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Manufacturing North America

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Collaborative creation

The future is here

Made in the USA

How automotive manufacturers are embracing 3D to ensure right-first-time results

The information gathered by SCADA systems is more valuable than ever

The regulation and policies associated with the coveted ‘Made in America’ label


Manufacturing North America

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| Contents

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Issue | 101

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The future is here

Made in the USA

How automotive manufacturers are embracing 3D to ensure right-first-time results

The information gathered by SCADA systems is more valuable than ever

The regulation and policies associated with the coveted ‘Made in America’ label

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Collaborative creation

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Lead Features Analysis and insights New product development To create cars that are lighter and stronger, as well as kinder to the environment, auto manufacturers are embracing 3D technology Manufacturing The label ‘Made in USA’ offers assurance for buyers and suggests a product of superior quality Technology SCADA systems have been around for years but now the data they collect is even more valuable

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Transportation

How incorporating smart technologies into existing and new infrastructure can more safely move people and goods

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News

Profiles Interviews and case studies Universal Robots

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Trelleborg Offshore

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Unitech Aerospace

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Unitech Composites

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Paul Fabrications Ltd

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Tods Aerospace and Tods Defence

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North Coast Composites Tool and Mold

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Suncor Inc

Editor editor@manufacturingnorthamerica.com

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Twin Disc

Sales pmonument@manufacturingnorthamerica.com

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Marketing & Engineering Solutions

Artwork studio@manufacturingnorthamerica.com

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Ricardo

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Elekta

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Wall Colmonoy Ltd

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News and views from across North America

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Please note: The opinions expressed by contributors and advertisers within this publication do not necessarily coincide with those of the editor and publisher. Every reasonable effort is made to ensure that the information published is accurate, and correct at time of writing, but no legal responsibility for loss occasioned by the use of such information can be accepted by the publisher. All rights reserved. The contents of the magazine are strictly copyright, the property of MNA, and may not be copied, stored in a retrieval system, or reproduced without the prior written permission of the publisher.

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Collaborative creation T Stephen Chadwick, Managing Director at Dassault Systèmes EuroNorth, discusses how automotive manufacturers are embracing 3D solutions 2 www.manufacturingnorthamerica.com

he auto industry is driven by a number of powerful imperatives that reflect our desire for aesthetics, performance and safety, while also recognizing the need for affordability and minimal environmental impact. An industry that not long ago was exclusively using steel and fossil fuels is embracing lighter metals and composites that increase strength and reduce weight, while frugal, electric and hybrid vehicles are reducing emissions on our roads. Automotive manufacturers are using Dassault Systèmes 3DEXPERIENCE Platform and Industry Solution Experiences

to explore new materials and processes that may mean tomorrow’s cars are not only lighter and stronger but also inherently kinder to the environment – even after they’ve reached the end of their useful life. Global demand for higher quality, systems-integrated transportation is driving suppliers and OEMs alike to pursue more capable, industry-proven solutions. Target Zero Defect Industry Solution Experience enables comprehensive vehicle development capabilities, in a collaborative 3D environment, to ensure right-the-first-time results from concept to final production.


New Product Development

source repository, supporting pro-active prediction of budget and development cycles, ensures accuracy and saves time and cost. The technology helps reduce risk for OEMs and their suppliers associated with introducing new vehicles, as well as minimizing the potential for vehicle recalls. Flexible and global manufacturing capabilities enable industry leaders to quickly react to changes in demand, and make critical updates late in the development process without compromising manufacturability

Leading automotive companies have invested in realistic simulation technology to increase their capacity to innovate. By integrating simulation with their 3D design software and product data management solutions, these organizations are not only improving their product development efficiency, they are also achieving better performance; speeding up product development time; meeting industry standards and regulations; and addressing environmental factors like fuel emissions.

In order to reach a sustainable compromise between individual customer demands and the increased cost of meeting those needs, vehicle makers are turning to platform standardization

Drive to the future Today’s transportation suppliers and manufacturers must introduce new high-tech capabilities and features faster than ever while managing increasing vehicle and development process complexity. The software solution provides an integrated and open development platform, with capabilities to minimize defects, automate knowledge, manage complexity and optimize performance across the entire product development process. Early virtual design, engineering and validation can reduce both vehicle weight and material waste. Dassault Systèmes single-

and schedule. Target Zero Defect provides a global approach to capture and leverage existing corporate knowledge. It connects design, engineering and manufacturing disciplines across a company’s entire ecosystem of partners and suppliers into a dynamic, collaborative product creation environment. It includes high-performance virtual design & simulation at all stages of product creation, from conceptual design to virtual manufacturing; including strategic domains such as powertrain, body engineering, styling and final assembly.

The routes to efficiency Over recent years the automotive industry has experienced a recession, increasingly tightened fuel-economy and pollution standards, strict government regulations and rapid market growth in developing countries. Innovative companies that planned for these challenges by investing in technology and resources have not only remained solvent, but increased their competitive advantage.

Demand for profit Global demand for transportation innovation is providing new, profitable opportunities in a competitive industry. Delivering advanced vehicle capabilities requires the management of sophisticated systems, global collaboration, and intelligence integration, all while fulfilling industry standards for vehicle safety and embedded systems. Dassault Systèmes Smart, Safe and Connected 3DEXPERIENCE accelerates product innovation to market, helps to manage complex systems, and provides an integrated platform for mechanical, electronics, software and simulation. With assurance that industry standards for safety and embedded systems are fulfilled, vehicle manufacturers can re-focus teams on strategic new vehicle innovation. More than 80 per cent of new vehicle innovations originate from electronics/electrical (E/E) and embedded systems, and can represent 20-40 per cent of global development costs. If not managed carefully, these

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critical success factors can readily become costly liabilities. Transportation industries are on a quest to deliver outstanding product and service support to their customers. This trend is epitomized by today’s masscustomization phenomenon. In order to reach a sustainable compromise between individual customer demands and the increased cost of meeting those needs, vehicle makers are turning to platform standardization. More recently they extended the concept to vehicle modularization, ultimately allowing marketing and sales teams to win new buyers with tailored products.

Virtual garage With such a broad vehicle configuration capacity, how can marketing and sales managers ensure they get individual vehicle information consistently and early, shared across all communication channels, devices, local markets sometimes even prior to product production? Virtual Garage Industry Solution Experience delivers stunning automotive sales and marketing materials and event experiences for both B2B and B2C audiences. Designed specifically for the vehicle industry, it enables companies to leverage existing vehicle CAD data to improve the speed, quality, and reach of digital product promotions and customer engagement activities across all brand and product touch points.

Case Studies

DS 3, in a dynamic and compelling way that virtually enhances the size of its booth, without using a physical car. Wearing an HTC Vive headset and controlling a joystick, visitors can virtually view, explore and interact with the new DS 3 as if it were real - walk around the car and sit inside it, change roof and body colors, trims and interior decor, and view animations of opening and closing front doors. Based on the 3DEXPERIENCE platform, Dassault Systèmes’ “Virtual Garage” industry solution experience delivers 3D automotive sales and marketing materials,

applications and experiences that communicate emotional brand or product themes to their target audiences. This technology is relevant for the new DS 3, a model which offers more than three million possible combinations to customers. “With the ‘Virtual Garage’ industry solution experience, companies have unlimited creative freedom to simultaneously support the launch of new vehicles costeffectively and embrace individual customer preferences,” said Olivier Sappin, Vice President, Transportation & Mobility Industry, Dassault Systèmes.

Get real DS, the premium brand of the automotive group PSA, used the “Virtual Garage” industry solution experience to create an immersive, virtual reality booth experience at the 2016 Geneva International Motor Show. The DS brand presented the new model of its product range of premium automobiles, the new

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Electric current Faraday Future has adopted its 3DEXPERIENCE platform. The electric-car company has deployed the “Target Zero Defect” and “Smart Safe & Connected” industry solution experiences for the development and delivery of its new fully electric vehicle and connected automotive experience


New Product Development

concept unveiled during CES 2016 in Las Vegas. Both Faraday Future and Dassault Systèmes see the fundamental shift that is now occurring in the relationship between people and cars. This emerging generation of cars requires manufacturers to integrate traditional automotive design disciplines with Internetconnectivity, alternative powersources, and autonomous driving technologies. Faraday Future determined that Dassault Systèmes’ 3DEXPERIENCE platform was the only innovation platform that made this rapid integration of design and technology possible. “We are taking a user-centric, technology-first approach to vehicle design with the ultimate aim of connecting the automotive experience to the rest of our customers’ life,” said Nick Sampson, Senior Vice President, Product R&D, Faraday Future. “Dassault Systèmes’ focus on customer experience and its unmatched technologies will enable us to meet our aggressive schedule to deliver the most

advanced electric vehicles into the market. Dassault Systèmes’ industry solution experiences like ‘Target Zero Defect’ and ‘Smart Safe & Connected’ clinched the decision for Faraday Future.” Based on the 3DEXPERIENCE platform, “Target Zero Defect” and “Smart Safe & Connected” industry solution experiences were fully deployed across the company of more than 400 employees worldwide within two weeks. It has enabled Faraday Future to design, simulate, and prepare for production in ways that were not possible with any other solution. “Faraday Future is attempting to transform the transportation and mobility industry. By choosing to partner with Dassault Systèmes, it has a proven solution it deployed quickly and fits with its very rapid and aggressive development schedule,” said Olivier Sappin, Vice President, Transportation & Mobility Industry, Dassault Systèmes. “Faraday Future has quickly adopted the 3DEXPERIENCE platform and is benefitting from the integration of our extensive experience in

the automotive and high tech industries. “In addition to helping Faraday Future turn its concept car into reality, the 3DEXPERIENCE platform will also be utilized in Faraday Future’s forthcoming manufacturing facility in North Las Vegas. Dassault Systèmes’ industry solution experiences for manufacturing, including “Lean Production Run,” are used by companies like Faraday Future for plant optimization, quality control, and real-time visibility into facility operations. By leveraging the breadth of the 3DEXPERIENCE platform’s capabilities for manufacturing, Faraday Future will be able to construct and maintain a high-tech factory of the highest modern standards, and stay ahead of future demand for nextgeneration automobiles.” M

Stephen Chadwick is Managing Director at Dassault Systèmes EuroNorth. For further information: http://www.3ds.com/ industries/transportationmobility/

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Made in the USA 6 www.manufacturingnorthamerica.com


Manufacturing

A closer look at American manufacturing in commercial and industrial sectors. By Jeremy Blankenship

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merican manufacturing has always been the standard of high quality products for local businesses and international brands. The highly coveted “Made in the USA” label offers assurance for buyers, suggesting that the product is genuinely superior, compared to companies that are unable to make such claims. In the past decade, globalization and international influence have placed a strain on US-based manufacturers that support “Made in the USA” products. With the intention of reducing costs and increasing margins, many businesses have resorted to outsourcing (just by moving operations to Mexico, some businesses have been able to cut costs by a whopping 75 per cent); and as a result, formed strategic partnerships with overseas groups that offer cheap labor and mass production services. US president Donald Trump promised to stop the proliferation of this trend and withdrew from the Trans-Pacific Partnership (TPP), forcing international companies that want to maintain their deals with US businesses to setup shop in the country. With Trump prioritizing American manufacturing, now is the perfect time to learn about what “Made in the USA” really means and its applications to consumer and industrial goods.

“Made in the USA” regulations and policies These days, companies that disclose the origin of their products through a statement or label must closely adhere to regulations set forth by the Federal Trade Commission (FTC).

Interestingly, most businesses aren’t actually forced to reveal the origin percentages of their products (there is an exception to this practice for cars, textile, wool and fur products). Yet, establishments want to be able to apply such distinct markings on their offerings because it helps improve sales and provides assurance for local consumers. One should carefully note that a company does not need approval from the FTC to apply the label. But to ensure compliance, the product must be “all or virtually all” made in the US, which includes all 50 states, the District of Columbia, as well as US territories and possessions – based on the Enforcement Policy Statement. The term “all or virtually all” refers to all major or significant parts and processing of the product, which must originate from the US. Furthermore, the product should not contain any or only “negligible amounts” of foreign content.

In another example, an LED lamp with a US-made label uses a tiny, custom switch that is imported from Taiwan. All of the other components, such as the housing, LED components, bases and plugs are made in the US. The lamp is also manufactured in the US, where it will be sold at local electronic shops. In this case, the practice of using “Made in the USA” labeling is not deceptive, because the custom switch does not make up a large part of the product’s overall manufacturing costs; and the small component can be viewed as insignificant (although crucial to the functionality of the lamp), when compared to other parts of the product. The FTC does not closely regulate the application of USmade labels, simply because it lacks manpower to serve as a policing agency against such practices. But when companies are caught exploiting the lax policies, the Commission aims to make an example out of the

Consumers who praise “Made in the USA” labels can sleep well at night, knowing that US-made products have gone through strict vetting and inspection processes How companies use the label Stretching the application of “Made in the USA” regulations can get businesses in trouble. For example, a chair with a US-made label contains an imported wooden base from Chile – a crucial component of the product. The product is assembled and finished in the US, using paint from Maine. In this scenario, the use of the label could be seen as deceptive, due to the incorporation of a major imported component.

negative behavior by imposing hefty fines. Although rare, the FTC does take action against businesses that cross the line. In the 90s, FTC officials engaged in a civil penalty case with Stanley, a brand that specializes in industrial tools and handheld equipment, asserting that the company’s “Made in the USA” labeling practices were misleading. The product in question was a line of Zero Degree ratchets, which the FTC proved was utilizing a significant amount of foreign components

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Manufacturing

during manufacturing. In 2006, Stanley was forced to fork out $205,000 in fines to settle the case.

What it means for consumers Consumers who praise “Made in the USA” labels can sleep well at night, knowing that US-made products have gone through strict vetting and inspection processes set by American manufacturing regulators. Some imported products that are made using foreign manufacturing standards may not be as reliable, sturdy or safe. For instance, in 2007 a nonprofit organization found some toys from China to contain unsafe levels of poisonous lead. Holgate Toys, a US-based manufacturer that applies US-made labels on wooden toys, benefited from

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the scare and saw a surge in sales during the incident. During this period, company president Richard Bly mentioned that people would walk into toy stores and specifically ask for “Made in the USA” products to avoid foreign products with potentially harmful substances.

