Industrial Machinery Digest - November 2023

IndustrialMachineryDigest.com | November 2023

North America’s Manufacturing Resource for Industry Professionals Since 1986

Innovative Solutions and Expert Insights from Scotchman Industries Impactful Cybersecurity Tips for Your Business Utilizing IoT-Enabled Predictive Maintenance in Manufacturing The A Team: Innovating Today’s Custom Tooling Process Electroimpact SCRAM system sculpts new possibilities Today’s Workforce Development Requires a Sound Strategy How CT Data Analysis is helping TE Connectivity Reach Their Ultimate Goal of End-to-End Quality Inspection Dry electropolishing — More Sustainability in the Field of Surface Finishing 10 Areas Manufacturers Might See an Impact from AI

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Table of Contents

November 2023 8 10 16

EDITORIAL DIRECTIONS

18

TALKING SHOP

22

SAFETY & MAINTENANCE

26

MANUFACTURING SHOWCASE

INDUSTRY NEWS BUSINESS 4.0 6 Impactful Cybersecurity Tips for Your Business Innovative Solutions and Expert Insights from Scotchman Industries Utilizing IoT-Enabled Predictive Maintenance in Manufacturing

16

The A Team: Innovating Today’s Custom Tooling Process The 2022 Tool of the Year entry showcases the capabilities and complexity that ARCH and ANCA can achieve together.

28

INDUSTRIAL AUTOMATION Electroimpact SCRAM system sculpts new possibilities This industrial, true 6-axis continuous fiber-reinforced 3D printer enables tool-less rapid fabrication of aerospace-grade integrated composite structures.

32

WORKFORCE DEVELOPMENT Today’s Workforce Development Requires a Sound Strategy

18

By William Weier, Human Resources Director at Mazak Corp.

34

NEW TECHNOLOGY How CT Data Analysis is helping TE Connectivity Reach Their Ultimate Goal of End-to-End Quality Inspection Manufacturer gains critical insights using Volume Graphics software throughout design, simulation and manufacturing

38

PROCESS

40

INDUSTRY INSIGHT

44 47 49 50

PRODUCT SHOWCASE

22

Dry electropolishing — More Sustainability in the Field of Surface Finishing 10 Areas Manufacturers Might See an Impact from AI

SURPLUS BUYING & SELLING CLASSIFIEDS ADVERTISER INDEX

4 | IMD November 2023

26 ON THE COVER Cover Sponsor: Dynabrade, Inc. Cover Image: iStock

To ls available in horsepowers ranging from .3 hp to 3 hp,with spe ds ranging f r o m 3 , 2 0 R P M t o 1 0 , 0 0 R P M .

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8/19/21 8:37 AM

SERVING AMERICAN MANUFACTURERS FOR OVER

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INDUSTRIAL MACHINERY DIGEST (ISSN 1542-5223) is published 12x per year by Source 360 Media. POSTMASTER: Please send change of address to INDUSTRIAL MACHINERY DIGEST, 3590-B US Hwy 31 South, PMB 233, Pelham, AL 35124. Printed in the U.S.A. SUBSCRIPTION POLICY: Individual subscriptions are available without charge in the U.S. to qualified individuals. Publisher reserves the right to reject nonqualified subscribers.

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Editorial Direction

William Strickland Publisher wstrickland@indmacdig.com

Reflecting on the recent Motion + Power Trade Show in Detroit, it's clear that our industry continues to evolve at an exhilarating pace. Our team was thrilled to be part of the event, mingling with over 300 exhibitors, and witnessing firsthand the stunning array of new products, from companies like HAINBUCH Workholding, ANCA CNC Machines, to Nidec Machine Tool America LLC. It was a fantastic showcase of industry innovation and collaboration.

Now, as we turn the page from the excitement of the EXPO, we dive into our current issue, which captures the ongoing revolution in industrial machinery and technology.

Our focus shifts from the show floors of Detroit to the broader horizon of industrial advancements and insights.

In this edition, we journey through various facets of the industrial landscape. Starting with Business 4.0, we address the ever-critical topic of cybersecurity, essential for protecting your business against increasingly sophisticated threats. We share insights and strategies that will empower you and your organization to stay ahead of potential risks.

Talking Shop features insights from the experts at Scotchman Industries. Their pioneering work in metal fabrication opens a window to the future of Precision Metalwork, blending innovation with practical wisdom.

On the topic of Safety & Maintenance, our focus turns to the pioneering application of IoT-enabled predictive maintenance in manufacturing. This not only underscores the advancements in technology but also highlights how these innovations can save money, boost efficiency, and empower workforce skills.

Manufacturing Showcase spotlights the team at ARCH and ANCA, who have been redefining the custom tooling process. Their achievements in the ANCA Tool of the Year competitions exemplify excellence and innovation in tool design, underscoring the creativity and technical prowess thriving within our industry.

We also explore the fascinating world of Industrial Automation, focusing on the groundbreaking Electroimpact SCRAM system. This feature illustrates how continuous fiberreinforced 3D printing is revolutionizing aerospace and defense manufacturing, offering a glimpse into the future of additive manufacturing.

Workforce Development remains a critical pillar for any industry, and our feature by William Weier of Mazak Corp offers strategic insights into developing and retaining skilled talent – an invaluable resource in our rapidly changing sector.

Lastly, our New Technology section delves into how TE Connectivity is utilizing CT Data Analysis for quality inspection, symbolizing a significant leap in manufacturing technology. It's a clear indicator of how interconnected digital platforms are becoming increasingly pivotal in our industry.

Each article and feature in this issue echoes the dynamic spirit of the Motion + Power Trade Show, continuing the narrative of progress and innovation. We've curated these stories to not only inform and inspire but also to offer practical insights that can be applied to your daily business and operational challenges.

Warm regards,

William Strickland Publisher, Industrial Machinery Digest

8 | IMD November 2023

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Industry News

INDUSTRY NEWS Industrial Machinery Digest's Industry News features the latest news and press releases from some of the industry's top companies.

WANT TO BE FEATURED? Send your press releases to editorial@indmacdig.com

Alloy Enterprises Launches Aluminum Cold Plate Components Alloy Enterprises, an innovative leader in metal fabrication, has introduced a groundbreaking aluminum cold plate component, significantly enhancing its suite of thermal management solutions. Celebrating its third year, Alloy has been actively expanding both its team and production facilities. This latest release represents a notable advancement in the company's technology offering, particularly in thermal management applications.

Distinctly, Alloy is the only manufacturer capable of creating aluminum cold plates with complex geometries without requiring any additional tooling or assembly.

The cold plate components are uniquely engineered to optimize heat transfer, featuring high strength-to-weight ratios, excellent thermal conductivity, and complex channel designs for integrated cooling. This technology ensures enhanced performance and reliability in thermal management.

Rob Martinsen, Chief Technology Officer at nLIGHT, underscores the importance of these advancements, pointing out that a 40% improvement in heat transfer is transformative in product performance. Alloy's cold plates stand out for their superior functionality and performance, offering durability, no porosity, and the absence of unnecessary post-processing steps like de-powdering or additional assembly.

These plates are part of Alloy's broader thermal management applications, which also include heat exchangers, heat sinks, casings, and housings. Their Sheet Forging process facilitates rapid product development and iteration, offering significant cost advantages over traditional fabrication methods such as casting, machining, or 3D printing. Alloy is extending

www.IndustrialMachineryDigest.com 10 | IMD November 2023

an invitation for design reviews, encouraging clients to begin discussions on how their solutions can accelerate development projects.

Arnold Magnetic Technologies Provides Solutions for Electric Transportation Arnold Magnetic Technologies Corporation, a subsidiary of Compass Diversified and a leading manufacturer of high-performance magnets, is actively addressing the critical challenges in electric transportation, particularly in electric motor design and manufacturing. As electric vehicles increasingly demand motors with higher power densities than traditional induction motors, Arnold is stepping up by providing innovative solutions, including its use of rare earth metals.

Arnold’s RECOMA® 35E, the most power-dense Samarium Cobalt (SmCo) magnet globally, exemplifies

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its commitment to meeting high-performance requirements. Designed for extreme environments in aerospace, motorsports, and industry, this magnet operates efficiently at speeds over 100,000 RPM and temperatures above 200°C. Additionally, the company's neodymium iron boron (NdFeB) magnets, compliant with ITAR & DFARS defense standards, further strengthen its product offerings.

To secure a stable supply of these essential materials, Arnold has partnered with Cyclic Materials of Kingston, Ontario. This collaboration is pioneering the world’s first circular supply chain for rare earth materials by focusing on material reclamation, thus enhancing the domestic economy.

Arnold also excels in providing materials that boost efficiency in motor and transformer designs.

Its precision rolled thin and ultra-thin metals, along with Arnon®, its non-grain oriented electrical steel, are crucial in achieving lower eddy current losses and higher power density, leading to significant energy savings.

