting and surface preparation of the inside diameters of industrial gas turbine components in manufacturing and repair operations. A Fanuc M-710iC robot is integrated into the blast system as the lance manipulator in an expanded process chamber with a servomotor-driven rotary table that is controlled as an auxiliary axis of robotic motion. The blasting enclosure is fabricated with an added rear vestibule to allow room for full movement of the pressure-blast lance as the robot follows the tool path required for coverage of complex-shaped internal surfaces, notes Guyson. The custom blast machine is designed with an enhanced media reclamation and delivery system for two different grit sizes, including a 26

The Yaskawa Motoman MH24 six-axis robot features a curved upper arm that claims to “enhance its reach and allows a wider range of applications,” such as assembly, dispensing, material handling, machine tending and packaging tasks. According to the company, the double yoke design also offers additional strength if the robot crashes due to a programming error.

A 50-mm thru-hole in the upper arm provides space to help reduce wear and promote cable life, says Yaskawa, adding that the MH24 is the fastest robot in its class due to Sigma-5 motors and ARM (Advanced Robot Motion). This model has a 1,730-mm horizontal reach and a work envelope that extends behind the robot, providing space for robot tool storage and maintenance. It also has brakes on all axes and can be floor- or wallmounted. Additionally, a smaller 12 kg payload model is available (MH12). www.motoman.com

November/December 2015 • Manufacturing AUTOMATION

nozzles, retaining heads and contact tips, along with details. www.tregaskiss.com

Six-axis aseptic robot

Tregaskiss has announced the availability of its latest automation catalogue, featuring the latest information on the company’s robotic MIG guns, consumables and peripherals.

The 22-page, full-colour catalogue includes information about the Tough Gun CA3 and Tough Gun TA3 robotic air-cooled MIG guns, including configurator spreads.

These pages reflect the online configurators offered by Tregaskiss, which allow users to customize a robotic MIG gun based on amperage, neck and cable styles, power pin, gun mount and more. The catalogue also features a new foldout consumables reference chart that provides technical and compatibility information for

Denso Robotics says its VS-050 six-axis aseptic robot, which features an ISO 5 cleanroom rating, is designed for applications where biocontamination control is required. According to the company, a protective outer coating and sealed joints allow the VS-050 to be safely sterilized with hydrogen peroxide or UV light. The rounded exterior of the robot has no external screws, which helps to keep dirt, dust or other contaminants from adhering to its surface. Wires are internally embedded up to the flange and the control-cable connector is located on the bottom of the robot. The VS-050 aseptic model has a cycle time of 0.37 sec. and repeatability of ±0.02 mm, with a reach of 520 mm and a payload capacity of 4 kg. Typical applications of the VS-050 include assembly, dispensing, inspection, machine tending, material handling, packaging and test handling. www.densorobotics.com

P R O D U C T S

MACHINE

S AF ET Y

Safety specialist website

while the long size box features a stainless steel housing, 4-pole positive guided contacts, three conduit entries, a two-colour LED for status indication and includes an emergency stop legend plate. IDEM emergency stop control stations are cULus listed, CE, RoHS2 and REACH compliant. www.automationdirect.com

6-mm safety relay

Phoenix Contact says it is the only provider in the market with a 6-mm safety relay. The design of the safety module, it says, is made possible through its newly developed relay technology. The design is based on a force-guided basic relay characterized by minimal space requirements, low

energy consumption, and high system availability, it adds. According to Phoenix Contact, the component features the same performance as traditional EN 50205-compliant elementary relays with forced guidance. The elementary relay from Phoenix Contact consists of a NO and a NC contact. www.phoenixcontact.com

Motion Industries, a distributor of industrial maintenance, repair, and operation (MRO) replacement parts, has introduced one of several new knowledge websites: www.MiSafetySpecialist. com. Designed as an information hub, the Mi Safety Specialist site offers resources to the industrial world about workplace safety and safety product knowledge. Visitors will have the opportunity to access various content on the subject, including articles, videos, white papers, training materials and more. “We are committed to helping people make well-informed safety decisions. The new site is a platform where our safety specialists can provide expert tips and share resources to help others improve safety in their workplace,” said Randy Breaux, senior VP of marketing, product management & strategic planning. www.motionindustries.com

IDEM e-stop control stations

AutomationDirect has added IDEM emergency stop control stations to its line of pushbuttons. Designed to provide “robust emergency stop protection,” the switches have a lid safety trip mechanism which opens the contacts if the station lid is removed, according to AutomationDirect.

Versions are available with a button protection shroud that accepts a padlock to lock out for maintenance activities, promising added protection. The units are available in two styles which are fitted with a 40 mm twist-to-release mushroom head operator; the standard size box features 3-pole positive guided contacts and is available with plastic IP67-rated or IP69Krated (NEMA 6) stainless steel housings and two conduit entries,

247 Lynnfield Street Peabody, MA 01960 800.921.3332 www.HarmonicDrive.net

Electromate Industrial* 6221 Highway 7, Unit #15 Vaughan, Ontario, Canada L4H 0K8 www.electromate.com

Harmonic Drive is a registered trademark of Harmonic Drive LLC. Robonaut image courtesy of NASA/JPL-Caltech. * Electromate Industrial Sales is the exclusive Canadian distributor of Harmonic Drive® products (except the Province of Alberta).