Moreover, companies that outsource manufacturing outside of the US may not be able to regulate operations as effectively due to limited access. This is prevalent in the fashion and garments sector, where large brands rely on rural factories to meet product demand and monthly quotas. Lastly, people who are concerned about the exploitation of child labor and destructive environmental practices in other parts of the world may be wary of purchasing foreign products that ultimately support such businesses. M This article by Jeremy Blankenship originally appeared as a blog on Larson Electronics website. For more information, visit: www.larsonelectronics.com


News New Lockheed Martin device targets overstress Lockheed Martin, the global security and aerospace company, has developed a new exoskeleton device; the FORTIS Knee Stress Release Device (K-SRD). Using the company’s Dermoskeleton bionic augmentation technology, the device is a computer-controlled exoskeleton designed to counteract overstress on the lower back and legs experienced during physically demanding tasks, while also increasing mobility and load-carrying capability. “FORTIS K-SRD features military-specification batteries that are approved for infantry use, improved control box ergonomics and faster actuators that generate more torque,” said Keith Maxwell, FORTIS program manager at Lockheed Martin Missiles and Fire Control. “These system upgrades have come as a result of soldier feedback on the initial design.” Sensors on the exoskeleton will report the soldier’s speed, direction and angle of movement to an on-board computer that drives electro-mechanical actuators at the knees. The exoskeleton will then deliver the right torque at the right time to assist knee flex and extension. Lockheed Martin has determined that these benefits will be most noticeable when ascending or descending stairs or navigating inclined surfaces. Versions of the exoskeleton are also now available for industrial workers and first responders who have to perform strenuous tasks in difficult environments. “For any mission that combines heavy man-portable gear and climbing, FORTIS K-SRD can enhance strength and endurance,” Keith added.

www.lockheedmartin.com

Changes afoot for Polaris Industries’ manufacturing network In an effort to consolidate production and better leverage its plant capacity, Polaris Industries Inc. has unveiled plans for changes to its manufacturing network. These include the discontinuing of manufacturing at its plant in Milford, and the transferring of production to its existing facilities in Huntsville, Roseau and Anaheim. The Milford location is to be repurposed as a storage and warehouse facility to support Polaris’ Spirit Lake plant. Polaris has also detailed its plan to transfer metal fabrication operations for its Pro Armor products from its facility in Riverside to its recently purchased Transamerican Auto Parts facility in Chula Vista. Approximately 390 jobs will be impacted by the plans, the majority of which will be relocated within the Polaris manufacturing network throughout 2017. “Since we opened the Milford facility in 2013, the team has performed admirably. They have been instrumental in driving manufacturing improvements across our off-road vehicle products, and we sincerely appreciate their contributions to Polaris,” said Ken Pucel, Polaris’ Executive Vice President of Operations, Engineering and Lean. “We evaluated a number of options to streamline our plant infrastructure. Discontinuing manufacturing at Milford allows us to consolidate the production of similar products and improve utilization of our available capacity across the rest of our United States manufacturing network.”

www.polaris.com

SSPC Award of Merit presented in Tampa The Society for Protective Coatings (SSPC) has presented the 2017 John D. Keane Award of Merit to Bob Murphy, Project Development Manager for Sherwin-Williams Protective & Marine Coatings. Named after the society’s former Executive Director, the award honors outstanding leadership and significant contributions to the development of the coatings industry. It was presented to Bob by SSPC’s Executive Director, Bill Worms, at the society’s Awards Luncheon Programme at its annual conference in Tampa, Florida. Bill said at the luncheon: “Bob has been an active member in SSPC technical committees and has been a subject matter expert in the development of several SSPC courses. I can think of very few other members who have contributed so much time and dedication to SSPC. Bob has also chaired SSPC’s Education Advisory Committee, authored papers for the conference technical program and is an instructor for several SSPC courses. He has also helped SSPC develop a good working relationship with other organizations such as AWWA and ICRI.” Reacting to the honor, Bob described the occasion as a humbling event. “There are a great many individuals who also deserved this award, so I feel truly honored to be named the 2017 recipient. It is a real privilege to be recognized by your peers. I am humbled by the recognition.”

www.protective.sherwin-williams.com www.manufacturingnorthamerica.com 9


SCADA becoming easier? Modular, on-demand subscription software built for the 21st Century offers economical predictive process analytics to improve efficiencies. By Bert Baeck, CEO, TrendMiner 10 www.manufacturingnorthamerica.com

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t times it seems hard to believe we’re already in the second decade of the 21st century; what is even harder to believe is that the majority of manufacturers are still only using technology that is at least 30 years old. Many of these systems work wonderfully for what they are meant to do, collect and store data and monitor systems. However, these systems alone cannot

help industrial companies meet the challenges of today’s global market. Although there are several reasons for this situation, the perception that change is too difficult and expensive is the leading cause for companies to remain hesitant to take advantage of the new opportunities promised by the Industrial Internet of Things (IIoT). A recent LNS Research


Technology

In addition to easy search, this new technology provides process data contextualization and predictive analytics capabilities survey of over 400 manufacturing executives showed the vast majority of companies do not have plans to invest in IIoT technology in the near future. When we consider how expensive many of the existing systems are, it’s understandable why industrial companies are reluctant to invest in new technology. Unfortunately, these executives are often looking at old technologies that have been tweaked to try to take advantage of IIoT opportunities and may require removing the current systems. The good news is there are very affordable technologies developed specifically for the Internet Age that work with existing systems to help manufacturers gain deep insight into process behavior that translates into fast ROI.

SCADA information is more valuable than ever Supervisory control and data acquisition systems (SCADA) were originally designed to collect data and monitor processes. Since they generate such enormous amounts of data, historians were added to store this data. Initially, historians were used to fulfill regulatory requirements, such as generating reports for government agencies. Leading industrial companies recognized the data hidden in their historians could provide valuable information on plant processes and production, but accessing and utilizing the data could be very difficult. The reason for this is historians weren’t designed for “read” purposes or a two-way transfer of information. Manufacturing execution systems (MES) were introduced

in the early 1990s in an attempt to bridge the gap between plant floor SCADA systems and enterprise ERP software. They also promised to provide analytics, such as KPI data, to improve plant floor operations. While they have been able to provide more advanced capabilities than SCADA systems, they are expensive and often require extensive engineering to be implemented. Moreover, they were developed for a different business era in which systems were still largely siloed and Internet optimization was largely an afterthought.

21st Century technology has arrived When we consider the amount of time and money industrial companies have spent for traditional software, we can understand the reluctance of some manufacturers to enhance their systems. They are still trapped in the fear that any new solution will be expensive as well as require extensive engineering and training for employees. In addition, they are apprehensive about becoming locked into a cycle of difficult and expensive upgrades, patches and limited scalability.

To really take advantage of the IIoT companies need next generation solutions that were developed for that purpose. These solutions are able to offer users the best of new technologies, particularly in terms of ease of use and affordability.

Google for Industry As mentioned earlier, while historians hold a wealth of valuable data for improving operations, accessing that data and turning it into actionable information has been time consuming and difficult. Many applications were based on data modeling, which required extensive engineering and data scientists to perform. As a result, only mission critical applications were targeted, leaving vast areas of improvement opportunities hidden. In 2008, engineers from Covestro (then known as Bayer MaterialScience) knew there had to be a better way to leverage time-series data. They worked with different types of analytics models and identified their limitations for scaling-up beyond pilot projects. Eventually, they were able to use their deep knowledge of process operations to create “pattern search-based discovery and predictive-style process analytics” developed for the average user. The unique multi-dimensional search capabilities of this platform enable users to find precise information quickly and easily, without expensive modeling projects and data scientists.

Above: Figure 1: Combining live data with historical context shortens the analysis latency to immediate, providing an opportunity to take actions even before an event can affect process performance.

A simple example of how this works is the song title recognition

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Technology

app Shazam. While the technology used by Shazam is different, the concept is similar. Instead of trying to map every note in a song to its vast database of songs, Shazam uses pattern recognition software that seeks “high energy content� or the most unique features of a song then matches it to similar patterns in its database. This is a very simple explanation of a complex process, but the important thing is that it enables users to quickly find a song title with a very high rate of accuracy. Naturally, industry demands more sophisticated algorithms that are capable of going beyond mere search. Often called Google for Industry, this software works by connecting to existing historian databases then implementing a column store database layer for an index. This software makes it easy to find, filter, overlay and compare interesting time periods to search through batches or continuous processes. Moreover, this next generation solution enables users to search for particular operating regimes, process drifts, operator actions, process instabilities or oscillations. By combining these advanced search patterns users unlock the true information they need. For example, an operator

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compares multiple data layers or time periods to discover which sensors are more or less deviating from the baseline then make adjustments to improve production efficiency.

Bringing it all together In addition to easy search, this new technology provides process data contextualization and predictive analytics capabilities. Engineers and operators can provide annotation to provide greater insight. Its predictive analytics capabilities enable an early warning detection of abnormal and undesirable process events by comparing saved historical patterns with live process data. Moreover, the solution calculates the possible trajectories of the process and predicts process variables and behavior before it happens. This gives operators the ability to see if recent process changes match the expected process behavior and pro-actively adjust settings when it does not.

21st Century business model This free predictive process analytics (discovery and predictive) also employs a modern business model: online

subscription pricing. In addition to making process analytics affordable to all companies, this also frees businesses from having to spend the time and money on adding additional licenses and upgrades. Each time a user logs in, they automatically get the latest version of the software. As we have seen, companies now have the option to enhance the value of the investment they have made in high quality historians. Low cost predictive analytics solutions that complement their existing historians enable companies to better use the data collected by historians to provide valuable business insights. With an affordable, plug and play solution to uncover new areas for improving operation efficiencies the question becomes why more businesses aren’t using software that is created for the IIoT generation. The future is here and companies can no longer operate solely using existing systems if they want to stay competitive in this new world. M Bert Baeck is CEO of TrendMiner. For further information, visit: www.trendminer.com


News Rockwell flips the switch with its latest product Rockwell Automation Inc., the world’s largest industrial automation and information company, has announced the release of its Allen-Bradley Stratix 2500 lightly managed switch. “Unmanaged switches deliver the network connectivity required for less complex industrial applications, but they can’t provide diagnostics, manage traffic or enhance security,” said Divya Venkataraman, global product manager, Rockwell Automation. “Manufacturers need a more robust switch when issues like packet storms are bringing down their network, or if they want to protect against growing security threats. This is where a lightly managed option like the Stratix 2500 switch delivers exceptional value.” The Stratix 2500 lightly managed switch has been designed so that it can be configured for application specific needs and utilizes embedded Cisco technology as part of the Rockwell Automation Integrated Architecture system. This has been integrated so as to ease network configuration, management and support while optimizing integration with the enterprise network. “With embedded Cisco technology,” explained Samuel Pasquier, director of product management, IoT Platforms, Cisco, “the Stratix 2500 switch delivers the security and monitoring capabilities required by IT professionals while exposing an easy-to-use web interface for operations professionals.”

www.rockwellautomation.com

Wabtec Corporation agrees major PTC contract Wabtec Corporation has announced the signing of a $40 million contract to design, install, test and commission Positive Train Control (PTC) for the South Florida Regional Transportation Authority (SFRTA). SFRTA operates the Tri-Rail commuter rail service, which consists of more than 70 miles of track along the east coast of Florida, between Mangonia Park and the Miami Intermodal Centre. Under the scope of the contract, Wabtec will provide SFRTA with Interoperable Electronic Train Management System (I-ETMS) equipment for 42 locomotives and cab cars. In addition, it will supply a back-office server, wayside communications and signals, a dispatch system, training, and system integration. SFRTA’s PTC system will be built so as to be fully interoperable with the system being implemented across the industry by all Class 1 railroads. Installation is expected to be completed by the end of 2018. Raymond T. Betler, Wabtec’s president and chief executive officer, said: “The scope of our work on this project demonstrates the wide-ranging roles that Wabtec can play in the implementation of PTC for our customers. We are continuing to invest worldwide in this important segment of our business.”

www.wabtec.com

CEC acquire a Tiger Massachusetts-based consulting services company, Civil & Environment Consultants Inc. (CEC) has announced a new addition to its portfolio of Ion Science handheld photoionization detectors (PID) in the form of a TigerLT volatile organic compound (VOC) monitor. Kyle Fortin, Project Scientist at CEC Inc. comments: “We implement projects that range from overseeing hazardous/non-hazardous contamination clean-ups to designing and maintaining landfills. Our equipment rental company, US Environmental Rental Corporation, has typically recommended Ion Science handheld Tiger PID’s in the past for headspace screening of total organic vapors (TOV’s) in soil, ambient air screening during chemical clean-ups and VOC’s in landfill soil gas probes. “US Environmental Rental Corporation is extremely trustworthy and has helped our business significantly over the years. As a result, we are happy to go with their suggestion that a specific instrument is superior to comparable VOC monitors on the market.” Designed to be a streamlined, lower cost version of Ion Science’s Tiger instrument, the TigerLT has been chosen by CEC for its durability in the field and its anti-contamination and humidity resistant design. Kyle continues: “Our office has doubled in size during the past three months so we had an urgent need for an additional PID. The TigerLT was a great choice because of its competitive price point and proven reliability of the Ion Science instruments we have experienced in the past.”

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Next generation mobility

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Regina Hopper, president/CEO of the Intelligent Transportation Society of America in Washington, D.C., discusses policy recommendations for advancing transformative mobility technologies 14 www.manufacturingnorthamerica.com

wight Eisenhower’s vision for a coast-to-coast interstate highway system began when he was serving as an Army officer in Europe during World War I. It would be a half-acentury later, during his first term as President, that the first of 47,856 miles of high-speed, four- and sixlane roads were constructed. The entire project would take 35 years to complete, and in today’s dollars, would cost more than $500 billion. Today, in cities and towns across the country, mayors, city commissioners, governors, state legislatures, and even the President, are looking for ways to

make our nation’s highways, roads, bridges, airports, public transit systems, and other key pieces of infrastructure once again the envy of the world. The Intelligent Transportation Society of America is playing a key role in helping frame those discussions and debates. As the nation’s leading advocate for the technological modernization of our transportation system, we believe that by incorporating smart technologies — from traffic management systems and integrated mobility systems, to connected and autonomous vehicles — into our existing


Transportation

and new infrastructure, we can have a safer, more efficient way of moving people and goods. We are fortunate to bring together all key stakeholders in the intelligent transportation movement, including established and emerging private companies, public agencies, and state DOT officials, as well as leaders in the academic and research communities, who are all working to deploy these technologies.