Having contributed to electric transportation since the advent of the electric train, Arnold Magnetic Technologies continues to innovate in electric propulsion systems across various sectors, including space, air, watercraft, motorsport vehicles, and heavy equipment. They offer comprehensive system integration services, from prototyping to production, and specialize in high-efficiency, lightweight designs using advanced manufacturing techniques like composite encapsulation. Arnold’s products, tailored to specific needs, include durable and high-performing electric rotors, stators, and motors, ready for the most demanding applications.

Burr King Announces Partnership with Kenbil Engineering, Inc. to Strengthen Presence in Northern California and Nevada Burr King, a prominent manufacturer of belt grinders and finishing equipment, has announced a new strategic partnership with Kenbil Engineering, Inc., a respected industrial representation firm. This collaboration is set to strengthen Burr King's market presence in Northern California and parts of Nevada, leveraging Kenbil Engineering's five-decade expertise in the manufacturing and industrial sectors.

Mark Drazba, Vice President of Kenbil Engineering since 1981, is poised to be a pivotal figure in this alliance.

His extensive experience and deep connections in the manufacturing industry are expected to significantly contribute to the partnership's success. Drazba's commitment and industry insights align well with Burr King's focus on precision and customer satisfaction.

Additionally, Johnny Dang of Kenbil Engineering will be instrumental in expanding Burr King’s reach, specifically overseeing customer service and support in Kern and San Luis Obispo Counties in California.

Don MacCarthy, President at Burr King, expressed

12 | IMD November 2023

confidence in the partnership enhancing their service to the manufacturing community in the specified regions.

He acknowledged the value of Drazba’s dedication and Dang's expertise in fulfilling their expansion goals.

Burr King's renowned belt grinders and finishing equipment, celebrated for their precision, durability, and versatility, find applications across multiple industries like metalworking, woodworking, and aerospace. This partnership marks a notable milestone, uniting Burr King's innovative products and commitment to quality with Kenbil Engineering's rich experience, relationship network, and industry knowledge. It promises to offer customers in Northern California and Nevada superior grinding and finishing solutions backed by exceptional service and support.

For further information on Burr King's products or to contact Kenbil Engineering in Northern California and Nevada, interested parties can visit Burr King's website or call Kenbil Engineering directly.

IFR - World Robotics 2023 Report The "World Robotics 2023 Report" by the International Federation of Robotics (IFR) reveals a sustained growth in global industrial robot installations, underscoring the increasing integration of robotics in manufacturing and industry. In 2022, the total number of installations reached 553,052 units, marking a 5% growth from the previous year. Predictions for 2023 suggest further growth, potentially surpassing 590,000 units.

Regionally, Asia leads with 73% of new robot installations, mainly dominated by China, the world's largest market. China alone added 290,258 units in 2022, surpassing its 2021 record. Japan and South Korea also show notable performances, indicating a robust Asian market. Europe and the Americas follow, with the EU registering a 5% increase and the Americas an 8% rise in installations.

In Europe, Germany maintains its position as the largest market despite a slight decrease in installations.

Italy and France, on the other hand, showed significant growth. The United Kingdom, post-Brexit, continues to grow but at a much smaller scale compared to its European neighbors.

The United States dominates the Americas with a 10% increase in installations, mainly driven by the automotive industry. Mexico also shows growth, whereas Canada experiences a decrease, predominantly due to a slump in automotive sector demand.

Overall, the report indicates a trend of continuous growth in robotic installations despite potential economic slowdowns. The automotive industry emerges as a major growth driver, particularly in the U.S. This global rise in robotic adoption, especially in Asia and traditional industrial nations, points towards an evolving landscape where robotics plays a crucial role in modern manufacturing and production. The report projects the milestone of 600,000 installations per year

could be reached by 2024, signaling not just recovery post-pandemic but also a transformative shift towards automation and smart manufacturing on a global scale.

Renny Fritz Joins Carlisle Fluid Technologies as Technical Sales Specialist.

Carlisle Fluid Technologies, specializing in capital equipment and systems, has recently announced the appointment of Renny Fritz as their new Technical Sales Specialist for the Northeast territory. Bringing over twenty years of industry experience, Fritz's expertise lies primarily in quoting and selling custom automated turnkey systems.

This experience is expected to significantly contribute to the growth and development of the company's presence in the Northeast region.

Renny Fritz's deep understanding of the products, processes, and industry landscape, coupled with his established relationships, positions him as a key player in generating new growth opportunities for Carlisle Fluid Technologies. His proficiency in handling sales relationships and identifying new growth avenues is especially noted by Matthew Reilly, Carlisle Fluid Technologies’ Regional Manager for the East Region.

Reilly expresses confidence in Fritz's capabilities and is enthusiastic about the fresh insights and expertise Fritz brings to the team.

Fritz's joining Carlisle Fluid Technologies aligns with the company's strategic goals of enhancing its sales relationships and expanding its market reach in the Northeast. His rich professional background and knowledge in the field are seen as valuable assets in achieving these objectives. The company warmly welcomes Renny Fritz to their team, anticipating a fruitful collaboration in fostering business growth.

Michael Weitzel Joins Carlisle Fluid Technologies as Account Manager.

Carlisle Fluid Technologies has recently expanded its team by appointing Michael Weitzel as the new Account Manager for the Northwest territory. Weitzel's role comes backed by extensive experience in the coatings industry, which is poised to significantly contribute to the company's growth and expansion in the region.

With a strong background in sales, management, and marketing, Michael Weitzel is expected to play a crucial role in supporting Carlisle Fluid Technologies' channel partners and end-users. His deep industry knowledge, coupled with established relationships in the field, are seen as key assets in fostering growth and enhancing the

company's presence in the Northwest territory.

Luis Barrales, Carlisle Fluid Technologies’ Regional Manager for the West Region, expressed confidence in Weitzel's capabilities. Barrales anticipates that Weitzel's experience and expertise will not only drive new business opportunities but also strengthen sales relationships and uncover new potential within the market.

Michael Weitzel's addition to the Carlisle Fluid Technologies team aligns with the company's strategic goals of bolstering their market reach and enhancing client relations in the Northwest. His appointment is welcomed with enthusiasm, both for the new insights and the expansion opportunities he is expected to bring to the company.

Combilift’s CB15-5E wins the Italian Terminal and Logistics Award Combilift, a leader in the manufacturing of multidirectional trucks, articulated forklifts, and straddle carriers, has achieved a notable milestone by winning the Italian Terminal and Logistics Award for its Combi-CB15-5E. The award was presented during the GIS Expo in Italy, underscoring Combilift's innovation, safety, and commitment to operator training.

The Italian Terminal and Logistics Award is a prestigious industry honor that celebrates excellence among operators in port, intermodal, and logistics terminals, both in Italy and internationally. The CombiCB15-5E, recognized for its innovation, is the latest in Combilift’s expanding electric model range. It stands out as the market’s shortest counterbalance truck with a 15,500lbs capacity and features multidirectional capabilities for handling long and bulky loads efficiently in confined spaces.

Martin McVicar, CEO and Co-Founder of Combilift, expressed gratitude for this recognition, emphasizing that the award affirms the company's commitment to delivering efficient, environmentally friendly, and safe material handling solutions. The CB15-5E exemplifies Combilift's dedication to innovative and versatile forklift designs.

For further information about the Combi-CB15-5E, interested parties can visit Combilift’s website.

Coxreels is excited to celebrate its 100th Year Anniversary manufacturing in the USA! Coxreels, a prominent U.S. manufacturer of hose, cord, and cable reels, proudly celebrates its 100th Year Anniversary in 2023. Beginning as a family-owned and operated business in 1923 under the name Cox Air Gauge, the company has grown into a key industry leader known for setting the standard in its field. Coxreels has been dedicated to enhancing the automotive service station market initially, but its brand and product offerings have significantly expanded over the years. Now, their products are utilized globally across more than twenty-four industries.

INDUSTRIAL MACHINERY DIGEST.COM

IMD | 13

» »

»

The company's commitment to quality and innovation is evident in its numerous patents, demonstrating a continuous effort to lead and improve the hose, cord, and cable handling industry.

Coxreels emphasizes the use of advanced engineering and manufacturing processes to offer high-quality, professional-grade reel solutions that meet diverse industrial needs.

In celebrating this centennial milestone, Coxreels reflects on its heritage, cherishing the tradition, passion, and conviction of its founders while remaining focused on its core values and quality manufacturing. They take pride in designing, building, and supporting all their products within the U.S., maintaining a strong dedication to professional-grade manufacturing since its inception.

For more information about Coxreels and their product line, customers can contact their Customer Service or visit the Coxreels website.

Now Open: DEWALT Trades Scholarship Application DEWALT, a Stanley Black & Decker brand, has announced the opening of applications for the 2024 DEWALT Trades Scholarship. This scholarship initiative is part of DEWALT's ongoing effort to support and grow the skilled trades workforce.