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www.AutomationMag.com • November/December 2015 27 2015-09-23 9:43 AM

P R O D U C T S

AUTOMAT I O N

S O F T WAR E

M AT E R IA L

PLM platform release

Aras has announced general availability of Aras Innovator 11, which introduces visual collaboration using “secure social technology” in the platform, it says. According to Aras, the new capabilities promise a faster, simpler way to collaborate across disciplines, locations and organizations.

With the software, teams from engineering, operations, quality and the supply chain can communicate about products more effectively, make decisions quickly and solve problems faster, notes the company. The software covers various data types including

H A N DLING

Pulse assembly line technology

3D, 2D, schematics and layouts, Microsoft Office and images.

It also offers discussion threads with embedded viewables that are linked with text comments to other users with the proper permissions. www.aras.com

CRITICAL INDUSTRY DATA IMPORTANT BUSINESS DECISIONS

Kuka Systems North America has launched the Pulse carrier conveyance system for automotive car body assembly lines. The concept utilizes linear synchronous motor technology provided by MagneMotion to move body sections through robotic work stations along assembly lines as joining and other functions are performed.

According to the company, Pulse technology is “extremely fast and flexible” and 30 per cent faster than conventional friction-based transfer systems. The line uses solid state linear motors, giving the Pulse system fewer wear components that require maintenance causing unscheduled downtime, says the company. A Pulse line can be configured to handle up to four models, notes Kuka Systems, and boasts a flexible design that allows it to be adapted to the physical conditions at each assembly plant. www.kukanao.com

Sanitary conveyors now BISSC certified

• LABOUR MARKET SUPPLY & DEMAND • TRACK KEY WORKFORCE TRENDS • CUS T OMIZED L MI REPOR T S • EVERGREEN INDUSTRY DATA

QC Industries’ HydroClean Sanitary conveyors are now BISSC certified. BISSC, which stands for Baking Industry Sanitation Standards Committee, is a distinctive certification recognizing that their conveyors conform to the American National Standards Institute

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features include a self-draining stainless steel frame, bearings filled with solid lubricant, and a tension release tail and flip-down stand brackets for belt sterilization and in-place cleaning. www.qcconveyors.com

Walkie counterbalanced stacker

Blue Giant Equipment Corporation has added a walkie counterbalanced stacker to its Big Joe by Blue Giant line of AC-powered industrial trucks. The CB-33, which has a 3300-lb. load capacity, can transport and stack pallets that straddle stackers find challenging to handle, says the company. The AC motor boasts travel speeds of up to 3.1 mph under load, and a multi-function steering control handle that promises to deliver superior load handling control and maneuverability. According to Blue Giant, the “optimized gear design reduces noise emissions during use, resulting in a quieter, more employee-friendly workplace.” www.bluegiant.com

I N D E X

Advantech industrial Automation Group .............................23

KUKA Robotics Canada Ltd. ..................22

Allied Electronics inc. ..................... 1 + 13

MiCROMO.............................................12

ASCO numatics .....................................21

Murrelektronik Canada ...........................3

AutomationDirect.................................iFC

Rittal Systems Ltd....................................7

Beckhoff Canada .....................................5

SCHUnK intec Corp. ............................ iBC

Eaton Canada .......................................11

Siemens Canada Ltd...........................OBC

Encoder Products Company ....................6

Techspan industries inc. ........................29

Excellence in Manufacturing Consortium ........................................28

Unitronics, inc. ........................................6

Lafert north America .............................10

Harmonic Drive LLC...............................27

yaskawa America, inc. Motoman Robotics Division ..................25

HARTinG Canada inc. .............................8

yves Landry Foundation ..........................4

Hiwin Corporation...................................9

November/December 2015 • Manufacturing AUTOMATION

EMC_MA_Nov.indd 1

(ANSI) qualification for design of bakery equipment. The conveyors belts are made with nontoxic material and available with anti-microbial and totally encapsulated options. A pull-pin design allows every HydroClean conveyor to be disassembled without the use of tools, notes the company. Other

2015-10-19 11:21 AM

P R O D U C T S

P R OCE SS

CO N T RO L

MeasurLink 8.0 gauge measurement

The Mitutoyo MeasurLink 8.0 promises to add increased performance and functionality to the entire suite of SPC software.

According to the company, reporting capabilities have been enhanced to allow easier customization of report templates.