The Road Ahead To be successful, any project needs clear direction, a plan, and leadership. To help advance the conversation at the local, state and national levels, ITS America worked with its members and other stakeholders to create a public policy roadmap: “The Road Ahead: Intelligent and Transformative Transportation, the Next Generation of Mobility”. We now have released this roadmap and key points include: • Intelligent, transformational, transportation technologies will save countless lives, improve our nation’s economy, and make our transportation system more efficient and safer. • The National Highway Traffic Safety Administration (NHTSA) reported that 35,092 people died in accidents on U.S. roadways during 2015. That is a 7.2 per cent increase from 2015 when 32,744 people were killed in accidents. The number of people injured was also up in 2015 by 100,000. If that many people were injured or lost, their lives in any other mode of transportation there would be outcries for ways to solve the problem. • New vehicle technology, such as connected and autonomous crash avoidance and driving automation systems, are game changers. Research shows that driver error is in part responsible for more than 90 per cent of all accidents. Impaired and

The White House is talking about creating a $1 trillion investment into upgrading our country’s infrastructure distracted drivers cause more than half of the deaths. • Intelligent transportation technologies will provide equities that do not currently exist in the system providing solutions for seniors, the disabled, and those who need more mobility options. • Intelligent transportation gets more bang for less buck. The “sharing economy” expands mobility by leveraging idle vehicles. This is exemplified in new car sharing, ride-sharing, and ride-hailing services, such as Zipcar, Via, Uber, and Lyft and we are seeing these options expand from cities to smaller communities and rural areas. • Vehicle-to-vehicle and vehicle to-infrastructure communications technologies are being rolled out by both automotive and after-market manufacturers. Lane departure warning systems, adaptive cruise control, and back-up and side cameras are becoming more standard, and with these technologies, the public is becoming more aware of what intelligent transportation systems are and what they can do. State highway departments are allowing testing of these technologies, as well as incorporating intelligent systems into existing and new highways and roads. • Squeezing more out of less infrastructure is also becoming critical. Smart parking features are already becoming commonplace in communities and other services that match drivers with parking spots and congestion pricing, paired with road capacity and trip demand,

can help achieve shorter, more predictable travel. • Include broadband networks in any infrastructure legislation, including broadband funding for rural or otherwise hard to-serve areas. Support a technology-driven approach to spectrum sharing between Wi-Fi and Dedicated Short Range Communication (DSRC) that allows Wi-Fi use in the 5 GHz band, but in a way that preserves the safety and utility of DSRC without unduly burdening road users and transportation infrastructure operators. The White House is talking about creating a $1 trillion investment into upgrading our country’s infrastructure. Congress is already discussing ways to finance such an investment. U.S. Department of Transportation Secretary Elaine Chao has acknowledged that a technological revolution is underway and changing the way “... we work, live, travel, and conduct commerce, and this Department has an unprecedented opportunity to help shape that future for our country.” It is not unlike the challenges our predecessors faced more than 60 years ago, as concrete was being poured to build the interstate systems and construct our airports. The future is full of possibilities, and ITS America is here to help serve as a source of information and experience to deliver the next generation of transportation. M Regina Hopper is president/ CEO of the Intelligent Transportation Society of America in Washington, D.C. For further information visit: http://itsamerica.org/. To read the report visit: www.itsamerica.org/wpcontent/uploads/2017/02/ Final-The-Road-Ahead-TheNext-Generation-of-MobilityRoadmap-020717b.pdf

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Bombardier and IBM renew partnership Global plane and train manufacturer Bombardier is to extend its long-term partnership with IT consulting and business services provider IBM. The six-year contract extension, valued at approximately $700 million, includes IBM Services and IBM Cloud management of Bombardier’s worldwide IT infrastructure and operations. “Bombardier’s global decision to extend its existing partnership with IBM and move to IBM Cloud is recognition of our broad expertise and experience helping our clients transform the business of IT to be more competitive, agile and secure through cloud computing and industry services best-practices,” said Martin Jetter, senior vice-president, IBM Global Technology Services. “We look forward to further developing our relationship with Bombardier and working with the talented team there.” “As part of our turnaround plan, Bombardier is working to improve productivity, reduce costs and grow earnings. This IT transformation initiative will help us better integrate globally to create a best-in-class IT organisation,” said Sean Terriah, Chief Information Officer, Aerospace and Corporate Office, Bombardier. “With IBM, we will transform our service delivery model to focus on our core competencies and leverage the best practices of our strategic partner across our infrastructure and operations.” The services management agreement spans 47 countries and represents one of IBM’s largest cloud partnerships in Canada.

www.bombardier.com

Construction begins on new Dow Chemical Company facility Fluor Corporation has commenced with the mechanical construction for The Dow Chemical Company’s new ethylene derivative facility in Freeport, Texas. Its scope of work includes setting precast and steel structures, piping equipment, painting and insulation for the unit. More than 400 craft professionals are expected at peak construction, with mechanical completion planned for 2018. The unit is designed for the production of High Melt Index polymers for hot melt adhesives, along with broad capability to produce conventional ENGAGE polyolefin elastomers and AFFINITY polyolefin plastomers for applications in packaging, transportation, infrastructure and consumer markets. “Having recently finished construction of Dow’s ethylene production facility in Freeport safely and on schedule, this project is a natural transition for Fluor and our craft workforce,” said Jack Penley, senior vice president of Construction and Fabrication for Fluor. “We are proud of our craft workforce’s attention to safety, productivity and experience on the Freeport site over the past five years. We will leverage these best practices and expertise to deliver this project with capital efficiency and schedule certainty for Dow.”

www.fluor.com

Kurt releases new vise design Workholding product manufacturer Kurt Workholding has unveiled its Kurt DX6 Crossover vise design. Created to enhance machinists’ ability to machine parts and increase productivity, the DX6 vise mounts and locates onto 40 millimetre, 50 millimetre and two-inch grid patterns in order to provide for an accurate setup, repeatable reference and the elimination of relocating, therefore reducing setup times. The DX6 Crossover vise has been designed to mount through traditional side clamping ears and through the body from the top-side, expediting removal when necessary. It also accepts sine keys for alignment directly on the machine table and mounts to an adjustable swivel base. A nine-inch opening within the inside jaw position targets larger workpieces than standard vises, while a narrow body has been crafted to mount multiple vises onto machine tables. Kurt Workholding has targeted the issue of chip build-up by equipping the DX6 vise body with easy chip and coolant evacuation, while additional features include an 80,000 psi ductile iron body, nut and movable jaw, a semi-hard steel screw and a hardened vise bed and jaw plates. The DX6 Crossover vise is also packaged with a GrooveLock jaw plate and workstop.

www.kurtworkholding.com 16 www.manufacturingnorthamerica.com


News METTLER TOLEDO transmits new M400 product Global precision instrument and service provider METTLER TOLEDO Process Analytics has officially launched a new version of its M400 transmitter series for process analytics applications. The new M400 has been created to address the needs of the process industries from chemical applications to pharmaceutical production. Featuring a combined high-contrast touchscreen and a soft-key user interface, it is compatible with analogue sensors and METTLER TOLEDO’s digital Intelligent Sensor Management (ISM) probes. ISM sensors can be calibrated away from the process and then connected to the M400. The transmitter’s HART communication protocol provides integration of the diagnostics into process control systems, while a software tool comes supplied as standard, enabling configuration of the M400 via PC and USB stick. “I think we’ve covered everything with the new M400,” says Kang Liu, product manager for transmitters at METTLER TOLEDO Process Analytics. “The combination of Touch & Key control, wide parameter coverage, ISM and robust design make it highly suited for modern production facilities across the process industries.”

www.mt.com

Stratasys demonstrates tomorrows advances Stratasys Ltd has announced the development of its Stratasys Continuous Build 3D Demonstrator. Unveiled at the RAPID + TCT show in Pittsburgh, the new platform is to be composed of a modular unit with multiple 3D print cells working simultaneously and driven by a central, cloud-based architecture. “The Stratasys Continuous Build 3D Demonstrator is an important milestone in the company’s long term vision to make additive manufacturing a viable solution for volume production environments,” says Scott Crump, Stratasys Co-founder and Chief Innovation Officer. “It combines our FDM print quality, GrabCAD control and monitoring, and a new multi-cell, scalable architecture to create a breakthrough manufacturing platform.” The Stratasys Continuous Build 3D Demonstrator has been designed to produce parts in a continuous stream with minor operator intervention, automatically ejecting completed parts and commencing new ones. Each 3D print cell can produce a different job to enable mass customization projects. Additional cells can be added at any time to the scalable platform, while automatic queue management, load balancing and architecture redundancy further contribute to accelerated throughput as jobs are automatically routed to available print cells.

www.stratasys.com

North American crowds introduced to the OR LASER German equipment manufacturer OR LASER has used the RAPID + TCT exhibition and conference in Pittsburgh to present its new ORLAS CREATOR industrial metal additive manufacturing (AM) machine to audiences in North America. Introduced to the European market at the end of 2016, at the Formnext international exhibition in Frankfurt, response to the ORLAS CREATOR has been strong, with commentators drawing particular attention to its contemporary design, functionality, accessibility and price performance ratio. Tests on the machine have also shown that its unique blade design can result in increased build speeds that produce parts up to 30 per cent faster than equivalent systems. Commenting on the RAPID event, Chief Operating Officer of OR LASER, Uri Resnik said: “We have been delighted with the market’s response to the ORLAS CREATOR and inundated with serious enquiries, which shows us that the production of a smart, fully capable, metal 3D printing system at an accessible price point for SME’s is exactly what the sector needs. We are looking forward to offering this same opportunity across North America and rolling out the ORLAS CREATOR in this region.” The ORLAS CREATOR is due to go into production at OR LASER’s dedicated facility in Dieburg imminently.

www.or-laser.com www.manufacturingnorthamerica.com 17


Flexible automation Universal Robots is dedicated to bringing safe, flexible and easy-touse robots to all types of businesses around the world

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A

lthough officially founded by Esben Østergaard, Kasper Støy and Kristian Kassow in 2005, Universal Robot’s history goes back two years earlier when the three men met at the University of Southern Denmark in Odense. While analysing the special requirements for robots in the food industry, they came up with the idea of creating an easy-to-install and simple to programme light robot in comparison to the heavy, expensive and unwieldy robots that dominated the robotics market at the time. In 2005, following investment by Syddansk Innovation, the company was established with the goal of making robot technology accessible to small and medium-

sized enterprises. In 2008, the Danish State Investment Fund became convinced of Universal Robot’s potential and invested in the firm, along with a new CEO. Looking back at Universal Robots’ early days, Co-Founder and Chief Technical Officer Esben Østergaard comments: “Myself and the other co-founder spent around three years making our product and running out of money, getting investors on board and taking on a CEO in 2008. One year later, in 2009, we started to sell our products commercially; since that moment we began to focus on the business, however a few years back we then moved back to focus on product development and now we do both. “When we first entered the


Profile

| Universal Robots

Our customers can combine the benefit of their employees’ process knowledge and promote them as robot programmers

market it was dominated by a few big players who made robots especially suited for the needs of the automotive industry, however we wanted to make a new kind of robot suited for small and medium sized companies and serve their needs for flexible automation. These types of organisations couldn’t have huge monolithic installations, they needed something that can fit on existing manufacturing lines and can be easily programmable; we made that kind of robot for them. We had some success with this and found that large companies need flexible automation too, so we expanded into this arena as we want to make it easier for everyone to automate. Today we have three models of collaborative

robots and are world leaders in this category with around 60 per cent of the total market share and increasing revenue every year. This has been a trend for the last seven years and is something we aim for every year.” Following an acquisition by US company Teradyne for $285 million in 2015, Universal Robots went on

to open regional offices in Delhi/ Bangalore, India, Munich, Germany and Prague, Czech Republic. This expansion has enabled the company to offer more local service to its diverse customer base, which typically includes those in the metal, plastic, wood and food industries but also includes industries such as film and TV, hospitals, construction and supermarkets. “I saw one of our robots land a Boeing 737, it was a robot co-pilot; although the main part of the IT is not ours, it is cool to see our arm used in this kind of application. Additionally, one of our robots was featured in the Alien Covenant trailer as it was building an android.” There are currently more than 12,000 collaborative robots in

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use worldwide in a variety of industries. Easily integrated into existing production environments, the three different collaborative robots have six articulation points and a wide scope of flexibility as they are designed to mimic the range of motion of a human arm. To further enhance efficiency and flexibility for customers, Universal Robots has recently launched two initiatives, UR+ and UR Academy, as Esben discusses: “UR+ is our way of making it easier for everyone to automate; the initiative was launched in 2016 at Automatica and is an eco-system of developers that make add-on products to our robots. It has had some traction so far and is going really well as it brings technology down to a more accessible level. By packaging up technology in modules, or caps as we call them,

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more people will have access to state-of-the-art technology and more integrators can require jobs from end users.” UR Academy, meanwhile, is a micro-education service that is free and available online to anyone and enables Universal Robots to not only train its distributors and integrators but also its customers’ employees. “By working with the staff of our clients we can train them to go from working like robots to becoming robot programmers. Unlike what traditionally happens where robots replace people, our customers can combine the benefit of their employees’ process knowledge and promote them as robot programmers while the robot delivers the consistency of quality and flow that automation provides. It is ultimately about humans being


Universal Robots

good at something and robots being good at something and combining the best of both worlds. It also means we can close the gap on who can automate and what can be automated, which offers a lot more potential,” says Esben. “Our whole way of working and what we deliver is based on collaboration, so it is collaboration between robot and operator to deliver the products on the factory

Roboworld US-based Roboworld has manufactured products to protect industrial robots operating in extreme environments for nearly 25 years. The company offers a host of protective suits, teach pendant bumpers, end-of-arm tooling covers and other gear to keep robots operating in harsh environments. Roboworld recently unveiled its latest innovation in robotics-related protective equipment. Pendant Armor is the first patented, mass-produced, shock-absorbing frame designed to protect robot teach pendants from damage when accidentally dropped. Each of the company’s products serves to protect key-components of its customers’ automation pipeline. Roboworld reduces vulnerable and costly shutdowns by proactively protecting its customers’ investments. Stay protected. Stay productive.

floor, but also the collaboration between us and users of the robot; we take the user very seriously when making a product for them. We also collaborate with our partners, for example with the UR+ initiative, by providing a free sales channel to them on our website and thus provide the global market with access to cutting edge technology,” he adds. With sales offices across the globe, the Denmark headquartered firm anticipates further significant growth in line with the trend of success over the last seven years. In response to this, Universal Robots will continue to invest in manufacturing facilities, sales offices and personnel while also maintaining a technical leadership position on a global scale. “On top of this, with the launch of UR+

and UR Academy, we want to get more automation out there and open up more potential markets. This is something we will continue to work on and improve,” Esben concludes. M

Universal Robots Products: Collaborative robot technology www.universal-robots.com

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A buoyant

approach T

As part of Trelleborg Group, a world leader in engineered polymer solutions, Trelleborg’s offshore operation takes performance to a new level as a specialist in the production of polymers and syntactic foam for all levels of the offshore industry 22 www.manufacturingnorthamerica.com

relleborg Group’s roots date back to 1905 and its offshore operation was established in 2009 with the goal of performing at every level to deliver innovative and reliable offshore solutions that maximize business performance and meet customer requirements. “Trelleborg started life in Sweden in 1905 as a rubber company and over the next few decades it became one of the leading suppliers of rubber products in Scandinavia, then Europe. During the 1980s the company underwent a period of conglomeration and moved into a number of different industries, however since the mid-2000s it has consolidated its operations to focus on engineered polymers in demanding environments. As such, the offshore segment of the business was developed through a series of

acquisitions and consolidations in the late 2000s, with the offshore operation being established in 2009,” explains Antony Croston, Business Group Director of Trelleborg’s offshore operation based in Houston, Texas.