Number of Recipients: Up to 40 students across the U.S. and Canada.

Educational Focus: The scholarship supports a variety of trade education fields including construction technology, electrical, plumbing, and more.

History: 2024 marks the fifth year of the scholarship program. So far, DEWALT has awarded $650,000 in scholarships to 80 students from 30 states and the District of Columbia.

Program Goals: »

»

»

Address Skills Gap: Aimed at combating the skilled trade shortage, particularly with over 350,000 job openings in construction.

Educational Support: For those pursuing trade degrees or certificates at two-year colleges or vocationaltechnical schools.

Stanley Black & Decker’s Commitment: Part of a larger $30 million commitment to grow the trades by 2027, aligning with their Environmental, Social, and Governance (ESG) strategy.

Eligibility and Application: »

» »

» » »

Candidates: High school seniors, graduates, or current undergraduate students planning full-time study in an accredited two-year college or vocationaltechnical school.

GPA Requirement: Minimum 2.0 on a 4.0 scale.

Fields of Study: Includes automotive technology, aviation maintenance, carpentry, construction, HVAC, welding, etc.

Application Deadline: January 17, 2024.

How to Apply: Applications can be submitted through learnmore.scholarsapply.org/dewalttrade.

Administration: The program is managed in partnership with Scholarship America®.

Key Details: »

Scholarship Amount: DEWALT will award a total of $200,000 in scholarships.

For additional information about the scholarship or DEWALT's offerings, visit DEWALT's website and their social media pages, or explore Stanley Black & Decker’s website.

Leading the Charge in Smart Factory Revolution and Global Partnerships Flexxbotics, a front-runner in robot-driven manufacturing and workcell digitalization, has recently announced several strategic moves solidifying its position as a key player in the Smart Factory domain. Gaining recognition as a Certified System Integrator (CSI) for Universal Robots (UR), Flexxbotics now fully integrates services with UR cobots, focusing on machine tending and extending their fleet using its proprietary FlexxCORE™ technology. This technology ensures smooth coordination between UR cobots, existing automation equipment, IT systems, and human workers, reinforcing Flexxbotics' leadership in CNC automation.

Moreover, Flexxbotics was selected to join Hexagon’s elite Sixth Sense program, a testament to its

14 | IMD November 2023

selected from hundreds of applicants for their innovative solutions to pressing manufacturing challenges, including product sustainability, waste reduction, real-time data capture, automated design, and cobot integration.

The nine selected startups are:

pioneering FlexxCORE™ technology, which enhances autonomous process control in next-generation machining environments. This inclusion is pivotal in merging Flexxbotics' software with Hexagon’s in-line inspection equipment, aiming to drive sustainable product design and manufacturing leadership towards a net-zero transition.

Expanding its reach, Flexxbotics partnered with Applied Automation, enabling wider distribution of its Smart Factory solutions across the U.S. This move, crucial for reshoring and Smart Factory transitions, positions Flexxbotics to meet the increasing demand for digitalized, robot-driven manufacturing. The partnership encompasses Applied Automation's various divisions, including Advanced Control Solutions, Automation, Inc., Gibson Engineering, Olympus Controls, and RR Floody Company, offering an extensive distribution network for Flexxbotics' innovative solutions.

Flexxbotics is also gearing up to showcase its latest advances at the upcoming Universal Robots Collaborate and Automate event in Boston. Here, Co-founder & CEO Tyler Bouchard will discuss best practices in deploying CNC tending automation. As an independent software solution provider and UR certified systems integrator, Flexxbotics' participation highlights its commitment to enhancing productivity and capacity gains through integrated, automated manufacturing solutions. These developments mark a significant leap in Flexxbotics' quest to redefine the manufacturing industry through innovative technologies and partnerships, cementing its role in the global transition to smarter, more efficient manufacturing practices.

Hexagon's Sixth Sense Announces Nine Startups to Transform Manufacturing Sustainability and Digital Reality

1. Acerta Analytics (Canada): Provides ML/AI-based analytics for defect detection and quality improvement in automotive manufacturing.

2. Circularise (Netherlands): Offers digital product passports for traceability and secure data exchange in supply chains, promoting transparency and sustainability.

3. Dessia (France): Develops virtual "bots" to assist engineers in designing mechanical systems, enhancing the design process.

4. Flexxbotics (Boston, US): Specializes in flexible next-generation machining environments with its FlexxCORE™ technology.

5. Launchpad (Los Angeles, US): Uses AI and advanced simulation for design, procurement, and manufacturing process automation.

6. Rafinex (Luxembourg): Provides stochastic AI topology optimization for lightweight, safe designs in high-risk sectors like aerospace and automotive.

7. RV Magnetics (Slovakia): Developed the world's smallest passive sensor based on MicroWire technology for diverse applications.

8. ToffeeAM (London, UK): Delivers generative design software for efficient, multi-physics engineering component optimization.

9. Zaptic (Manchester, UK): Provides job instruction and collaboration tools for frontline teams, along with a no-code toolkit for digital operational transformation.

These startups will undergo a 16-week program, working closely with Hexagon. Up to three winners will be chosen for global expansion support, including potential funding, office space, and product/service access. They'll also be featured on Hexagon's Nexus platform.

Josh Weiss, president of Hexagon's Manufacturing Intelligence division, emphasized the initiative's focus on sustainable product design and net-zero transition leadership. Milan Kocić, head of Sixth Sense, Hexagon, highlighted the startups' potential to address key manufacturing challenges and drive sustainable industry practices.

Hexagon's Manufacturing Intelligence division has chosen nine startups for its third Sixth Sense cohort, focusing on manufacturing sustainability and digital reality. These startups, originating from seven different countries, were INDUSTRIAL MACHINERY DIGEST.COM

IMD | 15

Business 4.0

6 Impactful Cybersecurity Tips for Your Business

T

here is no better time than now to analyze if you are doing all you can to keep your company safe from online threats. From phishing schemes to data breaches, hackers and con artists are constantly devising new ways to defraud businesses. So whether you run an online store or a multinational company, safeguarding against cyber attacks should be of utmost importance.

In my journey as the creator of the 9 Year Letter™ Method (a goal-setting system for the 4 pillars of life relationships, financial, health, and fun), I have discovered a number of ways both new and established business owners can maximize their cybersecurity. Here are 6 impactful online safety tips for business owners:

Use Strong, Unique Passwords for ALL Company Logins The use of robust and distinctive passwords is the most straightforward yet sometimes disregarded part of cybersecurity. So many business leaders just use the same password for all of their logins, or variations of the same password, which puts their company’s data and financial health at risk. Your first line of defense against unauthorized access is a password, so here are helpful ways to boost your password security: » Complexity Matters: To ensure the security of your password, use a length of 12 characters. It should include a combination of uppercase and lowercase letters, numbers, and special symbols. By incorporating this level of complexity, it becomes

16 | IMD November 2023

challenging for hackers to break your password using brute force attacks. » Avoid Predictability: Avoid using passwords such as "password123," "admin," or "letmein." Additionally, it's crucial to refrain from creating passwords based on information like your birthdate, name, or business name. » No Reusing: It's vital to avoid using the same password for different platforms or accounts. If one account gets hacked, it puts all your accounts at risk if they share the password.

Keep Software and Plugins Up to Date In the fast-paced business world, it is extremely important to keep your software and plugins up to date. When software versions become outdated, they unintentionally become points that can be exploited by hackers. Software developers address these vulnerabilities and release updates to protect against cyber attacks. Therefore, neglecting timely updates leaves businesses exposed and more susceptible to security breaches.

It's not just the core software that requires attention; plugins and third-party applications on platforms like WordPress, Joomla or Drupal also need careful monitoring and regular updates. Thankfully, with advancements in technology, there are now automated tools that simplify the updating process and reduce the need for checks.

Utilizing these tools ensures that your software constantly reinforces its defense against cyber threats.

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Implement SSL Encryption Take measures to ensure the safety of information exchanged between your websites and users. One essential tool to use is SSL (Secure Socket Layer) encryption. This digital shield acts as a safeguard for data like login credentials, your customers’ credit card information, and personal details as they travel across the internet landscape.

You can easily identify a website using SSL encryption by looking for "https://" in its URL. The ‘s’ in "https" represents security and signifies a protected environment for transmitting data. You may also notice a padlock icon in the URL, which provides reassurance of SSL’s protective embrace.

For businesses that haven't yet adopted SSL, it's essential to obtain an SSL certificate. Besides providing security benefits, it also will enhance your website's credibility among visitors. In an era where trust holds so much value, having an SSL certification serves as a symbol of reliability. Furthermore, it may have advantages like improving the website's search engine optimization (SEO) ranking, resulting in increased visibility in search engines and higher organic traffic.

Conduct Regular Backups Regular backups are extremely important for businesses.