In addition, the MeasurLink Team has reintroduced the gauge management module, not found in Measurlink 7. Other new functions in MeasurLink 8.0 include gauge tracking and calibration record retention modules; fullyannotated calibration procedures; customizable lookup of gauge inventory by location, status or user; configurable security settings; and automated printing of certificate on completion of calibration. www.mitutoyo.ca

performance without compromising power, while only consuming 95uA/MHz in active power and 850nA in standby power. According to the company, the MSP432 MCUs enable designers to “develop ultra-low-power embedded applications” such as industrial and building automation, industrial sensing, industrial security panels, asset tracking and consumer electronics where both efficient data

processing and enhanced low-power operation are essential. In addition, a 14-bit ADC consumes 375uA at 1MSPS. MSP432 MCUs include a selectable RAM retention feature that provides dedicated power to each of the eight RAM banks needed for an operation, so overall system power can be reduced by 30nA per bank, explains the company. www.ti.com

MULTI-POLE CONNECTORS Speciality versions Non-Metallic, Aggressive Enviroment, EMC & High Temp *available upon special request

Pinch valve series

Festo’s pinch valves VZQA with full bore passage claim to be a cost-efficient and energy-efficient alternative to diaphragm and ball valves in process automation applications. Festo describes them as a clean and technically straightforward solution for controlling and shutting off a range of media flows, whether liquid, fibrous, particulate or granular.

Full bore passage minimizes flow resistance, preventing the valve from becoming blocked or clogged, so media flows freely, it adds. VZQA pinch valves come in two versions: a normally open (N/O) version for media pressures from 0 to 4 bar and a normally closed (N/C) version for 0 to 6 bar media pressures.

The components of the VZQA are individually configurable, whether it’s connection types, materials or pinch valve sleeves, adds Festo. www.festo.com

• Ideal for Industrial and O.E.M. Markets • IP Rating up to IP67 (IP68 and 69 available upon special request order) • Available in 1 to 216 pole inserts. Ranging from 5 to 200amp (Based on pole configuration, 600v rating) • Screw, Crimp & Spring clamp termination • Rugged die-cast aluminum alloy housing with stainless steel levers & springs, thermoplastic glass fibre handles • CSA, UL, CE, ROHS approvals

32-bit MSP432 microcontrollers

Texas Instruments says its MSP432 microcontroller (MCU) platform is the industry’s lowest power 32-bit ARM Cortex-M4F MCUs. The 48MHz MCUs claim to optimize

Tel: 905-820-6150 Toll Free: 1-800-363-1588 Email: sales@techspan.ca

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www.AutomationMag.com • November/December 2015 29 2015-05-13 9:36 AM

B A C K S T O R y

The change in machinery 2003 In anticipation of Manufacturing AUTOMATION’s 30th anniversary next year, we will be digging through our archives for a look at various topics we have covered over the years to see how they have transformed our industry. But what good is it to simply look behind? Backstory will work to provide you with a fuller understanding of each theme by offering industry perspectives on where we’ve been and where we’re going.

I

n the span of just two decades, computerization has altered the landscape not only for my industry, print communications, but every manufacturing sector in Canada. Not so long ago, printers (those skilled and trained operators) had complete control of the entire printing process. Quality varied wildly since skills and craftsmanship had no set standards from shop to shop.

In the halcyon days of print, many a company pushed the envelope on quality and it showed as the public could actually see the difference in reproduction. Annual reports for large corporations were reserved for this small group of “lithographers.” They paid their skilled operators more money and almost always were first to buy the next latest gadget that would keep them at the top.

Then along came computers. No printer could really fathom the changes that were in store for them. The initial response was positive from management but those seasoned operators who did everything with a manual touch refused to see how a computer could put a printing plate on a press or even adjust the ink keys properly. It took at least a decade for the transition to go from operational ability to pushing buttons.

But two things altered the landscape since the beginning of the 1990s. First came dependability in machine construction. It wasn’t only operators that were exposed to the computer but also the guys that made the machinery. Old problems of poor designs, fast wearing undependable parts, became a thing of the past. Manufacturers using consistent CAD engineering could now make machines faster with more features at lower prices and less likely to break down.

The other watershed moment saw the World Wide Web enter the landscape. Just as these workers started to take advantage of easier to run, bullet-proof machines, the Internet arrived and played havoc with print, as so much of what we produced was suddenly no longer relevant and needed.

Digital print, using toner and ink jet devices, is the new technology for print. With it comes an even more simplified world, less needed skills and entirely in the hands of software.

Ironic then that the print sector finds itself in a bouillabaisse with other Canadian industries. Technology and the ability to communicate difficult design and manufacturing problems, is racing faster than ever before. New technology (e.g. 3D printing) is creating so many new possibilities that what we did yesterday will be redundant tomorrow.

2009

2004

1998

1998

2009 — Comments by Nick Howard C.E.A., president of Howard Graphic Equipment.

He has been involved in the printing industry since 1976, first as a technician, then latterly managing the sales and administration with wife and partner, Liana.

2008 2008

2008

30

November/December 2015 • Manufacturing AUTOMATION

Meistermacher.

Made in Germany.

Dominic Schneider, Master – Workholding Technology

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SINAMICS G120 advantages at a glance • Works with wide range of communication protocols • Innovative push-through cooling design and side-by-side mounting saves cabinet space • Integrated, comprehensive safety concept up to PLe/SIL3 takes away the need for external safety components • Available in three voltage versions: 200–240, 380–480 and 500–690 V The second generation of SINAMICS G120 drives features higher power density in the same enclosure size. Depending on the application, the power module can be combined with the matching Control Unit and optional components such as an operator panel. Additionally, the functionality of the Control Unit has been expanded to offer precise vector control as well as basic positioning.

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