Engineered solutions Following a 20-year period of market consolidation of wellknown brands such as Emerson and Cuming, CRP, Balmoral Marine and Wood Corp to name a few, Trelleborg’s offshore operation was the leading solutions provider of buoyancy, insulation and asset protection. Moreover, the offshore operation benefits from the long-term expertise and financial strength of its parent company, which has around 23,000 personnel in 50 countries across the globe and leads the way in delivering reliable and high quality


Profile

engineered polymer solutions that seal, damp and protect critical applications in demanding environments. The Houston-based offshore operation has proven syntactic experience and expertise in solving its customer’s challenging requests; focusing on design, project management and manufacturing solutions, the company provides products to customers that principally operate subsea. “Our solutions include cable protection, buoyancy products, thermal installation, fire protection and other engineering polymers,” says Antony. “While we can’t be specific on the clients we provide these services to, it is generally to original equipment manufacturers, such as first-tier contractors, installation and drilling contractors and so on, while the operators we work with tend to be major and independent firms.” He continues: “The reason people come to us is our technology; we have always had a focus on demanding environments that require highly

| Trelleborg Offshore

So while we are revolutionizing deepwater drilling and increasing performance we are also actively engaging with our customers to understand what their challenges are and to try and alleviate these engineered solutions. In fact, the company was essentially built on syntactic foam more than 50 years ago. Today our attention is on investment in product development and innovation as well as material development. This is supported by a strong team that is focused on delivering high quality solutions for customers, whether that is the development of a new product or material. We also partner with various industry bodies such as universities and clients with intellectual property that they are looking to commercialize. Ultimately we have a technology-driven approach to business that is fed by the needs of our customers.” Notable products within the company’s enviable portfolio

include Drill Riser Buoyancy, which provides critical support to the riser; a conduit for the drill string and drilling fluids from the ocean floor to the rig. This product has significant weight that must be supported by its own structure and by the drilling vessel. In order to reduce this weight in water to a more manageable amount, discreet buoyancy units are fitted along the length of the riser. There is also the RiserGuard, which provides complete protection of bare riser joints and external lines during handling, storage and drilling operations. This abrasion resistant product is designed to protect the drilling riser from impact damage during running or retrieving through the moon pool area.

Increasing efficiency As a company that is committed to strategically aligning with market developments, the Houston operation’s current core activities are centered on revolutionizing deepwater drilling operations through the utilization

Sea transport of Drill Riser Buoyancy Modules

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NjordGuard Wet Test

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Trelleborg Offshore

of software analysis. “In Houston the deepwater drilling market is a major focus for us as it is a huge challenge for companies in this sector to reduce the cost of drilling the well. In order to lower costs, they need to expand usability of assets in harsh environments, so what we are looking at doing is reducing the impact of the environment on these vessels by changing the profile and performance characteristics of our products. This will include incorporating specific features to reduce vibration, Helical Buoyancy is one example of this,” highlights Antony.

Helical Buoyancy Developed alongside Diamond Offshore Drilling, the Helical Buoyancy riser technology is a patented riser buoyancy design that reduces riser drag and mitigates vortex-induced vibration in offshore applications, while also enabling enhanced operational efficiency. An alternative to adding fairings or strakes to the drilling riser, this solution can reduce deployment time and expenses during operations; it also improves safety as it eliminates the need for employees to work below the drill floor to attach the separate apparatus. Thanks to its innovative features, Helical Buoyancy not only improves the economics of offshore drilling for operators, but will also boost efficiencies in highcurrent environments. “We need to partner with our customers to ensure we are all working together to reduce the break-even costs of a barrel of oil; that is the goal for everybody.

Global Finite Element Analysis of Drilling Riser

So while we are revolutionizing deepwater drilling and increasing performance we are also actively engaging with our customers to understand what their challenges are and to try and alleviate these. In terms of innovation, this means we are looking to push VIV suppression with Inverted Helical strakes side view

VIV suppression with Inverted Helical Strakes ISO view

materials for harsh environments even further, whether that means significant reductions in the density of the material or at the same time maintaining or even increasing its strength,” says Antony. “We have already seen huge benefits from a life cycle cost point of view when we have reduced the size of components, while still providing the same performance, as this saves our clients a significant amount in storage and installation charges. In fact, we have seen that the higher performing materials add a significant amount of overall value to our clients.” With the oil price remaining a challenge for those in the oil and gas industry, Trelleborg’s offshore operation is keen to become a leader in the segments that it operates in through the development and delivery of new technology that will benefit customers and complement its existing product line. “We want these products to become the industry standard over the next three to five years,” says Antony. “During this period we also want to consolidate our position as a market leader and enhance the technological relationships that we have with our partners.” M

Trelleborg Offshore

Eddy Shedding on Conventional Buoyancy

Services: Specialist in the production of polymers and syntactic foam www.trelleborg.com/en/offshore

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A unified

brand

Operating as the parent company of five unified manufacturing businesses, Unitech Aerospace provides the aerospace, marine, medical, defence, nuclear and rail industries with composite and metallic structures and components that meet demanding and complex production requirements

E

mbodying more than 80 years of experience in the manufacture and assembly of high-quality composites and metallic components and aerostructures, Unitech Aerospace is a leading provider of build-toprint and design-build solutions for clients operating within the aerospace and defence industries. Unitech Aerospace is the parent company of Unitech Composites (Hayden, Idaho), North Coast Composites and North Coast

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Tool & Mold (Cleveland, Ohio), Paul Fabrications (Derby, UK), Tods Aerospace (Yeovil, UK) and Tods Defence (Portland, UK), which allows the business deliver a comprehensive range of specialisations comprising: • Structural and non-structural composites laminates and assemblies • High standards of quality, on time delivery and lead-times • Fast turnaround in prototype manufacturing


Profile

| Unitech Aerospace

We also maintain virtually 100 per cent control of our manufacturing steps so that minimal outside processing needs to be performed

• Design, development, test and manufacturing expertise • Honeycomb core machining, forming and sandwich panel construction • Carbon fibre, fibreglass and Kevlar composites with multiple resin systems • In-house ultrasonic and x-ray non destructive testing (NDT) • Manufacturing and tooling engineering • Broad OEM and tier 1 approvals The business previously operated

under the name of AGC AeroComposites until February 2017, when it was announced that the decision had been taken to rebrand the company as Unitech Aerospace. Under this new branding the business continues to provide its established portfolio of services with a fully unified brand and direction. “We operate composites, tooling, resin transfer moulding and metallic-based businesses within our portfolio of companies. We felt that we should present to our various markets as a unified group and yet trade on our industrial heritage with the brand names that are well known and respected across our industry,” reveals Unitech Aerospace CEO, Wayne Exton. “For example Tods Aerospace is well known as a highly engineered composites provider. Going forward we plan to maintain the Unitech Aerospace parent company name and as we progressively grow both organically and by acquisition, we will maintain the core brand values inherent in our operating businesses.” Throughout the company, Unitech Aerospace maintains a strong core of values, which are further translated into the group’s processes and procedures. These processes are standardised across the business to allow each company within the Unitech Aerospace group to fully leverage the advantages of its operational procedures, while remaining committed to the local development of each division. “Our leaders can be focused on execution and growth and have significant autonomy to do what

is in the best interest of their business locally. We look for our leaders to be entrepreneurial and nimble,” Wayne elaborates. “Each of our businesses has a combination of unique manufacturing processes and specific customer and regulatory certifications to support the customer base.”

Highly efficient Unitech Aerospace boasts many years of industry experience of working with the manufacturing industry’s top OEMs and tier 1 companies across multiple platforms and programmes. These include military and commercial applications, while the company carries over 30 process and qualification specifications for composite, sandwich and bonding related work. These are further supported by a strict quality statement that is committed to delivering high quality products on time through the continued adherence to AS9100 and NADCAP guidelines. “We supply to most of the aerospace community as either a tier 1 or tier 2 partner. For example, we produce air-to-air refuelling pods for Cobham, complex fabrications for Rolls-Royce engines and the F-35 BOSS helmet for Rockwell Collins. We also manufacture multiple products for GE, Honeywell, Spirit, Boeing, Airbus, Triumph and others. We provide products for the commercial aircraft, business jet aircraft and military aerospace markets. We also provide sonar domes to various sovereign naval forces as well as prime defence contractors,” Wayne details.

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“On the composite side, this covers the entire range of inautoclave to out-of-autoclave operations and RTM/VARTM capabilities to support the wide range of structural applications for our products and to create the most cost-effective basis for the end user. On the machining side, we possess a full range of machining applications ranging from forming capabilities to laser weld/drill and metal forming,” he continues. “We also maintain virtually 100 per cent control of our manufacturing steps so that minimal outside processing needs to be performed – this gives us the broader ability to continuously improve cycle time and cost yet also maintain our total quality expectations. We have embraced lean manufacturing principles to focus on waste

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elimination, level loading, and high quality yield. Even our daily status boards have been standardised to drive common metrics, focus, and communication. Our end goal is an entirely visual factory providing our employees with the tools, planning parameters and capital investment to support the dynamics of the complex requirements of our clients.”

True partnership At any given point in time Unitech Aerospace has a number of exciting projects moving forward, which include technology applications using its advanced fibre-laser machine or its automated composite lay-up machine. These range from continued support to the company’s existing clients as well as the introduction of new


Unitech Aerospace

services to new clients, with details of the these projects being communicated through the Unitech Aerospace web-site and press releases. “Our competitive edge beyond our strong technical capabilities and track record is to develop a true partnership with our customers above the normal day-to-day business. This includes dedicated resources assigned to a project, joint-planning sessions to establish a future state capabilities matrix and capacity allocation, and finally a process agreement that streamlines everything from the commercial terms to the delivery parameters,” Wayne says. “We are continuously looking at new programmes and opportunities and we perceive significant potential for growth through partnership with our customers and are in the process

of developing several exciting new technologies.” With years of industry experience and a newly unified and strong industry brand, Unitech Aerospace is well placed to continue to deliver worldclass manufacturing solutions to its clients across a range of industry sectors. During the coming months and years, the

company will focus on increasing its position and service portfolio, while serving the needs of both new and existing clients. “Our vision for the future of Unitech is expanded capability to take on a higher level of support for our customers,” Wayne concludes. “This includes continually growing our engineering team into a world class developer of new technologies and the application of new materials as well as our methodology for creating manufacturing enhancements, sub-assembly to final assembly support and logistical control to provide a seamless interaction.” M

Unitech Aerospace Services: Complex composite and metallic manufacture www.unitech-aerospace.com

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Components of

success Unitech Composites, a Unitech Aerospace Company, has over 35 years experience in the manufacture and assembly of high-quality composite components and aerostructures

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Profile

| Unitech Composites

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Unitech Composites

M

ark Withrow, Vice President & General Manager, began by explaining that today Unitech Composites is specialised in the production and creation of complex laminates and sandwich panels, as well as multi-axis machining, close tolerance fabrication and automated hand layup. “We serve the commercial and defence aerospace sectors, and we have establised a long standing reputation for quality, on-time performance, broad industry certifications and processes, low cost and agility,” he said. In fact, the manufacturer has numerous design platforms and a range of manufacturing technologies from which to choose and utilises over 80,000 square feet of manufacturing space in Hayden, Idaho (close to Spokane, Washington) allowing it to offer premium results throughout all phases of manufacturing. “We offer complete composite solutions with extensive manufacturing capabilities and a highly skilled workforce, and we have the ability to handle process specifications on a full spectrum of materials with a full suite of regulatory certifications,” Mark noted, when highlighting more of Unitech Composites’ skills and services. “What we provide is a low-risk, optimised solution, from a trusted lifecycle partner and we can work from conceptual design to full-rate production. “We were founded in 1979 and we have our roots in the NASA space programme,” he added, further highlighting the organisation’s exemplary pedigree. Today clients include companies such as Airbus, Avcorp, The Boeing Company, GKN, Honeywell, MD Helicopters, Northrop Grumman, Spirit Aerosystems, the US Army and many more companies both large and small. Many of these clients come to

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Unitech Composites to utilise its expertise in autoclave processing, the hand lay-up of carbon fiber parts and automated hand layup. Indeed, the organization has recently invested in a state-ofthe-art automated hand lay-up machine, which produces quality superior to hand lay-up and offers increased mistake-proofing, consistent laminate thickness, elimination of bridging, voids and variability. “We are committed to investing in technology to support future state-of-the-art developments,” Mark highlighted. This new technology has been

added to the existing equipment used within the factory, which includes: • Six clean rooms • Three autoclaves (largest 15’ x 30’) • Four ovens (largest 24’ x 26’) • A self-contained machine shop and tooling manufacturing center • Complex composite ducts using eutectic salt and plaster mandrels • Three 4-axis Haas CNCs • Three 5-axis DMS CNC (largest 25’ X 10’) • Two 3-axis routers

Larkin Precision Machining Larkin Precision Machining started with a division of AGC called Integrated Composites in 2005 in Marina, CA. We started with some prototype components to join with composite structures to replace much heavier metal structures, mounted to Military Aircraft. As time went on, Integrated Composites was awarded multi-year production and shipping contracts. Eventually the division of AGC Integrated Composites was transferred to Unitech Composites. Today Larkin Precision Machining is very proud of the fact that it currently supports Unitech with titanium components for the F-35 aircraft pilots’ helmet. Larkin Precision Machining is a diversified company. Not only does it work in defense, it also has customers in the medical and food industries. It prides itself on being a small shop with big customers. The company recently obtained AS9100 and ISO9001 certifications that sets it apart from competitive businesses in the small shop category. Larkin Precision Machining is investing into its future with technology and automation. The milling department comes with state-of-the-art and high-speed CNC machining centres comprising of vertical and horizontal machining centres. A pair of palletised Matsuura H-Plus 405s with 30hp and 240 tools takes care of the horizontal side of things, while currently all of the verticals are Haas, including three new UMC-750 5-axis machining centers and six 3-axis verticals including a large 40” x 64” VF-8. The UMC-750’s have increased overall productivity and efficiency due to ease of set up, getting more done in one operation, and allowing operators to run multiple machines more efficiently. We want potential customers to know that we offer a lot more than some of our competitors. We always deliver quality products, above and beyond our customer’s expectations. We are looking forward to many more years supporting Unitech.