They act as a safety net that protects businesses from cyber threats and unexpected challenges. Whether it's an attack, accidental data loss, or any other unforeseen problem, having up-to-date backups ensures that business operations can continue without interruption.

It's crucial to maintain backups that include website content, databases, important configurations, and all other essential data.

An effective strategy is to store these backups securely, off-site from onsite dangers. However, it's not enough just to create backups – it's equally important to test them for reliability and functionality. This ensures that they are not just stored archives, but also that they can actually be used for recovery when needed.

Limit User Permissions It is paramount to prioritize the principle of privilege (PoLP) especially when granting user access. The core idea behind this principle is to restrict user permissions to what's necessary for them to effectively carry out their assigned tasks. By following this approach, businesses can ensure that they do not unintentionally provide avenues for security breaches.

Sometimes, organizations may grant access to a range of users or administrators in an effort to simplify administrative processes. However, this can become a vulnerability. Granting access should be the exception rather than the norm. By assigning and regulating roles and permissions, businesses can significantly reduce the risks associated with activities, data breaches, or accidental errors.

This focused approach serves as a deterrent against threats. When permissions are streamlined and closely monitored, it becomes incredibly difficult for malicious individuals within the organization to cause harm, make changes, or gain access to data. By ensuring that each individual only possesses the access they truly need, companies establish a more resilient defense infrastructure.

Leverage AI for Threat Detection Online platforms often deal with a vast amount of data that is impractical and inefficient for humans to manually monitor and manage. Luckily, artificial intelligence has revolutionized the data monitoring process. AI has the ability to process enormous amounts of data quickly, making it an invaluable asset in modern cybersecurity strategies. AI-powered tools delve into real-time data to quickly identify anomalies and patterns that may go unnoticed by humans but could indicate security threats or impending cyberattacks.

Furthermore, AI goes beyond enhancing threat detection; it also greatly speeds up response mechanisms.

The effectiveness of AI guarantees that dangers are not only discovered, but also swiftly dealt with in situations where every second matters.

AI’s predictive capabilities are truly game-changing.

It can anticipate threat vectors, allowing businesses to proactively adopt security measures and strengthen their systems before a threat materializes. In essence, AI isn't merely a tool; it serves as an ally in the battle against cyber threats.

To Wrap It All Up Now is the perfect time for you to amplify your business’s online safety measures. Using strong and unique passwords for all logins, keeping software and plugins up to date, implementing SSL encryption, leveraging AI for cyber threat detection, and limiting user permissions are just a few ways you can safeguard your business. By implementing these measures and by fostering a culture of cybersecurity awareness within your team, you will protect your company's assets, its hard-earned reputation, and its promising future.

ABOUT THE AUTHOR Ray Blakney has nearly two decades of business experience that have included starting, growing and leading over a dozen profitable companies along with hundreds of staff from across the USA and Latin America. His newest venture, Kairos Venture Studios, is on a mission to bring a fresh take to online businesses in the Latin American market by launching 12 new businesses in the region each year. A renowned business coach/mentor/advisor, Ray is also the creator of the 9 Year Letter™ Method (a goal-setting system for the 4 pillars of life relationships, financial, health and fun). www.9yearletter.com INDUSTRIAL MACHINERY DIGEST.COM

IMD | 17

Talking Shop

FEATURING:

TALKING SHOP WITH: Scotchman Metal Fabricating Solutions

Innovative Solutions and Expert Insights from Scotchman Industries In the latest edition of "Talking Shop" from Industrial Machinery Digest, we dive into the world of metal fabrication and cutting-edge machinery with insights from industry veterans at Scotchman Industries. As a leader in this domain, Scotchman has been pioneering innovations and solutions tailored to the evolving needs of the metalworking industry. In this feature, we bring you an engaging Q&A session with Jerry Koetch, Scott Olivier, and Mike Albrecht from Scotchman.

They share their deep knowledge and expertise on an array of products ranging from Hydraulic Ironworkers to advanced Cold Saws. Jerry introduces us to the multifaceted and powerful Hydraulic Ironworkers, highlighting their Swiss Army knife-like versatility and efficiency. Scott takes us through the sophisticated world of Cold Saws, focusing on the GAA-500 CNC DT20 Automatic Upcut model and its programmable, multifunctional prowess. Lastly, Mike rounds out the discussion by exploring the range and advancements in cold saw technology, from manual to fully automated systems.

Each segment provides a unique glimpse into Scotchman's commitment to quality, innovation, and customer-centric engineering, offering invaluable insights for anyone in the field of industrial machinery.

Jerry from Scotchman on Hydraulic Ironworkers Jerry, could you share some history about Scotchman Industries and its significance in the hydraulic ironworker market?

Scotchman Industries has a proud history dating back to 1967, marking our beginning in the hydraulic ironworker manufacturing industry. We hold the distinction of being both the oldest and the largest American manufacturer in this sector. Our experience over the decades allows us to deeply understand the industry's evolving needs and craft solutions that meet these changes head-on.

18 | IMD November 2023

What is the range of models Scotchman manufactures for hydraulic ironworkers, and what are their capacities?

Our production line currently boasts 13 diverse models of hydraulic ironworkers, catering to a wide spectrum of needs. The models range from 45 tons to a robust 150 tons, ensuring we have a machine suitable for different scales and types of metal fabrication.

Can you delve into the specifics of the 50-ton hydraulic ironworker and its unique features and capabilities?

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Absolutely! Our 50-ton model exemplifies versatility and power. One of its key features is the ability to cleanly shear up to a size of 4" x 4" x 3/8", delivering precise cuts without distortion, wedges, or burrs. The machine also excels in mitering, capable of handling up to 2" x 2" x 1/4".

The precision and neatness of these cuts make them weld-ready, which is a substantial time-saver in fabrication.

How does the design of Scotchman's hydraulic ironworker reflect its versatility, particularly in terms of tool adaptability?

We often compare our hydraulic ironworker to a Swiss Army knife because of its multifunctional capabilities. This versatility is largely thanks to what we call the 'component tool table' design. This feature allows operators to swiftly swap out tools like the angle shear and replace it with a press brake, rod shear, or a pipe notcher under the power cavity within seconds. This adaptability transforms the machine's functionality for various tasks, ranging from notching to punching, making it an invaluable asset in a workshop.

What innovations does the 50-ton model bring to punching and notching operations?

The 50-ton ironworker stands out for its three-station turret punch, which is quite unique in the industry. This feature allows for quick changes between different shapes or sizes,

Jerry Koetch

like moving from an oval slot punch to a square hole within seconds. Additionally, the machine is equipped with a rectangular notcher for precise and varied notching tasks on different materials like angle iron or flat stock.

Scott Olivier on Scotchman's Cold Saws Scott, as a Cold Saw Product Manager at Scotchman, what are the standout features of the GAA-500 CNC automatic upcut cold saw?

The GAA-500 CNC DT20 Automatic Upcut non-ferrous cold saw, which we're showcasing, is a true representation

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IMD | 19

of Scotchman's innovation in saw technology. This saw is specially designed for non-ferrous materials and integrates a unique drill and tap attachment. This feature allows the saw to advance material and perform drilling or tapping operations up to ten holes per length. Furthermore, the unit can be programmed for up to 30 different part lengths, each with up to ten different lines, offering unmatched flexibility in production.

Can you describe a typical operation cycle of the GAA-500 CNC DT20 as showcased at the FABTECH show?

During a demonstration at the FABTECH show, the GAA-500 CNC DT20's operational prowess was on full display. The saw first makes a trim cut on the material then accurately cuts a part to the length specified.

Following this, it positions the material under the drill for drilling and tapping.

The precision of this machine is highlighted as it drills a hole and then switches to a tapping speed, even reversing at the bottom of the tap. The versatility of this machine was evident as it processed parts with varying numbers of holes and different lengths – showcasing its adaptability for different manufacturing needs.

Mike Albrecht on Advancements in Cold Saws

Scott Olivier

precision is key. The semi-automatic saws also boast mitering capabilities, allowing for adjustable angle cuts with either automatic or manual head locking.

Moving towards fully automated sawing solutions, how does the CPO AutoLoader enhance production efficiency, and what software features does it offer?

Our fully automatic CPO AutoLoader is a game-changer for high-volume production settings. It's designed to handle bar lengths ranging from 12

Mike, could you elaborate on the variety and capabilities of cold saws offered by Scotchman, particularly the manual and semi-automatic models?

At Scotchman, our range of cold saws is carefully curated to meet various needs and operational scales. Starting with our manual CPO 350 saw, which operates with a manual trigger switch and a pull-down action, we provide an essential, straightforward cutting tool with a manual vise. Stepping up, our semi-automatic models offer enhanced productivity with a foot pedal operation. This not only increases efficiency but also ensures consistent quality with each cut — essential for repetitive tasks where

20 | IMD November 2023

Mike Albrecht

to 24 feet and features an automated loading system that significantly reduces manual intervention. On the software front, the saw's interface can store numerous cut lists, facilitating diverse cutting operations. It vividly displays different cut lengths and tracks completed parts, ensuring a seamless and efficient production flow. The optimizing software embedded within this system is another standout feature, enabling users to get the best possible yield from their materials, thereby boosting productivity and profitability.

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Safety & Maintenance

Utilizing IoT-Enabled Predictive Maintenance in Manufacturing

M

anufacturing professionals must embrace the Internet of Things (IoT) to leverage what Industry 4.0 offers and prepare for the widespread shift to Industry 5.0. Predictive maintenance is one of the ways it is the most influential and powerful.

IoT-enabled predictive maintenance empowers workforce skills, saves money and has numerous other plusses. Explore the IoT’s role in manufacturing and how the benefits justify swift implementation.

Manufacturers usually rely on preventive maintenance to increase uptime, but predictive has better timing and can consider the future’s influence on current operations.

IIoT devices notify operators when to execute repairs, cleaning or parts replacements only as needed instead of on a potentially excessive schedule. Alternatively, some production lines may rarely perform maintenance, and IIoT-enabled predictive maintenance reminds technicians of their responsibilities.

What Is the Role of IoT in Predictive Maintenance?

What Are the Benefits?

Industrial IoT’s (IIoT) role in predictive maintenance is to increase a machine’s efficiency and life span while reducing unnecessary upkeep. IIoT tools do this using data collection from sensors, cameras and other peripherals. The goal of employing the IIoT in manufacturing is to minimize downtime and save on labor and maintenance costs.

Manufacturing experts may understand the basic boons of IIoT for predictive maintenance, but its influence spreads to more parts of a business structure than initially perceived.

22 | IMD November 2023

1. Increased Safety and Compliance Regulatory efforts and technological assistance have

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decreased manufacturing-related injuries and deaths in the last half-century. The IIoT’s ability to suggest predictive maintenance reduces the likelihood that machines fail, break or run incorrectly.

Faults increase the chances workers get hurt. The IIoT heightens safety and, therefore, improves worker comfort and morale. The safer they are, the more likely they will stick to maintenance schedules and suggestions for their well-being.

2. Boosted Sustainability Numerous factors impact a machine’s performance power.

Is there dust and dirt under belts or do motors need more lubrication to move at optimal speeds? Faulty or old parts compound these influences. These hindrances force manufacturing machinery to pull more power than expected, resulting in downtime and supply loss from poor products.

Additionally, degrading equipment may cause excess pollution and contaminant spread, such as oil and chemical leaks or particulate air contamination.

A failing machine creates excess waste and uses copious amounts of power it would not otherwise. The IIoT keeps everything from energy expenditure, landfill contributions, water use and carbon emissions down by reminding techs to fine-tune the machines. IIoT sensor data will illuminate countless green process discoveries.

3. Opportunistic Upskilling and Reskilling Digital transformation in Industry 4.0 makes tenured operators learn new tools and skills. New entrants can get firsthand experience with technologies shaping their future.

No matter the technician's demographic and experience level, IIoT-powered predictive maintenance provides openings for workers to up- and reskill. Delaying IIoT implementation puts essential maintenance training on hold for manufacturers needing to stay adept.

discontinuing and replacing things that should have been in operation longer. IIoT-empowered predictive maintenance could double equipment life, reducing annual revenue loss and downtime spent installing new machinery.

5. Provided Competitive Advantage Well-maintained machines with the help of the IIoT are also more likely to help quality control. As-needed, relevant predictive maintenance solidifies the chances every facet of a product is top-notch. Because predictive maintenance considers the future of the machine and

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IMD | 23

development, it makes its quality timeless and consistent, even as months and years go by.

A manufacturer’s reputation becomes more reliable, allowing more customers to trust a specific brand over others. High reputation translates to industry leadership as companies leveraging IIoT and predictive maintenance become role models for industry progression.

How Do Manufacturers Implement IIoT for Maintenance?

With AI and related technologies adding more than $13 trillion back to the global economy by 2030, it makes sense to jump on the IIoT bandwagon now. The benefits only arrive on production lines when the sector undergoes a smooth, logical digital transformation. Scaling based on budget, worker capabilities, and stakeholder goals will influence installation and timetables. Manufacturers can follow these distilled steps to begin their predictive maintenance journey.

First, manufacturing professionals must identify which assets they want to be influenced by predictive maintenance peripherals. Businesses may need to divide them by priority, as comprehensive implementation may take time, mainly if a company tests multiple IIoT devices.

The second step is choosing the right software and tools for priority machines. Management should consider factors like compatibility with existing digital infrastructure, data gathering abilities and diversity, price and third-party compliance, and operability standards.

24 | IMD November 2023

Manufacturers should rewrite technical documentation and procedures for workforces with these new systems in mind. Enterprises risk efficiency and morale if these knowledge bases do not exist before implementation and training. Everything from beginner briefs to troubleshooting information must be available to technicians.

Cybersecurity compliance is another consideration.

Address these concerns before handing off responsibilities to workers. Consider authentication measures, data collection, record-keeping, backups, permissions and risk management.

Finally, there is installation alongside training.

Companies focusing on these major categories before opening the doors to IIoT-driven predictive maintenance will yield better results.

The IoT Keeps Manufacturing Machines Alive Predictive maintenance empowered by the IIoT requires dedication to implementation and attentiveness to upkeep. These efforts have numerous benefits for manufacturing workforces, leaders and stakeholders.

Timely repairs and replacements set a precedent for a more seamless manufacturing sector that produces less waste and prioritizes safety. The machine’s life span directly translates to how a manufacturer’s reputation will transform after IIoT implementation — one of longevity and reliability.

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Manufacturing Showcase

The A Team: Innovating Today’s Custom Tooling Process The 2022 Tool of the Year entry showcases the capabilities and complexity that ARCH and ANCA can achieve together.

B

ased in Detroit, Michigan, ARCH Cutting Tools provides an experienced team of application specialists and custom tooling designers, who provide customers with a line of standard cutting tools and custom tooling.

Throughout the years, ARCH Cutting Tools has supplied custom tools to various industries including aerospace and defense, power generation, transportation and automotive.

They also provide custom solutions to clients of their sister division, ARCH Medical Solutions.

They have participated in several ANCA Tool of the Year competitions, winning in 2020 with their complex, multifunctional tool, and placing as the first runner up in both 2022 and 2023. They demonstrated excellent use of multiple Toolroom iGrind software operations with several complex profiles. This started a trend towards multi-functional and complex designs for Tool of the Year winners onward. Turkish company TURCAR won with a similar concept for its tool in 2021, a multi-functional tool with axial and radial cutting features to machine five independent operations in one cycle.

The Mexican winner in 2022, SJ Tools, created a cutting tool that combined multiple features into a single tool where all features were finished with a very accurate surface finish.

The idea behind the 2022 entry was to combine multiple tools into one and show what ARCH Cutting Tools

26 | IMD November 2023

could do for customers and what an ANCA tool grinder could produce. The creation of this tool played on the aspect of teamwork and brought in players from multiple ARCH facilities. One of these was Charles Montgomery, CNC Programmer at ARCH Cutting Tools Mentor, Ohio location. Montgomery’s design was chosen as the Tool of the Year entry. The tool was then sent to the Latrobe, Pennsylvania location. Jim Gray, the Regional Director of Operations, programmed it, made the ToolDraft print and manufactured it on an ANCA MX7 grinder.

Commenting on why ARCH entered the competition initially and why they continue to do so, Montgomery, said, “We enter the contest because it gives us the opportunity to be creative and push ANCA [machines] outside their everyday use. Being part of ANCA Tool of the Year annually helps us to continue to improve and showcase our capabilities.” Jim Gray added that the company is excited to continue its partnership with ANCA as it garners more exposure of ARCH through the co-op marketing.

Discussing the impact of their previous win, Montgomery said it brought a positive attitude to the workplace and showed that there is more to tool grinding than solely making tools for customers.

Gray mentioned that, as a result, ARCH has become well-known worldwide.

IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986

Montgomery described the tool process starting with the tip of the tool as a three-flute right-hand helix endmill with chip breakers, to help stop the tool from creating long chips. Next, it moves into a three-flute form radius cutter for form milling, then transitions into a threadmill. This can be used to create internal and external threads of different sizes. A concave spin grind was added to create relief for chip flow and ejections. Lastly, the back portion changes to a left-hand helix right hand cut reamer to change the forces down into the part to keep it stable in the fixture.

Known as the “Fiver,” due to its multiple functions, Gray said that “ARCH Cutting Tools is a solution driven specialty tool company that provides solutions like this tool that cut down on the end users cost in tooling and cutting cost in production.”