• In-house non-destructive testing (ATTU) • Laser ply placement • Automated ply cutting The full spectrum of materials in use at Unitech Composites include:

Prepregs • Polyester-glass • Phenolic-glass • Epoxy-glass • Epoxy-Kevlar® • Epoxy-graphite

Industri-Tech LLC Industri-Tech LLC has been a supplier and partner of Unitech Composites for approximately 32 years. We have watched Unitech grow internally and supported the company through its acquirement by AGC Aerospace. We have enjoyed growing along with Unitech and the relationships we have developed with the company’s people over the years. Richard McMillan and his team hope this relationship will continue to grow successfully for Industri-Tech LLC and Unitech.

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Cores • Nomex®-Honeycomb • Aluminum Honeycomb • Klegecell® Foam • Urethane Foam These state-of-the-art technologies and materials are combined and used in the creation of products including: • Environmental Control System (ECS ducting) • Active Winglets • Brackets and Intercostals • F-35 BOSS Helmet • Edgebands • Weapons Pylons (Lightweight Armament Support System (LASS) and Multi Station Lightweight Armament Support System (MLASS) It is apparent from this list that Unitech Composites’ products are extremely sophisticated and


Unitech Composites

used in demanding applications that require the highest levels of quality and service. “This means we have to maintain constant communication with the customer,” Mark confirmed. “We are a totally customer-focused business and we have stringent quality reviews in place to ensure we always meet the needs of our clients.” He went on to give more details on specific products that perfectly illustrate the technical capabilties of Unitech Composites. “We developed the Binocular Optical Support Structure (BOSS) Helmet for the F-35, and we make this part for Rockwell Collins,” he said. “This is an extremely high precision composite/metallic structure for the helmet mounted heads-up displays. “We also developed weapons

pylons – the LASS and MLASSthat were designed to replace the legacy steel weapon pylon on the Blackhawk helicopter (UH-60). These are lightweight and corrosion resistant, but use the same installation kits and procedures. Made from a full carbon structure with aluminum

fittings, they offer 53 per cent weight reduction and meet all US Army service load requirements. These are currently in service with the US Army.” As it advances into 2017, Unitech Composites is in a strong position to build further success, and the recent rebranding of parent company AGC AeroComposites to Unitech Aerospace can only help to develop its reputation for performance, quality and value. “We feel that the market is strong and offers great opportunities for growth for our company,” concluded Mark. “We are optimistic about the future.” M

Unitech Composites Products: Composite products www.unitech-aerospace.com/ content/composite-manufacturing

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Reliable reputation Founded in 1937, Paul Fabrications Ltd has provided precision manufactured complex sheet metal and machined assemblies to the aerospace, defence and nuclear power refuelling industries for over 70 years

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he company has been involved in the development of major aero-engine programmes for both civil and military applications and has honed strong expertise when it comes to the production of value-added complex fabricated and machined components and assemblies. Previously under the name AGC AeroComposites - Derby, the company returned to its original name of Paul Fabrications in January 2017. Paul Fabrications’ VP and Managing Director, Kevin Brown discusses this development: “Our organisation recognized the history, value and pedigree behind the original Paul Fabrications name and made the strategic decision to operate under the legacy name. Our parent company, AGC AeroComposites, has also rebranded to Unitech Aerospace and all of its companies are branded under their original legacy names; these include Unitech Composites,

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North Coast Composites, North Coast Tool and Mold, Tods Aerospace and Tods Defence.” Working in 60,000 square feet of manufacturing space in the East Midlands (UK), the company’s 145 employees reinforce the reputation that Paul Fabrications has built through the successful application of sound engineering principles that ensure the everchanging demands of customers are met. Moreover, personnel take pride in consistently exceeding the expectations of customers when it comes to both the delivery and quality of products. These strengths have resulted in an enviable customer base that includes world leading aerospace organisations and long-term contracts with both nuclear and aerospace clients. “Springfield Fuels is our main nuclear customer with a relationship lasting over 50 years and our products going into all


Profile

UK nuclear power stations. Our aerospace customers include Rolls-Royce, strategically located close to our Derby facility, MTU, Safran, ITP, Meggitt and FACC. We are particularly proud to have received a recent major contract award from Rolls-Royce based on our collaborative approach to conducting business,” says Kevin. Indeed, while Paul Fabrications has strong orders for 2017 that will result in more than 50 per cent revenue growth to the business; the main increase stems from the company’s long-term strategic partnership with Rolls-Royce that was signed in October 2016. “Historically, the business did not have a strategic relationship with Rolls-Royce, but today a collaborative approach centred around a deeper understanding of how we can add value has led us to a strong partnership with common goals. We will work together to manage a growing portfolio of both volume and legacy parts and we are now starting to see the benefits of being a larger and more strategic supplier to Rolls-Royce. This is a long-term relationship and we see this relationship growing significantly over the coming years. The key to our success is in execution and this is our absolute

| Paul Fabrications Ltd

focus,” says Wayne Exton, CEO of Unitech Aerospace. “This partnership is a critical part of the ongoing transformation of Rolls-Royce’s supply chain for metallic fabrications and was signed based upon our ability and commitment to provide a turnkey new product introduction (NPI) process. This innovative, integrated process will embed a Rolls-Royce team inside of Paul Fabrications’ Derby site allowing for new levels of collaboration, transparency and risk reduction between the two organisations. The ultimate goal is to significantly reduce RollsRoyce’s time to market and risk levels through a consolidation of its mature legacy products,” elaborates Kevin. Not only benefiting from longterm expertise in the aerospace and defence industries, the company boasts an impressive manufacturing plant that ensures complex projects are completed on time and to the best possible quality. Current key manufacturing and test capabilities include sixaxis fibre laser drilling and cutting machines, five-axis CO2 laser cutting machines, three, four and five-axis CNC milling machines; turning, hot and cold forming, resistance fusion and welding

equipment, heat treatment up to 1100 degrees Celsius, CMM and optical inspection and nondestructive testing, which includes x-ray inspection. “Paul Fabrications produces highly technical and complex products. The effective use of capital to ensure we have a world-class plant and equipment is essential to our competitive advantage. We will stay ahead of the curve by working in partnership with Rolls-Royce and our other customers using a common technology roadmap to carefully plan our future capital deployment on state-of-the-art machinery. When you walk into any Unitech Aerospace business, you are going to experience a premier facility, people who take pride in what they do and strong management practices,” says Wayne. With a state-of-the-art manufacturing facility, the financial strength of its parent company and long-term experience, the future looks positive for Paul Fabrications as it continues to deliver high quality solutions to its demanding customer base. “We will strive to continue the transformation of our business so we are positioned to meet our customers’ expectations of 100 per cent quality and on-time delivery whilst also providing a seamless new product introduction process. Our company’s vision is to ‘deliver solutions together,’ and we firmly believe that by embracing this approach and continuing to invest in both our business and employees, we will see year-onyear growth,” Kevin concludes. M

Paul Fabrications Ltd Products: Advanced manufacturing and engineering expertise for a wide variety of metallic precision products and assemblies found in commercial and military aircraft, nuclear reactors and power generation turbines www.paulfabrications.com

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Strength in

numbers Operating as part of Unitech Aerospace, Tods Aerospace and Tods Defence specialise in the engineering, design and manufacture of advanced materials technology for aerospace and naval acoustic structures

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Profile

| Tods Aerospace and Tods Defence

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Tods Aerospace and Tods Defence

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ods Aerospace was established in 1932 as W&J Tod Limited and transitioned into boat building and defence work during the 1960s before finally joining the Unitech family in 2013. The company is based in Crewkerne, Somerset and today represents an industry leader in the design and manufacture of complex composite structures for the aerospace, rail and defence markets. Within this dynamic group of companies, Tods Aerospace specialises in the engineering, design and manufacture of advanced materials for the aerospace sector, while Tods Defence is focused on serving clients within the naval and defence industries. During its

Tods Aerospace is extremely customer focused and we strive for superior quality, on-time delivery, customer value and satisfaction. This is complemented by world-class design and engineering history of operating within the aerospace sector, Tods Aerospace has provided products and advanced support services to prestigious industry operators including Rolls-Royce, Leonardo Helicopters, Airbus, BAE Systems, Zodiac Interiors and Hitachi Rail. By operating as a key part of Unitech Aerospace, Tods Aerospace is able to leverage the strengths of the wider business to gain further efficiency and

generate further benefits for its clients. “Through our membership of Unitech Aerospace we have gained additional financial strength with an added capability for investment to grow the company’s product portfolio. We can draw on the expertise and support within the group to achieve a greater offering for our customers, as well as access to a larger customer base,” reveals Vice President and Managing Director, Peter Eckersall. “Tods Aerospace has been a recognized and respected brand in the industry for over 30 years and merging this reputation with Unitech Aerospace results in a very powerful combination. Having the support of a talented and experienced senior executive team also further provides the

Desktop Engineering Desktop Engineering (DTE) has been a supplier to the TODS Group of companies for nearly 10 years, supplying advanced engineering software for design and analysis. As a partner with the major software author Dassault Systèmes, we have supplied and supported CATIA PLM software enabling TODS to design and manage information within its engineering design teams. Furthermore, TODS is a user of NASTRAN and PATRAN written by MSC Software and supplied and supported by DTE throughout this period. Its level of high use places technical demands on our support team and we are pleased TODS continues to use this service.

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Tods Aerospace and Tods Defence

stability and direction to allow each individual business within the group to flourish and grow.”

World-class engineering Throughout all of its operations, Tods Aerospace is dedicated to providing its clients with the highest standards in quality, in accordance with the strictest industry certifications and customer requirements. This includes more than 30 separate qualification specifications for composite, sandwich and bonding related works. These qualifications are continually kept up to date, while new process credentials that are demanded by the manufacturing industry are further incorporated through on-going investment and training. “Tods Aerospace is extremely customer focused and we strive

Westec Precision Limited Having worked closely with Tods Aerospace and Defence divisions for a number of years, Westec Precision has developed a dynamic working relationship that improves production processes and manufacturing techniques through innovative tooling and special purpose equipment solutions. Having the opportunity to offer our expertise to assist the development of Tods marketleading products has been an interesting and rewarding experience that we hope will continue for many years.

for superior quality, on-time delivery, customer value and satisfaction. This is complemented by world-class design and engineering, which enables the business to provide a complete composite solution,” Peter says. “This incorporates concept design, process development, qualification support, manufacture, repair and full through-life maintenance. We are fully committed to investing in technology and people to support future state-of-the-art developments with continuous improvement through lean practices, staff development and training throughout the business.”

Modern facilities Tods Aerospace presently maintains three production sites, with two located at Crewkerne and the other in Portland,

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Dorset. Each of these sites is AS9100 approved and the two Crewkerne sites are additionally NADCAP approved for composite manufacture. The company operates an extensive array of equipment including three clean rooms, four autoclaves, two fiveaxis CNC machines, an X-ray and NDI lab, reticulation machine and curing ovens. Tods Aerospace also operates two design offices that employ industry standard design tools comprised of CATIA, NASTRAN/PATRAN and MARC with configuration control using ENOVIA PLM. These enable vital design operations relating to: • Types of analysis • Stress analysis – Static, fatigue and dynamic • Requirements – Safety, environmental • Acoustic analysis – Sonar domes • RF analysis – For radome construction • Testing • Material qualification - Strength and environmental “The company’s facilities are constantly developed to meet

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Tods Aerospace and Tods Defence

the challenges of a continually changing industry and dynamic customer requirements. New product introduction and adapting manufacturing technology alongside continuous lean activity, means that Tods Aerospace is always challenging itself to improve the layout and capability of its facilities. Being part of Unitech Aerospace has supported this development and during 2016 we invested in an X-ray capability, additional paint facility, larger autoclave, new digital curing ovens and our reticulation capability,” Peter details. “Investment in people and personal development is also a core value within the company. We have a very successful apprentice scheme and graduate

training scheme. All employees have a personal development plan and all staff will go through some type of formal or workplace-based training while working with Tods Aerospace.” While Tods Aerospace has already achieved a strong reputation with both new and existing clients, which is further bolstered by its membership of Unitech Aerospace, the company will seek to expand its reputation even further during the coming years. This it will do by placing a high priority to achieving the 100 per cent on-time delivery of products, while maintaining the highest levels of quality. “We will continue to utilise the financial strength of Unitech Aerospace alongside our own capability

for investment to grow the company’s product portfolio,” Peter concludes. “Perfect delivery and quality performance through continued lean initiatives and investment in new technologies will equally remain a high priority, as well as continued investment in people through apprenticeships, vocational training and graduate training schemes. All of these initiatives will further allow Tods Aerospace to develop a stronger supply chain that is inclusive to looking to identify low cost countries for further growth.” M

Tods Aerospace / Tods Defence Services: Complex aerospace solutions www.todsaerospace.com www.todsdefence.com

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Aerospace composites and tools North Coast Composites Tool and Mold manufactures advanced composites and tooling for the aerospace industry

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orth Coast is made up of two business units: North Coast Tool & Mold Corporation, founded in 1976, and North Coast Composites, founded in 2003. Both business units are located in a 65,000 square foot facility in Cleveland, Ohio and are ISO9001 and AS9100 certified. In July 2016, North Coast was purchased and became part of Unitech Aerospace. Eddie Morrison, Vice President and General Manager of North Coast was keen to explain the reasons behind the partnership with Unitech Aerospace. “We were very much a stand alone business prior to being acquired by

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Profile

| North Coast Composites Tool and Mold

Unitech Aerospace. We didn’t have a lot of capital investment and selling the business to Unitech provided the access to capital that we needed. Furthermore, Unitech brought improved business practices and a larger portfolio of customers. What was originally a small company without a lot of leverage has now formed meaningful relationships with the bigger customers that Unitech has access to.� North Coast specialises in the development of complex, high tolerance composites and is an industry expert in Resin Transfer Molding (RTM),

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North Coast Composites Tool and Mold

vacuum-assisted resin transfer molding (VARTM), lay-up molds, compression molds, bond tools, invar tooling plastic injection molds, assembly jigs, trim & drill and machining fixtures, investment cast dies, handling equipment, stretch form dies, turnkey manufacture work cells and contract machining. It provides turnkey solutions for RTM/VARTM and resin impregnated parts, including product-design assistance, tool design and fabrication, prototype part fabrication, manufacturing planning assistance, and production part fabrication. The company’s main focus right now is on resin transfer molding: “Our core competency is in RTM and the majority of the parts we manufacture are resin transfer molding based. We make large containment cases for the Honeywell HTF7000 Series Engine, ducts for the new GE LEAP engine and inlet guide vanes for the B-1B Lancer Bomber. The applications

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are varied, but its mainly all RTM now. We are starting to move towards compression molding and will be focusing more on these components this summer,” says Eddie. This is an exciting development for the company as it has been given the go ahead to manufacture compression molding components for the military helmet heads up displays, a see through display that sits directly in a pilot’s line of sight to significantly increase the perception of environmental elements. “We are going to provide compression molding components for the heads up display and have invested in a brand new press to carry out the work. We expect to complete the contract by the end of the year and will be looking for additional compression work,” explains Eddie. In 2016, North Coast produced over 1550 composite assemblies with a 100 per cent on-time delivery record. The tooling side of the company supports the manufacturing

side of the business. The sector develops tools for its own company and produces precision mold tools, holding fixtures, trim fixtures, assembly fixtures, breakdown autoclave tooling and steel and invar autoclave tooling for its customers. Currently it’s the tooling side of the business that has attracted most of the company’s international interest, and its biggest tooling job is for the French owned multinational aircraft company Safran. Membership and recognition by worldwide organisations highlights the level of service provided by the company. “As a National Aerospace and Defense Contractors Accreditation Program (NADCAP) certified manufacturer, we instill confidence in our clients that North Coast Composites is a vendor with unmatched quality, highly responsive, and industry-leading services for the dynamic global aerospace industry,” explains Eddie. “Our strategic vision for the next three years is to double the business. The tooling side of things currently represents about a third of the group. We are purchasing a lot of new equipment including new CNC machines. We want to expand the area of tooling so we can deliver larger fixtures and more complex tools. We’ve spoken to our customers about this and they are excited about moving forward with us. Regarding the composite side of the business, we have a reputation for being able to create complex parts that other companies can not do. We already work with the likes of Honeywell, GE, and IAI and we are striving towards expanding our portfolio in 2017,” concludes Eddie. M

North Coast Composites Tool and Mold Services: Manufactures composites for the aerospace industry, and tools to support its work and other companies www.northcoastcomposites.com


Structured

growth S Suncor, Inc. is a structural steel fabricator with offices in Hialeah, Florida and DeForest, Wisconsin - it provides structural steel products throughout the US 50 www.manufacturingnorthamerica.com

ince its foundation in 1992, Suncor Inc has built a solid reputation in the market for structural steel fabrication thanks to its strong performance and customer-centric approach to business. As such, the company has provided structural steel to a wide range of industries and buildings, working on notable projects such as industrial buildings, airport expansions, medical buildings, offices and schools to name a few. Looking back at the early days of Suncor Inc is Managing Director Doug Kuiper: “The initial focus on any start-up company is survival.

Creating cash flow and selling the first contract is always difficult. My personal background is within the engineering sector as well as drafting related to structural steel fabrication so I used these skills to generate income. Once this was accomplished, I started bidding on small jobs in Florida and other regions; the next challenge was to establish a location where we could successfully create a market for fabricated structural steel. After experimenting with three different regions we settled on southeast Florida where we found a stronger demand for our goods and services. From


Profile

there I partnered with other steel fabrication companies who preferred to work on a labor only basis outside the region to produce the products we sold; once a market for steel products had been created, I was able to back away from the technical side and manage the projects. About three years later, I was able to increase my staff and increase our volume.” It is in this Tri-County region of Southeast Florida where Suncor Inc. created a loyal and returning customer base. This is attributed to its focus on meeting customer requirements in an efficient and quality-centric manner, as Doug notes: “In those early days, once we had increased our staff and volume, rather than booking more contracts I focused on maintaining the same quantity of contracts but sought larger contract amounts. After we survived five years in operation, I felt confident we would be a successful company. I believe we have maintained this success because of our focus on solidifying customer relationships;

when it comes to priorities this is placed highest on the list because happy customers will be repeat customers. I believe that profitability will take care of itself with a strong and returning client base.” A year later, Suncor built offices in DeForest, Wisconsin and Hialeah, Florida. These premises were not purchased until Suncor Inc., which was developed around a zero-debt strategy, had the money to build them in 2007 and 2008 respectively.

Diverse markets To further enhance operations, the company established a sister company, National Metals, in June 2009. Handling the manufacturing of specialty metal

Indeed, not only can it handle huge construction projects, Suncor is also capable at delivering smaller, customized specialty projects that require unique and intricate details

| Suncor Inc

products, National Metals is certified by the American Institute of Steel Construction. “Since our inception and up until 2008 our primary market was providing structural steel for public schools, mostly K-8 and high schools; however, after the bank collapse, this all changed,” says Doug. The public school market began a depressed phase from which it still has not recovered. Suncor Inc has since diversified its markets to retain a well balanced customer base spread out over many sectors. “Even though the public school market has not returned, we have seen an increase in the amount of charter schools being built over recent years. There are a number of reasons for this increase in charter schools, for one thing, some parents want to be more involved and this offers the opportunity to be. Moreover, these schools also offer teachers the chance to be more innovative, so this has a strong appeal to certain faculties as well as students who have a strong interest in a certain

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area; these students will also be attracted to these programs such as science, technology, engineering or math (STEM). We feel that building charter schools will represent around 20 per cent of our volume over the next several years and perhaps longer.” He continues: “Nevertheless, based on our learning experience from 2008, we realize nothing lasts forever. For the health of the firm, it is important for Suncor to remain in many different markets rather than focus on just one or two. We are currently offering structural steel products in the areas of aviation, healthcare, public and private schools, gaming, industry and hotels.” Although Suncor has developed its reputation on expertise within structural steel fabrication, providing the foundation for

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retail facilities, office expansions and so on, the company has also mastered the finer art of this complex process. Indeed, not only can it handle huge construction projects, Suncor is also capable at delivering smaller, customized specialty projects that require unique and intricate details. Products created by the company include specialty canopies, custom rails, egg crate grilles, perforated metal rails, pan stairs with picket rails, sun shades and aluminum walkways.

Technology investment While diversification of market segments and services has financially strengthened and cemented Suncor Inc’s role as a structural steel fabricator to trust, the company is also keen to stay ahead of the competition


Suncor Inc

through investment in cutting edge machinery and equipment. “Five years ago we realized we had to change our detailing program from a 2D CAD program to a 3D modelling program. We use a Tekla modelling program that is integrated with new equipment that we have purchased over the last few years to speed up production without having to add manpower,” says Doug. With state-of-the-art efficiency and quality enhancing equipment and a broad customer base, Suncor Inc is keen to continue serving its loyal clients in the State of Florida as well as up the east coast of the United States while also sourcing opportunities for growth further afield. “Our focus over the next 12 months will not change much, except that we would like to focus on

larger structural steel projects in New England, where steel is the building material of choice as opposed to concrete that is prevalent in the southern states,” Doug concludes. M

Suncor Inc Services: Steel fabricator and provider of structural steel products www.suncor.net

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Harnessing horsepower Since 1918, Twin Disc power transmission technology has been changing the way the world works

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or nearly 100 years, the company has remained a leader in designing and manufacturing the most innovative heavy-duty industrial equipment. Its products can be found in the drivelines and powertrains of a huge array of equipment—from tractors, trucks and turbines to work boats and pleasure craft. Its line-up includes powershift transmissions, mechanical and hydraulic power take-offs, gearboxes, torque converters, pump drives, air clutches, electronic shift controls and universal control drives. The company’s story began with a unique twin disc clutch designed to make a farm tractor more reliable, more productive and easier to operate. It worked like a charm and helped to revolutionize the agricultural equipment industry. One innovation led to another, and today Twin Disc has

built a worldwide reputation on its ability to engineer and build power transmission and propulsion systems for a vast array of applications. In fact, Twin Disc’s basic powershift automatic transmission design has proven so strong and versatile it has evolved into all sorts of niches. For example, manufacturers of aircraft rescue and firefighting (ARFF) vehicles all over the world routinely specify Twin Disc automation transmission systems. Military transport trucks and tank retrievers endure the rigors of the battlefield, utilising Twin Disc transmissions. And oil and gas field operations use Twin Disc transmissions to harness the huge horsepower of cementing and fracturing trucks. The company’s marine propulsion products – transmissions including the revolutionary QuickShift,


Profile

| Twin Disc

Innovation is one of the driving forces behind the success at Twin Disc and this is supported by its superlative manufacturing capabilities – summed up by the phrase ‘if we can think it, we can build it’

Arneson Surface Drives, Rolla Propellers, electronic controls, and the Express Joystick System – continue to set the industry standards for high performance applications. Furthermore, it is far and away the world’s leading supplier of power take-offs (PTOs) and clutches for heavyduty applications such as wood chippers, tub grinders, rock crushers, irrigation pumps and marine installations. Thanks to a rigorous dedication to continuous development and a highly-experienced research and development (R&D) department, over the last 12 months numerous solutions have been announced and launched, which demonstrate the level of engineering expertise and service afforded to its customers by Twin Disc. As recently as January 2017 the organisation announced the a new ‘Remote Over Center’ PTO, the RO

314/311. The innovative product uses a patent-pending design to remotely engage the over-center mechanism in the company’s proven SP 314/311 PTO and is complementary to the previously released RO114/RO214. The RO 314/311 can be engaged and disengaged remotely via a control valve and/or electronic control when machinery configurations or location hinder easy access to activation. Hydraulic or pneumatic actuation is achieved through ports, making access to the fittings uncomplicated and straightforward. Hydraulic or pneumatic pressure is required only to engage or disengage the PTO; the fluid or air supply can be shut off when not needed. Without the constant hydraulic or pneumatic flow of other designs, the unit’s clutch operation is far more efficient and cost-effective than that of

its competition. The RO 314/311 is dimensionally similar to the current mechanical SP 314/311. It continues to utilize three 14” friction plates in the 314 and three 11” plates in the 311. Existing SPs may be field converted to an RO using kits available from Twin Disc. The advanced design of the PTO allows for side load and inline applications. External cooling, filtration or a rotary union are not needed. Built strong to last, the RO 314/311 excels in a wide range of industrial applications including agriculture, construction, manufacturing, marine, mining, timber, and oil and gas production. The units are installed by OEMs and in custom settings.

HP800 launched The RO 314/311 was followed up by another debut in March (at CONEXPO-CON/AGG, in Las

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Vegas, Nevada) of the HP800, a middle horsepower range option in its industrial lineup of heavy-duty, hydraulically-actuated PTOs. With an impressive maximum power rating of 800 hp at 1800 rpm, the HP800 is built to deliver serious muscle where other PTOs would falter. It’s ideal for driving pumps, grinders, crushers, dredgers, chippers, shredders, heavy-duty drills and other severe applications. Like Twin Disc’s first hydraulically actuated PTO, the HP1200, the HP800 has a modular design allowing for either side-load “P” or in-line “I” applications with the simple change of bearing carriers. An advanced control system allows for smooth engagement of the driven equipment. A key feature of the HP800 is the auxiliary drive pump towers with 400 hp maximum capacity

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per tower, or 450 hp maximum for both. They’re rotatable by 0°, 45° and 90°, either clockwise or counter-clockwise, to allow for clearance in any installation. Optional speed increase ratios of 0.77:1 and 0.83:1 are available. Pads and splines are easily interchangeable to accommodate varying pump sizes. Sizes SAE A through SAE E are available.

Innovation A popular option that can be built into the HP800 is an integrated reservoir. Unlike a separate, externally mounted unit, it saves space and reduces installation cost. This innovative design allows for the installation of the standard charge/lube pump on a separate pad, freeing up all four auxiliary pads for customer use. A spring applied, hydraulically released

brake (SAHR) has been added as a standard feature. An integral, mechanical brake release allows the output shaft to easily be rotated if the driven equipment becomes jammed. An innovative, high-capacity brake with control logic is offered as an option. It slows the output when driving large masses in a shorter amount of time. The HP800 is available with SAE #0 (SAE J617) input housing and 18” SAE 460 (SAE J620) input coupling, or SAE #1 input housing and 14” SAE 355 input coupling. Initially offered with a dual auxiliary pump tower, a single tower version will be released at a later date. It is clear from just these two examples that innovation is one of the driving forces behind the success at Twin Disc and this is supported by its superlative


Twin Disc

manufacturing capabilities – summed up by the phrase ‘if we can think it, we can build it’. The company has invested in the finest computer controlled machine tools and organized them in the most efficient, effective and flexible manufacturing floor plans. It cross trains its operators so that they can quickly adapt to changing production line orders. Its flexible, cell-based manufacturing facilities can adapt quickly to create new products as they are developed. Its manufacturing centers in the US and Europe are certified under the provisions of ISO 9001.