This tool was first designed and programmed using the ANCA iGrind software. Next, ARCH used an ANCA MX7 with special wheel packs to grind the tool for their submission. Explaining the complexities in design and production, Montgomery said, “It can be a very complex process to design a tool with multiple functions. You need to use the full capabilities of the software and hardware available, making sure you have all the correct wheels and clearances to avoid any machining issues.”

ARCH Cutting Tools had multiple submissions they prepared for the Tool of the Year contest and company personnel voted on which entry to submit. The tool was

made to showcase the capabilities and complexity that ARCH and ANCA could achieve together. The “Fiver” took second place in last year’s competition. Gray mentioned the company’s great partnership with ANCA stating, “ANCA’s ingenuity and advanced technology have given our company the competitive edge that goes along with the expertise of the ARCH team. ANCA and ARCH have a true partnership in the cutting tool industry…The A-Team.”

For further information, please contact: Amanda Bakun Marketing & Communications Manager - Americas 248-497-1168 amanda.bakun@anca.com

ABOUT ANCA ANCA is a market leading manufacturer of CNC grinding machines. It was founded in 1974 in Melbourne, Australia where the company still has its global headquarters. ANCA has offices in the UK, Germany, China, Thailand, India, Japan, Brazil and the USA as well as a comprehensive network of representatives and agents worldwide.

ANCA CNC grinders are used for manufacturing precision cutting tools and components across a diverse range of competitive industries including cutting tool manufacture, automotive, aerospace, electronics and medical.

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IMD | 27

Industrial Automation

Electroimpact SCRAM system sculpts new possibilities This industrial, true 6-axis continuous fiber-reinforced 3D printer enables tool-less rapid fabrication of aerospace-grade integrated composite structures.

Pushing the envelope in additive manufacturing Aerospace and defense design engineers and the complex components they develop require true manufacturing agility. Shepherding ideas from seeming impossibilities to sparks of inspiration to groundbreaking products that enable innovation can be both exhilarating and maddening.

To iterate quickly and enable true collaboration, the fastest teams in engineering employ the Electroimpact SCRAM system powered by the Siemens SINUMERIK ONE CNC. Helping to make the impossible possible, Electroimpact has integrated an in-situ out-of-autoclave thermoplastic Automated Fiber Placement (AFP) process, an advanced Fused Filament Fabrication (FFF) 3D printing process, a Fused Granulate Fabrication (FGF) 3D printing process, and subtractive machining into a unified Scalable Composite Robotic Additive Manufacturing (SCRAM) system. SCRAM is an industrial, true 6-axis continuous fiber-reinforced 3D printer that enables the tool-less rapid fabrication of aerospace-grade integrated composite structures.

High-performance thermoplastics combined with a high percentage of continuous fiber reinforcement are used to produce parts with exceptional material properties previously unheard of in the world of additive manufacturing. The enhanced performance of the 6-axis system offers unmatched dexterity and flexibility, enabling shapes, accuracies and intricacies not possible otherwise.

This technology has no equal in the industry and is a unique offering available only from Electroimpact. The capabilities and processing speed of the SINUMERIK ONE control empower Electroimpact engineers to achieve these breakthroughs in additive manufacturing.

True 3D printing Most 3D printing processes are more accurately described as 2.5D printing. The material is deposited successively in flat slices, which when stacked together form a 3D object.

In contrast, the SCRAM process renders true 3D printing.

Layers of continuous fiber-reinforced thermoplastic capably take the shape of complex contours, including aerodynamic surfaces and ducts for fluid flow. As a 6-axis process, fiber orientation within each layer can be tailored to the specific application, providing optimal strength and appropriate stiffness distribution throughout the part, much like a conventional AFP system.

28 | IMD November 2023

In addition to the continuous fiber-reinforced thermoplastic printing process and the FGF support tool printing process, SCRAM cells are also fitted with two FFF nozzles optimized for deposition of thermoplastic material reinforced with short or “chopped” fiber.

A proprietary laser heating system is incorporated, producing exceptionally strong bonds between layers.

This process is ideal for situations in which layering continuous fiber is geometrically impossible or otherwise does not make sense. “It allows us to deposit the material exactly where it needs to be and only where it needs to be, achieving the highest possible strength and lowest weight,” says Ryan Bischoff, senior composite engineer at Electroimpact.

This is a true 3D printing process where the layers are not simply a stack of planes. Complex geometries such as variable density core and other internal structures can be printed directly onto continuous fiber-reinforced layers with widely varying curvature. If desired, additional continuous fiber-reinforced layers can then be deposited on top of the chopped fiber-reinforced core structure, forming an upper skin.

The system is an integration of several additive and subtractive processes, combined with Electroimpact’s patented accurate robot, a rotating build platform and a

IMD – North America’s Manufacturing Resource for Industry Professionals Since 1986

SCRAM is capable of performing several different manufacturing technologies—all in the same cell, all in one place, and all controlled by SINUMERIK ONE from Siemens.

climate-controlled build chamber.

Electroimpact then supercharges everything with the SINUMERIK ONE control from Siemens. “SINUMERIK ONE allows us to run more complicated code much faster,” says Kylie Martineau, Electroimpact controls engineer.

“Electroimpact expanded from doing mostly drilling and fastening to additive manufacturing about 15 years ago,” Bischoff says. “That move and the advancements over the years led to the development of a system that we call a ‘factory in a cell.’ Instead of needing a whole assembly line, with each dedicated machine only performing a single function, it is one system, which can be printing ducts for jet engines one day and a wing component the next. It can be quickly changed and adapted according to needs.”

The SCRAM enables the tool-less rapid fabrication of aerospace-grade integrated composite structures.

This factory in a cell gives builders the option to produce low-run parts that make all the difference in their designs.

This might be a carbon fiber element for Formula One racing or a part made from a revolutionary alloy that is destined for space. For short runs or small runs, nothing can compete with this technology. “Here is where the factory in a cell helps teams develop parts much more quickly than a traditional facility. You complete the whole process within the SCRAM system. It makes sense because these are not the kind of parts that are produced in the thousands,” Bischoff says.

“Our customers are doing extraordinary work, and we are right there alongside them,” he adds. “Your Electroimpact engineer is with you though the lifespan of the system for all questions and requests. We are here to help builders push boundaries. We service our equipment till the day it dies. Support is one of the things that Electroimpact does better than anyone else in the industry.”

With the SCRAM system, 3D printing replaces the need for the traditional complex tooling development typically used for automated carbon-fiber layup. This eliminates the inflated cost and time investments needed in traditional

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Ryan Bischoff, Electroimpact engineer, discusses the breakthrough capabilities of the SCRAM system for prototyping and low volume production of complex carbonfiber components. Powered by the Siemens SINUMERIK ONE, the system is an integration of additive and subtractive processes, combined with Electroimpact’s patented accurate robot, a rotating build platform and a climate-controlled build chamber.

tooling and development; therefore, the SCRAM system allows for faster corrections and modifications.

Once the complex tooling is printed, the SINUMERIK ONE control facilitates rapid changes throughout the process. First, the SCRAM system changes to a multi-axis milling head that finishes the form to exacting specifications. Then the SCRAM system changes once again to the 6-axis carbon-fiber placement head and applies the intricate pattern of carbon fiber tape to the support material.

Bischoff explains that the tape is deposited quickly, establishing the form. Next, the support material additive is then completely dissolved away, leaving behind a component in the exact shape the manufacturer needs.

“The knowledge that we’re able to dissolve the tooling without creating graywater brings us great peace of mind,” Bischoff says.

The SCRAM system, with the power of SINUMERIK ONE, also enables iteration. “We are working to make an open system that will support the material choices and make the parts each customer needs. We are driven by customer demand,” Bischoff explains.

The processing speed of the Siemens SINUMERIK ONE CNC Electroimpact engineers appreciate the advanced features of this next-generation control platform.

“The faster processor times for both motion control and PLC, combined with new functionalities of the SINUMERIK

30 | IMD November 2023

Ryan Bischoff of Electroimpact discusses the hybrid-manufacturing process of the SCRAM system and its ability to efficiently generate both the tooling and the finished part, all within one cell.

ONE, further enable the incredible work Electroimpact is doing with the SCRAM system,” says Steve Czajkowski, engineering manager at Siemens.

Brian Cubie, account manager for Siemens, agrees.

“Our system is the foundation on which they are building, and it is just incredible to experience,” he says. “I have been in robotics for many years, and to see what the engineers at Electroimpact are doing in terms of digitalizing the factory floor is exciting. They are always at the forefront.

Electroimpact does a phenomenal job of taking our new SINUMERIK ONE control and adding encoders for feedback and run it though their own kinematics.”

SINUMERIK ONE is built for high-speed processing that enables the accuracy needed for specialized parts. It is ideally suited to the SCRAM’s groundbreaking ability to shift from 3D printing to finishing and continuous carbonfiber placement, all from one control.

SINUMERIK ONE makes product development faster, more flexible, and more efficient.