Trusted brand It also has an approach where rather than supplying individual components, Twin Disc designs, engineers and manufactures carefully matched power

transmission systems. All the elements of the system – transmission, torque converters, fluid couplings, electronic controls – are designed to work together to transmit power from the source to the work – quickly, efficiently, smoothly and reliably. Twin Disc successfully builds products for so many diverse applications because it controls every step from development, from research and engineering to manufacturing to sales and service. It has the engineering and application experience to anticipate the power transmission or propulsion challenges a machine, vehicle, or marine craft will face, and has the resources to develop a specific product solution to meet those challenges. This philosophy not only produces innovative designs,

but also allows customers to integrate Twin Disc products into their production lines, which provides the end user with a better performing product while increasing the original equipment manufacturer’s brand value. With its unique engineering skills and manufacturing expertise, Twin Disc delivers systems that offer incomparable effectiveness and efficiency under the most gruelling conditions. With a vast network of distributor and dealer locations around the world, Twin Disc is more than just a name that customers know – it is one they can trust. M

Twin Disc Services: Manufacturer and distributor of power transmission equipment www.twindisc.com

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Global supply As a full service provider of global manufacturing and supply chain management services, Marketing & Engineering Solutions (MES) has developed a strong customer base that includes some of the largest OEMs and OEM suppliers in the US, Europe and Australia

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Profile

| Marketing & Engineering Solutions

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lobal sourcing and supply chain management firm MES has achieved significant success since it was founded by Hiten Shah in 2007; establishing its Ohio warehouse the same year, the company went onto achieve ISO 9001 certification a mere two years later. Opening its India sourcing office in 2010, the company went global in 2011 with the establishment of its China office and a 3PL warehouse in Mexico; incorporating its Hong Kong business the same year, the company went on to establish a warehouse in California in 2012. Following this period of major expansion, MES began to source products from Vietnam and Taiwan in 2013 and achieved a stratospheric 220 per cent growth in sales in comparison to sales in 2012. Not a company to rest on its laurels, the company inaugurated its own warehouse in Mexico and Houston in 2014 while also becoming a beneficiary of the IMMEX programme in Mexico. Following this major growth and success, the company won a number of awards in 2015, while Hiten Shah became an Ey Entrepreneur of the Year 2015 finalist in Ohio Valley. Further awards were achieved in 2016, the same year the company completed its first acquisition and entered the hydraulics industry, reached 100 employees across the globe and launched a one-ofa-kind, cross-department, tool of data storage and analytics known as MESH. As of March 2017, the company was honoured to make the Inc. 500 ranking as one of the fastest growing companies in the US and to also achieve, for the fourth year in a row, the Columbus Business First’s Fast 50 Award. Complementing each other, the two awards recognise the incredible growth rate of MES, which has gone from $30 million revenue in 2013 to

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As of March 2017, the company was honoured to make the Inc. 500 ranking as one of the fastest growing companies in the US $75 million forecast for 2016. Indeed, these two awards exemplify the relentless passion and talent of the individuals at MES who strive every day to ensure customers receive optimum quality products and services. “In the business of delivering engineering solutions, we work with various OEMs and tier one suppliers to develop a range of industrial components such as castings, machined parts, forgings, plastics and rubber parts. Working primarily in lighting, agriculture and electrical and telecom components, we are currently involved in a number of projects that include the development of a light housing casting, with a tooling lead time of just four to five weeks; providing parts in this short time frame has helped us gain a lot of business over recent years. To maintain this competitive edge, we have a very tight project

time frame and we work with suppliers that can deliver to our expectations,” says Hiten Shah, Founder and President of MES. He continues: “Another major project for us involved an engineering change from a machined component to a forged copper component for a significant cost savings to the customer. The challenge with this project was that the component required a 99.995 per cent purity. As such, we did a lot of engineering work and conducted a design of experiments (DOE) with various providers from India, Europe and Japan; trials were undertaken at a facility in India to ensure we could achieve the purity level that the customer wanted. “Currently approximately 60 per cent of our business is lighting; the agriculture segment meanwhile, is where we anticipate interesting developments and growth over the next 24 months. The automotive segment is less than 15 – 20 per cent of our business. We anticipate good growth in automotive market over the next five years.”

Worldwide operations Headquartered in Columbus, Ohio, the company today has offices


Marketing & Engineering Solutions

and warehouses dotted across the globe. Operating as a trading hub for global operations, the main activities for MES Hong Kong include direct purchasing from suppliers in mainland China, Taiwan, Malaysia, India, Vietnam and other countries in Asia as well as the management of negotiations, logistics and supply chain pricing. Acting as a consultant to suppliers, MES Hong Kong ensures quality improvement processes and provides its usual services while also acting as parent company of Ningbo Metrics, a supply chain, sourcing and trading firm that is based in the Zhejiang province of China. The main activities performed by Ningbo Metrics include supplier research and audits, supplier development, quality audits and inspection services, supplier quality management activities and purchasing and sourcing.

Focus on India Alongside Ningbo Metrics, the company has Bombay Metrics, a Mumbai based supply chain, sourcing and trading company that also provides services such as supplier research and audits, quality audits and inspection services, purchasing and sourcing. While Mumbai is the economic hub and commercial financial centre of India, it is also well connected to the rest of India, making it the perfect place for MES to benefit from the recent aggressive development in the production of metals, chemicals, automobiles and electronics. “Over the last year-and-a-half we have focused on India, which is partly due to India gaining a new prime minister, Mr Modi, who has put a number of initiatives in place; additionally, Indian manufacturers are becoming very competitive compared to China or Vietnam,” says Hiten. It is within these strategic locations that 100 associates deliver engineering solutions

to customers within industries that include lighting, industrial, automotive and agriculture. The range of talented staff within MES include six sigma engineers, sourcing experts, quality inspectors, supply chain experts, sales and account managers, business analysts and support staff. Striving to acquire talented and skilled employees in the international locations it operates in, the company retains employees by giving them a strong sense of autonomy, encouraging trust and integrity and providing a transparent and fair environment that feels more like a family; keen to develop personnel, MES also provides oneon-one coaching and training.

Delivering the best Firm in its belief that customers don’t have to settle when it comes to quality, speed and price when sourcing internationally, MES ensures optimum customer satisfaction across the globe thanks to its “win-win solutions” mission to its global customers. Inspiring organisations to turn away from compromise, the company ensures its supplier focus on delivering the best and thus, becoming the best. Looking ahead, Hiten sees opportunities for further growth and success for MES as the company seeks to increase its presence throughout Europe and Mexico while also continuing to improve its supply chain, quality metrics and inventory management metrics with the goal of enhancing its excellent reputation for customer service. “This is the secret recipe to our success and what we focus on every day, every month, every quarter and every year,” Hiten concludes. M

Marketing & Engineering Solutions Products: Delivering Engineered Solutions Supply chain and Global sourcing www.mesinc.net

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Yazaki is the world’s largest manufacturer and marketer of automotive wiring harness systems and supplier of innovative solutions to all OEMs.

Here, our special focus has always been on creating a reasonable balance between our customers’ needs and a responsible use of our environment.

Our product portfolio contains smart junction boxes, control modules, connectors & terminals, highvoltage systems, instrument clusters, displays and components.

CONNECT to the Future - to reach this goal constant innovation is necessary.

The success story of the family-owned company began in Japan in 1929. We now have more than 289.000 committed and highly motivated employees working at 478 locations in 45 countries contributing to Yazaki’s global success. Customers appreciate our expertise and core competencies in consulting, development, industrialization and manufacturing.

Our guiding principal is vertical integration and the constant optimization of products, processes and services. Modern and customer specific solutions are only possible through the close interaction of electronics, electrical components and wire harnesses whether applying fast BUS systems like Ethernet for highly flexible platforms or product scaling in a challenging global market. Yazaki connects its customers with the future – worldwide.


Profile

| Ricardo

Drive for success Ricardo is renowned for delivering class-leading, cutting edge services and products to customers in sectors such as transportation, energy and scarce resource

T

he history of Ricardo stems back to the childhood of Harry Ricardo, who from a very young age was interested in all things propulsion and even built steam engines as a child. As Harry’s passion for propulsion continued, he went on to design and build his first combustion engine by the age of 17; this was used to pump water from the well at the family home. Forming Ricardo in 1915, Harry became one of the foremost engine experts of his generation and received a knighthood for his work in internal combustion engineering in 1948. The first major project for Ricardo took place in 1915, when Harry was commissioned to apply his advanced combustion knowledge to the mark five tank engine. To solve the issue of smoke emission, Harry came up with an engine that not only significantly lowered the copious amounts of smoke but was also far more powerful; more than 8000 of these engines saw military service since 1917, making it the first engine to be mass produced. Following this innovative development, the company went on to create the turbulent cylinder head during 1918 and 1919; this was a low cost

combustion system that increased the power of side valve gasoline engines. The variable compression ratio E35 research engine, developed in 1919, followed, and enabled the combustion properties of fuels to be accurately analysed; this innovation also laid the groundwork for today’s octane rating system. Over recent years, the company has strengthened its foothold in the motorsport arena, a development caused by the Ricardo’s invention of viscous coupling in the 1980s. Viewed as one of the company’s most significant transmission innovations, viscous coupling transformed world rallying in the pioneering group b rally cars. The runaway success of these four wheel drive cars led to a whole new market sector for all wheeled drive passenger cars and led to Ricardo assisting the likes of Bugatti and McLaren in delivering high quality, high specification engineered solutions. In 2001 the company assisted Bugatti in the

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ASSO WERKE was established in 1973, carrying on the activity of Pistoni Asso, initially started by Mr. Silvano Ferrucci in 1949. Today his daughter Mrs. Elda Ferrucci who is continuing her father’s mission holds the company’s ownership. In early times ASSO WERKE had the opportunity to mature significant experiences in the piston manufacturing area: the two stroke combustion engines represented one of the main strengths of the whole production. Later on the product range has been extended to cover all main engine applications, both for mass production and competition: automotive - petrol and diesel -, motorcycles, scooters, karts, snowmobiles, off-road vehicles (ATV), marine, light agriculture machines, air and refrigerating compressors. Currently ASSO WERKE produces in-house pistons, cylinders and cylinder liners, piston rings and gudgeon pins, with a complete engineering service, going from the client preliminary data entry requirements to the part feasibility study, rapid prototyping and test bench samples, to the final high volume mass production. Special attention is given to the development of four stroke engine pistons for OEM high performance applications. For its parts ASSO WERKE can provide the customer with suitable advanced and superlative design solutions. ACT© special nickel and silicon carbide coating suitable for liners, with high wear resistance and oil retaining effects. PTWA© by Comau is our plasma spray coating suitable for automotive engine block coating solutions. KDN5© special ASSO WERKE patented piston ring alloy for superior tribological and durable behaviour. NIT: Gudgeon pins in nitrided aerospace steels, also with a selection of DLC coating specifications.

ASSO WERKE is able to produce cast and forged pistons for 2 and 4 stroke high performance applications using special aluminum alloys, with in-house produced low and high layer thickness selective anodizing treatments, suitable for long life turbocharged applications. In 2015 ASSO WERKE started with new challenges: become the reference point for forged piston manufacturers, starting from several innovative high fatigue property aluminium alloys to a state of art forging equipment.

Today many dream sportscars worldwide have an ASSO WERKE heart inside and we are proud to be the sole piston and cylinder liner supplier for the RICARDO’s engine programme.

T: +39 0587 282111 | F: + 39 0587 421760 | E: info@assowerke.it | www.assowerke.it


Ricardo

design, development and manufacture of driveline, a highly advanced, four wheel drive, dual clutch driveline system, for the world’s most powerful road car, the Bugatti Veyron. “This project is a clear example of our ability to engineer and manufacture complex and high value systems. A lot of traditional tier one companies can provide a full engineering service for their components or subsystems, but we offer something unique in our ability to take a clean sheet concept through to production and onto supply into the market. For the Bugatti Veyron project we provided all engineering, supply management and warranty management services for Bugatti throughout the lifecycle of the Veyron,” says Mark Garrett, Chief Operating Officer at Ricardo.

Cross industry skills Using this expertise, Ricardo went onto collaborate with McLaren on the design, development and manufacture of the M838T 3.8 litre twin turbo V8 engine; as part of the project, Ricardo also developed a dedicated assembly facility to supply the engines within a timeframe of 18 months. This groundbreaking engine has three times been named

At the heart of Ricardo’s success in a number of demanding business sectors is its forward thinking approach to market trends international Engine of the Year in the three to four litre category. While continuing to supply transmissions to many motorsport formulae and deliver world-firsts in four-wheel drive systems, the company also works in a range of sectors. One notable example of this is Ricardo’s work with JCB to deliver a groundbreaking solution for the JCB DieselMax in 2006. With the JCBDieselMax powered by two JCB444 backhoe loader diesel engines, the two companies worked together to boost the power to produce a total of 1500 horse-power from the two engines; in 2006, this vehicle took the FIA international diesel powered land speed record of 350.092 miles per hour. Having previously demonstrated its whole vehicle design capability with the US FED Alpha protected vehicle which delivered over 70 per cent fuel savings vs the current HHMMWV, Ricardo went onto deliver innovative solutions

in the defence sector with the development of the Ocelot/ Foxhound for the UK Ministry of Defence. The Ocelot/Foxhound was created from a clean sheet of paper through to full production in less than two years. “Another example of our ability to engineer and manufacture complex and high value systems is our successful project with the British Army on the Foxhound/Ocelot light protected patrol vehicle. Developed to support troops in Afghanistan, we were involved in the project from the start, working with Force Protection Industries, now part of GDLS, to bring this vehicle to market. In total we manufactured 376 vehicles, which are in service with the British Army today,” highlights Mark. At the heart of Ricardo’s success in a number of demanding business sectors is its forward thinking approach to market trends, its commitment to innovation and its cross industry skills, the latter of which has resulted in the development of novel technologies that are then carried over into other business sectors. “One example of our cross industry skills is our strategic decision to bring sensor technology from the wind industry into the rail industry, which has

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Ricardo

resulted in the monitoring and performance of the rail network and the ability to sense cracks appearing in rails before they become an issue,” reveals Mark. Another major strength of the company is its continued investment in facilities. In fact, the company marked the start of 2016 with the launch of a newly expanded engine assembly plant. While another state-of-the-art facility based in the Midlands has the equipment and machinery necessary to produce complete transmissions and driveline systems or produce separate components on a ‘make to print’ basis for a range of sectors. Ricardo is keen to stay ahead of the competition and has made further investments throughout the year. These include machine tools to ensure the machine shop can offer full prismatic facilities of turning and milling as well as wire erosion, shaping, hobbing, spiral bevel-axles, computerised heat treatment, grinding and gear grinding.