Digital twin technology Looking towards the future, the SINUMERIK ONE control platform will take the SCRAM The SCRAM system provides a true 3D printing process, where the layers are not simply stacked into advanced digital twin technology. This on top of each other, but 6-axis tools paths with continuous fiber filament as well as chopped will help teams engineer a fully functioning fiber. Laser heating of the substrate and incoming material provides superior inter-laminar adhesion between the layers. machine even before a real-life prototype exists and for teams to transfer tasks from the real world to the virtual environment. It will keep projects higher for complex aerospace design and development. moving consistently to the work preparation phase.

The SINUMERIK ONE control will continue to evolve Having SINUMERIK ONE as a built-in tool will help reduce and support the next wave of design and development in overhead costs for projects and support. machine building.

“There‘s a huge industry push to having a digital twin,” Martineau says. “I am extremely excited about supporting For more information SCRAM in our customers’ endeavors moving forward. Each customer is pushing what is possible. They are reaching For more information and to watch the video, visit: for ideas that are slightly out of the ordinary. With this true usa.siemens.com/ei-scram digital twin, instead of needing to travel for an on-site visit or asking for photos or video footage of their challenges, the PLC will allow simulation right inside the control.”

Just as customers can run the digital twin from their computer, Martineau will be able to operate the digital control of a customer’s SCRAM right from hers.

“We hear from customers when they’re striving for the every time. next level, pushing the system to the max. Being able to jump in and see what’s happening is so valuable,” she says.

“The digital twin capabilities of SINUMERIK ONE will enable us to work extremely close to our customers in the future, supporting their desires to push the envelope of product development. With digital twin technology this accurate, customers will benefit from knowing we can jump in anytime to seamlessly help troubleshoot.”

quality matters.

Strong partnership Siemens and Electroimpact have been partners for more than 10 years. The SCRAM previously included the SINUMERIK 840D sl, a precision CNC control highly favored by the aerospace industry. SINUMERIK ONE is faster and excels at more complex code. With the advancements of the SINUMERIK ONE control, the possibilities are endless.

“Electroimpact is always pushing the envelope,” says Brian McMinn, head of the Siemens Machine Tool Systems business. “Their approach is to always be at the very leading edge of manufacturing technology. We are glad to be a part of their team as SINUMERIK ONE has the power and speed to make it all possible.”

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IMD | 31

Workforce Development

Today’s Workforce Development Requires a Sound Strategy

By William Weier, Human Resources Director at Mazak Corp.

C

ompanies continue to face unprecedented workforce challenges. In the manufacturing sector, meeting the demand to find, recruit, develop and retain qualified, skilled employees has become a business imperative that requires a holistic, highly strategic approach to workforce development.

Approaching manpower recruiting and retention without a well-conceived approach is like plugging a hole in a dam without first considering how the hole initially developed and what should be done to keep it from happening again. The questions must be asked: Where are our weaknesses, and what can we do to reinforce them?

The current workforce is not what it used to be. Today’s potential employees want flexibility, advancement, a sense of purpose and equilibrium in their work/life balance. If those needs are not addressed and met, there’s a good chance talent will move on, assuming they were able to be hired in the first place. Each month, 3 to 4.5 million employees quit

32 | IMD November 2023

their jobs, bringing yet another challenge to be overcome.

Turnover and talent drain costs employers about 33% of the worker’s annual salary to replace them. However, successful recruiting and retention are possible when companies take a truly strategic approach to workforce development.

The first aspect of such a plan involves evaluating job descriptions and compensation plans. In evaluating job descriptions, the key is to determine the skills and talents required for each position as well as the necessary training.

Once those criteria are established, the focus should move to the employee candidate with an eye toward identifying potential future leaders within the company.

Compensation strategies are simple and straightforward. Salary and benefit packages need to be competitive and designed in such a way that they attract the best talent available. Participating in multiple salary surveys will provide valuable data to restructure compensation based on positions, skill sets and experience. To satisfy

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employees’ desire for a sense of purpose in their work, companies should come out of the recruitment box by positioning their employment opportunities not as a job, but a career. Such a mindset and philosophy benefits everyone.

In terms of recruiting, today’s challenges require casting a broader net with stepped up posting efforts to target key candidate pools such as military veterans.

During the pandemic, Mazak didn’t lay off any employees; however, we also did not bring on any new hires.

However, the post-pandemic customer demand surge forced a corresponding surge in recruiting efforts to regain manpower.

Through internal promotions and new hires, many of which were military veterans, we brought our workforce back to its optimal level. Military veterans have been instrumental in our efforts to move past the skills gap challenging companies throughout the manufacturing industry, and our staff now includes more than 87 veterans in departments ranging from field service and parts to production and purchasing.

Once hired, keeping employees happy and engaged is critical to a durable, dynamic workforce. Advancement opportunities are an essential element of employee satisfaction and provide employers with a succession plan to identify future leaders. A solid strategy is to fill lower-level jobs as much as possible then provide employees with extra training through internal and external opportunities that will

advance them to higher level positions within the company.

A solid succession plan should not be overlooked. It is critical to a company’s success, and without one, they are destined to fail.

In addition to advancement opportunities, flexible work schedules and job rotations are excellent methods of retaining employees who are fulfilled and engaged with their work. Offering employees an alternative to the standard five-day/40-hour routine is the 10-hour/four-day per week schedule for certain shifts. Three-day weekends allow workers more work/life balance and provide an opportunity to earn overtime pay for the 10-hour days.

Job rotations, much like the alternative work week, not only prevent employee burnout, but also help build a stronger, more versatile workforce. In addition to adding skills to an employee’s resume, job rotation enables workers to cross train in various positions and tasks, allowing them to fill in when the need arises. Employee retention is enhanced because workers are stimulated by the challenge of gaining new skills and knowledge.

It’s important to note that a strategic workforce development plan is not a one-and-done proposition. It must be ongoing and dynamic to mirror the ever-changing labor pool landscape. The end goal of a truly strategic workforce development plan – now more than ever – is to attract the best and most talented individuals then retain them once they are hired. Business depends on it.

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IMD | 33

New Technology

How CT Data Analysis is helping TE Connectivity Reach Their Ultimate Goal of End-to-End Quality Inspection Manufacturer gains critical insights using Volume Graphics software throughout design, simulation and manufacturing

T

he all-digital movement is winning over manufacturers seeking more automation, connectivity and reliability from their models and machines. Surveys from the Manufacturing Leadership Council and others show strong investments and results from Manufacturing 4.0 and related digital design and manufacturing initiatives. With a robust digital framework in place comes greater speed, depth, and agility in how product data is created and managed.

As impressive as interconnected digital-platform benefits are for traditional CAD/CAE/CAM disciplines, Computed Tomography (CT)-data analysis for quality inspection has greatly expanded its reach and purpose within today’s growing digital landscape. Its new influence on the central tools of design, simulation and manufacturing are significant; CT data analysis software is making these tools, normally used well upstream of it, even better in their roles.

Feedback from CT analysis to design and production

Simulation serves a quality-measurement workflow early on by predicting material behavior and testing design parameters. A final CT production scan of this automotive charging inlet also informs the simulation about new variations and manufacturing distortions. Image courtesy of TE-Connectivity.

The establishment of Model-Based Definition (MBD) is increasingly guiding engineering beyond drawings and hybrid approaches. The move away from manual readings of data to MBD creates deeper and wider information threads throughout product development, from Product Manufacturing Information (PMI) files to machines and other programs.

It’s not just geometric annotations and manufacturing instructions that travel on digital threads. Companies are creating information loops to design, simulation and virtual testing that improve accuracy, conformance to specifications and shorten time-to-production.

These new development cycles are reinforcing a forty-year trend toward earlier and earlier decision making and less late-stage, at-production validation of products and methods of manufacture.

Setting the benchmark for quality inspection It makes sense that a company engaged in connectivity and sensing solutions for electric vehicles, aircraft, digitalintelligent factories, wind and solar energy, cobots, IoT,

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Real-world molded sample of a high-power charging inlet combo body previously tested in Moldflow software. Image 2B. (top right) CAD model of inlet with PMI quality annotations listing tolerances. No data conversion is needed from Creo; detailed CAD PMI is automatically imported directly into VGMETROLOGY. Image courtesy of TE-Connectivity.

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Virtual and physical quality workflow—(L-R) Design part and define quality measurements; generate digital reports and simulation feedback to design, if needed; visualize and evaluate part from PMI; use AI within simulation and scan programs to optimize parameters; CT scan sample parts for real-world deviations. Post-design: prepare inline inspection macros and scan, analyze, and evaluate. Post-production: analyze field return parts and provide design feedback—resulting in continues improvement.

Image courtesy of TE Connectivity.

high-speed connectivity and more, would invest in MBD and advanced inspection methods. With a stated goal of helping create transformational technology change grounded in reliable and durable electronics products, TE Connectivity is serious about engineered quality.