Collaboration commitment The prismatic machining offers 16 CNC and conventional lathes as well as 12 milling stations/ machining centres, which includes five axis and both horizontal and vertical capability; the horizontal machines with pallet change means that HPTP (High Performance Transmissions Products) Division are able to carry out transmission case

machining. Furthermore, the new Hofler PROMAT 400 machine offers non helical form or spur gear grinding. “We take a very pragmatic view in how we will continue to invest in our in-house manufacturing, but one of the most important aspects is our ability to support our programme development that in turn results in product development for our customers. The ability to machine one-off prototype components for engines, transmissions and hybrid systems gives us the flexibility and speed in then bringing products to market,” says Mark. “We also have high performance transmission production and manufacturing capability, which is an intense machining and heat treatment capability that enables us to develop high quality, high spec components for customers. In this area we do a lot of gear sets for motor sports as well as actuation components for the aerospace industry; we are also able to machine large castings, gear cases and transfer cases so we can manufacture and supply full transmission systems for our customer base in batch volumes.” Complementing these strengths is the company’s commitment to collaboration, whether that is with customers or organisations such as the University of Sheffield. “We are currently involved in the Advanced Manufacturing Research Centre collaboration, otherwise known

as AMRC, which is affiliated to Sheffield University that was funded originally by Boeing. We have signed a memorandum of understanding (MOU) to develop highly advanced manufacturing technologies that will allow the automotive industry to both make complex high value components in a cost effective manner. We have teamed up with AMRC to bring its background knowledge in high quality aerospace systems into the automotive space, which is then complemented by our expertise in the automotive sector. By applying this knowledge and experience that this joint partnership will bring some real added value to customers,” comments Mark. “AMRC has a lot of experience in complex machine tool processes, tool vibration and cutting speeds that enable them to look for fundamental improvements to machining processes and thus reduce operation times; the organisation also works with carbon fibre reinforced composites, complex assemblies and robotised assembly systems, which is where our knowledge of the automotive application and process advancements can bring something unique into the automotive sector,” he adds. With the project beginning in October 2016, Ricardo will remain focused on collaborating with some of the UK’s leading academic research groups, while also seeking out its own fuel efficient solutions to bring forward cutting edge technologies for the future generation. As demand increases for a more green planet, the company is committed to playing an integral role in the delivery of a lower carbon and increasingly sustainable transportation sector. M

Ricardo Products: Manufacture engines, transmissions, vehicle systems, intelligent transportation systems (ITS) and hybrid & electric systems www.ricardo.com

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Profile

| Elekta

Revolutionising

cancer care Elekta is an innovation leader in pioneering radiation therapy solutions, with imageguided radiotherapy at the forefront of what it does

E

lekta was founded in 1972 by Laurent Leksell and his father, Lars Leksell, a Swedish physician and Professor of Neurosurgery at the Karolinska Institute in Stockholm, Sweden. He was a pioneer in modern neurosurgery techniques and renowned as the inventor of radiosurgery and developer of the advanced radiosurgical platform, Leksell Gamma Knife®. This noninvasive method for treating brain disorders works by applying a single dose of high radiation to a small and critically located antracranial area through the skull. It is the preferred radiosurgical method for its precision, efficiency and exceptional therapeutic response. Today, Gamma Knife surgery is performed in hundreds of leading

hospitals and clinics around the world, to around 70,000 patients. No other non-invasive procedure in this field has greater clinical recognition. “Our history is what drives us forward. We have dedicated ourselves to pioneering advancements for cancer care,” said Global Vice President of Supply Chain and Manufacturing at Elekta, Steve Wort. “There have been many developments over the years since our beginnings. We are the leading innovator of equipment and software used to improve, prolong and save the lives of people with cancer and brain disorders. Elekta solutions are used in more than 6000 hospitals worldwide and we employ around 3600 people around the world,” explains Steve.

Professor Lars Leksell

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Indeed, over the last four decades Elekta has grown and acquired Philips Radiation Therapy Division, which became Elekta Ltd in 1997. Additional key acquisitions include Neuromag in 2003, IMPAC Medical Systems Medical Intelligence in 2005, Beijing Medical Equipment Institute (BMEI) in 2006, 3D Line Medical Systems in 2007, CMS in 2008, Resonant Medical in 2010, Nucletron in 2011, Radon in 2012, and a number of key distributors, in line with market developments and its own strategic vision to gain a strong international presence in cancer care. Further innovative developments have taken place over the years advancing the company to the very forefront of radiation therapy. Elekta was the first to integrate CBCT and introduce

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image-guided radiotherapy in 2003, developed the first Monte Carlo based treatment planning system in 2008, the first to introduce an analytics platform to mine MOSAIQ® data in 2014 and it developed the first on-line adaptive radiosurgery system, Leksell Gamma Knife® Icon™ in 2015. In addition to these significant advancements, Elekta has been working on a new and revolutionary machine for the oncology department.

Next generation An exciting breakthrough in the treatment of cancer is a new product called the MR-linac that has taken ten years to develop. “This is next-generation innovation for the treatment of cancer patients using radiotherapy. Development started in 2007 and


Elekta

it’s the first high-field MR-linear accelerator of its kind,” said Steve. MR-linac integrates an ultramodern radiotherapy system and a highfield MRI scanner with advanced software that allows a physician to capture diagnostic quality images of tumours and surrounding tissue during treatment. The MR-linac is expected to improve tumour tissue targeting while reducing exposure of normal tissue and critical anatomical structures to the radiation. It will allow physicians to precisely locate a tumour and visually track it. This allows physicians to rapidly respond and offer personalised care. Elekta, its technology partner Philips, and the MRlinac consortium members are working to make the MR-linac a reality. MR-linac has the potential to fundamentally transform radiotherapy by enabling radiation

MR-linac has the potential to radically improve the precision of radiation delivery, through crystal clear imaging

oncologists to see the treatment target in real time, and to rapidly adapt the plan in response to diagnostic quality MR images. The technology fully integrates three subsystems to achieve unparalleled precision and accuracy in radiotherapy, an advanced linear accelerator that is manufactured by Elekta in Crawley, a 1.5 Tesla magnetic resonance imaging (MRI) system supplied by Philips and online adaptive workflow software. These three systems combined

allow for simultaneous radiation therapy delivery and high-field MR tumour monitoring, enabling online treatment alterations in response to changes in the targeted tumour position. It is hoped that the precision of the treatment will reduce patient concerns around after care. “Radiation plays a central role in approximately 50 per cent of patients who are ultimately cured of cancer, but still causes anxiety in patients who fear negative post-treatment side effects,” said Professor Kevin Harrington, Joint Head of the Division of Radiotherapy and Imaging at The Institute of Cancer Research, London and The Royal Marsden. “MR-linac has the potential to radically improve the precision of radiation delivery, through crystal clear imaging. We expect MR-linac to increase physician confidence in

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Versa HD is designed to provide the precision and speed necessary to deliver advanced treatment techniques that demand maximum accuracy in tumor targeting

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Elekta

treating the intended target, while also putting patients at ease.” Currently the MR-linac is being tested in seven hospitals in the US and in Europe, including two sites in the UK. Consortium members are currently engaged in various stages of evaluation and are collaborating to establish new protocols for clinical research and develop methods for data collection and analysis. The system is undergoing thorough tests and various objects have been selected for shape and weight. Elekta is not only an innovation company, but it also values manufacturing excellence. The manufacturing side of the business happens within Europe, Asia and the US. The primary manufacturing site for the company’s linear accelerator in the UK is located in Crawley, West

Sussex. The company makes a significant contribution to the regional economy with around 200 manufacturing jobs in the UK supply chain. “Over the past years, we have had significant job growth at the Crawley facility, and we also work to develop young talent by hiring apprentices, many of whom are now in technical roles within the company,” concludes Steve. M

*Elekta’s MR-linac is a work in progress and has not yet been released or received regulatory approval for clinical use.

Elekta Services: Specialise in providing radiation therapy, radiosurgery, medical equipment and clinical management for the treatment of cancer and brain disorders www.elekta.com

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Dynamic and progressive As a leading name in global materials engineering, Wall Colmonoy has remained a pioneer in manufacturing for over 75 years

D

ating back to when Albert F. Wall founded the business during 1938 in Detroit, Michigan, Wall Colmonoy has persevered in the spirit of Mr. Wall’s entrepreneurial ambition, with a culture of innovative vision ever-present at the core of what shapes the ongoing success of the company. Today, Wall Colmonoy has grown into a global organisation that employs close to 400 staff, with offices in the US and UK. The company has had a presence within the UK since 1952. Wall Colmonoy Limited (UK), was originally based in Motherwell, Scotland, before moving to its current location in 1969 to the Welsh town of Pontardawe. The region was made attractive to Wall Colmonoy due to its rich

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200-year metallurgical history and a readily available, highly skilled workforce. The town of Pontardawe also boasts a good source of qualified graduates from local Welsh universities and in close proximity to a major metal supplier at the Vale refinery, Clydach (formerly INCO Ltd). Wall Colmonoy Limited (WCL) is a US family-owned global leader in advanced materials engineering and has been a major employer in South Wales for close to 50 years. Managing Director, Steph Curtis explains: “WCL is a worldwide leader in manufacturing nickel and cobalt-based powdered alloys; castings and precision machined components. We provide advanced metal coatings, brazing, heat treatment and welding to aerospace standards. We currently


Profile

| Wall Colmonoy Ltd

Wall Colmonoy’s Precision Components for the Power Generation Industry

Wall Colmonoy’s Precision Components for the Glass Container Industry

employ around 170 members of staff within the UK and generate a turnover of £25 million annually, with 90 per cent of the company’s products being exported across Europe, Russia, Scandinavia, the Middle East and North Africa (MENA), South Africa and India. The products and services that the company provide play an integral role in many industries that are instrumental to our everyday lives. “We help our customers operate more efficiently and effectively. We develop value added solutions to minimise customers’ operational expenditure and extend product life. What does this mean? Well, it means, through the application of a wide range of powdered alloys, solving wear, corrosion, erosion and abrasion issues for parts like neck rings and plungers that

are used in glass bottle making; for continuous cast rolls in steel making; for downhole drilling tools in oil & gas extraction; for boilers in waste to energy plants; it means joining parts for high-temperature and corrosion applications like Exhaust Gas Recirculation units (EGR’s) and Catalytic Converters for automotive industry, for heat exchangers that are found in aerospace or power industries.” Wall Colmonoy is a diverse business – but it is focused on listening to its customers in order to meet their needs. “In a passionate, focused and disciplined manner, we are constantly developing products and applications in partnership with our customers - applying the skills and experience of our talented engineers and

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metallurgists,” Steph declares. Wall Colmonoy brands include Colmonoy® (nickel) and Wallex® (cobalt) for hardsurfacing applications to extend useful life of components and Nicrobraz® (nickel), Niferobraz® (iron) and CuBrazTM (copper) brazing alloys and brazing aids for joining parts for hightemperature and corrosion applications for aerospace, automotive, energy, nuclear and defence. “Wall Colmonoy was established when Albert F. Wall met the metallurgists who had originally developed Colmonoy and subsequently purchased the patent and manufacturing processes. The word Colmonoy is the amalgam of the word alloy, and the names of the product’s original metallurgists, Cole and Edmonds, who invented the

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specially formulated superior performing nickel-based alloy. Colmonoy is the original nickelbased hardsurfacing alloy and was originally developed for application on downhole drill bits for the oil industry. It now has many different applications in a variety of industries from glass container to steel,” Steph explains. “Wall Colmonoy is also a pioneer and leading expert in high temperature nickel-based brazing. In 1950 the company’s then Materials Engineer, Bob Peaslee, invented a new brazing technology involving nickel-based filler metals and hydrogen atmosphere furnaces. This product was named Nicrobraz. Mr. Peaslee pioneered the application of hydrogen braze for aircraft turbine engine components. The technology and process continues today.”

In order to advance and educate customers’ engineers on furnace brazing technology, Wall Colmonoy hosts a Brazing School that takes place at Wall Colmonoy EU Headquarters in Pontardawe and at Brazing Engineering Center in Cincinnati, USA. The first European school was held in October 2014 and Wall Colmonoy Limited (UK) has continued to host the school annually. The school teaches top engineers from around the world about high-temperature brazing. Since 1977 Wall Colmonoy Corporation (USA) has been hosting the brazing school in the USA. “We have world class employees, with a strong senior management team from a broad range of manufacturing industries; we have highly qualified professionals across the whole business - PHD’s,


Wall Colmonoy Ltd

Master’s Degrees, Bachelor’s Degrees, Diplomas, HNDs and HNCs. To collaborate and partner with our customers around the world, many of us speak many languages. We have extensive foreign language capability in French, German, Spanish, Russian, Turkish, Bulgarian, Punjabi and Urdu.”

Organisational change Recently, Wall Colmonoy Limited has been going through an important cultural and organisational change. “I joined in 2014 and before that worked for 30 years in several different industry sectors for major international PLC’s and SME’s. My background and experience is in strategic business improvement. We have recruited a new management team these last two years, and we have a very clear direction of where we are going. We are focused on continuous improvement and profitable growth – health, safety and welfare of our employees; quality, cost and delivery of first class products; technical support and customer service. We have applied lean management and manufacturing to our operations and in the last few years, we have made big steps forward in our thinking and quality. This is supported by continuous investment into the company’s technical and quality capabilities and manufacturing facilities,” Steph says. Wall Colmonoy is heavily investing in its UK facility and its people. Some key facility investments include introducing ESI ProCAST virtual prototyping software to optimise manufacturing process for precision cast components; adding and upgrading advanced testing equipment for powders in order to meet increased technical demands; and new machines for the machine shop to produce larger parts faster and more efficiently.

Home grown talent In order to develop the next generation of engineers and ensure its growth, Wall Colmonoy Limited launched a Bespoke Apprenticeship Programme focused on developing ‘Home Grown Talent’. It is a structured programme to meet the unique needs of the business and to ensure the development of specialist skills and technical knowledge needed for its growth. WCL hires apprentices who take part in a specific learning and development programme that involves rotating through the different divisions of the company for three-month periods, along with college study. The apprentices go one day a week to college to study engineering and learn the job first hand through a

structured work programme. “This is what we call ‘Home Grown Talent.’ In fact, our apprentices learn not only about the company, its products and processes, and quality, but it also means that we can ‘develop’ their minds, to align them with company culture and our corporate vision of where we want to be,” Steph explains. “Our apprenticeship programme is just a part of our training and development programme, there are several other initiatives as well. We have two young engineers doing an MBA (Master’s in Business Administration) and an Engineering Master’s programme, we also have one engineer who is going to do a PhD research project next year on the specifics

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The word Colmonoy is the amalgam of the word alloy, and the names of the product’s original metallurgists, Cole and Edmonds, who invented the specially formulated superior performing nickel-based alloy

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Wall Colmonoy Ltd

of what we do. We are doing a lot of this collaborating with the Welsh government.” Wall Colmonoy’s extensive experience in developing innovative products and continual investments in its people and facility has made WCL a market leader within advanced materials engineering. Indeed the company embodies a culture of rich manufacturing history and longevity that dates back over 75 years, including 48 years of proven industry excellence at its facility in Wales. This trusted market presence and an ongoing process of investment will prove vital in enabling WCL to navigate the market through a volatile period in the wake of the Brexit decision and changing industry demands. “Wall Colmonoy anticipates

major changes to take place in the coming years as economic, technological and sociological demands increase. In respect of this change we are at the frontier and will continue not only to embrace change, but also to positively influence it through our commitment to leadership, our people, innovation and our continuous improvement philosophy. We are developing a strong lean culture that is

focused on eliminating waste, being lean and agile. We are relentless in our pursuit of excellence and desire to become a world class enterprise,” he concludes. “We will continue to develop engineered solutions for our customers, helping them to improve their businesses and to seize new opportunities.” WCL has a dynamic culture based upon absolute customer focus and customer satisfaction, teamwork, employee engagement and development, relentless continuous improvement and aspiration for excellence in everything it does. M

Wall Colmonoy Ltd. Services: A leading global materials engineering company. www.wallcolmonoy.co.uk

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Editor: editor@manufacturingnorthamerica.com Studio: studio@manufacturingnorthamerica.com Sales: pmonument@manufacturingnorthamerica.com

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Manufacturing North America Issue 101 June 2017  

The latest edition of Manufacturing North America

Manufacturing North America Issue 101 June 2017  

The latest edition of Manufacturing North America