That “engineered” path brings to bear the advantages of ISO Geometric Product Specification (GPS) standards and virtual metrology against the limits of using classic design workflows. Old workflows use drawings, 2D and 3D-digital systems and, while favorably less complex than MBD, can often lose information during model conversions and require high-effort, manual programming when creating quality-measurement programs.

“GPS is the only way to build true model-based systems and exact mathematical definitions,” says Alexander Stokowski, development director at TE Connectivity.

Stokowski, a certified Six Sigma Black Belt and lecturer for measurement technology and GPS at the BadenWürttemberg Cooperative State University (DHBW), has been involved for a decade in digital transformation.

“GPS is important in deriving the center axis of the part, getting a 90-degree measurement direction, detecting points—and if you are not precise in a mathematical way on this you can’t realistically create, let alone automate, a measurement system," For Stokowski and TE Connectivity, the journey toward MBD and GPS conformance and integration with CT data analysis began in the automotive-products division around 2012. That’s when the first pilot projects started. “By the end of 2013, two years after we began,” says Stokowski, “we more or less made the decision to bring everything that was new product development into the CT measurement environment—aiming towards a 100 percent ratio.”

This pioneering decision, made early in the industry implementation of new ISO standards, sparked a close and intense collaboration between PTC (Creo), TE Connectivity

and Volume Graphics (VG) to create an integration around fresh ISO-compliant GPS capabilities.

In addition, TE-Connectivity’s principal engineer of molding simulation, Patrick Bertram, felt that inclusion of mold simulation simultaneous to the quality process was key to accelerating innovation cycles. Bertram then convinced suppliers Volume Graphics and SIMCON to create an automated interface between the measurement and simulation-optimization software sets.

The full, multi-vendor integration allowed for greater use of model-based annotations and PMI, leading to a looping of virtual test and real-world measurement results back to design and FEA-mold simulation, and forward to prototyping, First Article Inspection (FAI) and production.

“We surprised people by implementing standards well before their final release dates,” says Stokowski. “Why wait 3-5 years when the directions, such how to display 3D annotations, are made clear in the ISO drafts?"

"STEP 214 and 242 didn’t work for our integration," he says. “We used the Application Programming Interface (API) in the Creo toolkit and ISO-GPS to establish our direct interface to VGMETROLOGLY and VGSTUDIOMAX software.

There are customized, added special functionalities that let us reuse values derived from FAI. And that’s it: Geometric Dimension & Tolerance (GD&T) capabilities from Creo and VGMETROLOGY, along with the integration of VARIMOS from SIMCON. No other software is needed to interconnect design and simulation with quality measurement.”

The first goal of TE Connectivity’s digital metrology program was to ensure that the as-designed parts matched the as-manufactured parts. In most cases, this means working with molded products with normal centertolerance concerns in the tooling and typical push-out marks and small flaws. Mold simulation and virtual metrology help identify and resolve both functional and cosmetic aspects of producing molds and plastic parts.

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IMD | 35

FAI leads to a feedback loop where 3D-model and simulation, mold, and manufactured part are reconciled and unified with few-to-no discrepancies. From there, quality templates are created from the Volume Graphics software for automated inspection.

“Ten or fifteen years ago designers didn’t really spend too much time thinking about the details coming out of the mold,” says Stokowski.

“And much of that is taken care of now with tooling software and the automation loop we are creating. The full data is there for our interdisciplinary teams to see and use quickly.”

Quality’s return on investment (ROI) The value of quality overall is not much debated.

Quality builds brands, attracts customers and softens the back-end costs of warrantee claims, service labor, and revisiting process and design methods to find the root-cause of unanticipated problems.

On the other hand, financial managers often question all but fundamental operational investments and are happy with a profitable Patrick Bertram, principal engineer molding simulation; Alexander Stokowski, director status quo. Engineers can find frustration in Engineering Transformation, holding the first ECU project to be CT measured and digitalized; and adapting systems that are new and even more Tabrez Ahmed Ajaz, manager COE GD metrology. Image courtesy of TE Connectivity. complex than past programs. Investing in, learning and implementing quality upgrades can strain an mold and part development of an engine-control unit. The organization in many ways. unit, belonging to the automotive sector, had more than 200 “The real value of quality for TE Connectivity is the time electric-connection pins and was the first of its kind. we save,” says Stokowski. “Time and the value customers Says Stokowski: “It took nearly a year and more than ten place on durable, reliable, superior products." iteration loops to bring the part into drawing requirements.

He continues, "What is the value of four-to-six weeks It was an exhausting, never-ending story. And then just of development time saved in engineering and potentially three-and-one-half years later, the first tooling replacement realized in shipping? How is that calculated against machine had to be done. You can imagine the team’s response! ‘Oh and software costs? There are no exact answers. “But we my goodness…we will need another year just to do the have a Centre of Excellence (CoE) that collaborates with conditioning and correction loops,’ they thought, heads customers, trains our personnel, and creates our quality lowered,” he laughs. infrastructure that contributes to innovation. That is a “But by that time we already implemented the process of business value statement in and of itself.” digital metrology, and we made the mold design within one loop,” he points out.

Time savings and the early engine-control unit “We are on target for a ten-day turnaround for design, simulation, scanning and producing a digital metrology report,” says Stokowski. “So much is now going on upfront.

We want as much done as possible before we hold a physical part.”

Volume Graphics has helped TE Connectivity in this frontloading and looping of data with their Adaptive Measurement Templates. The templates can classify, localize and segment defects using AI and Machine Learning.

They also automate much of the scan analysis and then capture information for metrology reports. The goal at TE Connectivity is to lower analysis time from 10 days to five.

One of Stokowski’s “classic design cycle” projects was taking place just before the full 2014 CT digital analysis initiative that used Volume Graphics software. It entailed

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A goal to cut development times by 75% Today, TE Connectivity hopes to cut their mold and part development process to 25 percent of the time it took in the past. There will always be some manual tasks, says Stokowski—a hands-on refinement of GD&T, or times to debate an issue, or resolve a digital discrepancy in the “thread” that links programs. There aren’t the resources, either, for every mold to go through Design of Experiments (DOE). But the company’s critical molds will use DOE and all new molds will pass through the VGMETROLOGY software.

Suppliers are taking on the new approach as well. Many have purchased virtual metrology systems of their own.

Twenty-to-thirty percent of the external tool builders use the whole integrated digital system. Others go to scanning locations out-of-house and use the software internally. All

tool builders do material compliance checking and basic measurements ahead of TE Connectivity conducting a full metrology report within the CoE. Stokowski expects that eventually TE Connectivity’s quality process will be adapted by all suppliers, but that vision is not yet near-term—as cost and culture barriers exist for both GPS and virtual metrology. Meanwhile, his team and the CoE will work toward a future “push button” process even though they expect, for practical reasons, that it would apply to “seventy-five percent of our work,” says Stokowski.

As a result of their quality-process improvement approach, many advances and milestones have taken place for TE Connectivity: » All new injection molded parts are implemented in MBD » 100% of injection molded parts are scanned, and there are no more tactile measurements » Part specifications are created in Creo to ISO-GPS standards and converted to a 3D PDF as a neutral document, where needed » The integration between Creo and VGMETROLOGY software is direct » 75% of all product data is transported via PMI » Only isolated rework is done due to interface incompatibilities For final part inspection, TE Connectivity has six scanners working inline in the EMEA region for injection molded

parts. The scanners and Volume Graphics software look— post-metrology report—for key dimensions and targeted areas of a part rather than at the whole of the component.

Costs and time weigh in here. But also, the upfront virtual design, analysis and testing of parts so early in creation, combined with checks during First Article Inspection, ensure that compliance has been met and rechecked on the factory floor. The company maintains 23 scanners worldwide, a global license for Creo, and complete suites of Volume Graphics’ software. And it operates a competence center for integrating and distributing these digital technologies.

Quality is the end game Business debates about how much to invest in technology are perennial and the accounting science to unearth the facts is rarely used fully. But quality is the end game for many institutions and particularly for manufacturing. Quality is an aligning value that attracts customers, keeps customers, and centers engineering teams on what is important and so pervasive in its organizational impact.

“TE Connectivity’s quality tools and digital systems are telling us a lot about our products—how to improve them, why they behave in such a way, and how to spot and predict variation,” says Stokowski. “Most immediately, we are saving time and building great products that advance other fields such as e-mobility. “Virtual metrology and digitalization offer an endless box of treasures, if you chose to use them.”

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IMD | 37

Process

Dry electropolishing — More Sustainability in the Field of Surface Finishing Consistent and resource-saving high gloss finishes in perfect quality

The dry electropolishing technology is also ideal for finishing life style products, like this tamper.

T

he field of surface finishing is characterized by demands for higher quality with, at the same time, an increasing need for process consistency, traceability and resource efficiency. Frequently, this requires new finishing methods. With the DryLyte system Rösler Oberflächentechnik offers an innovative system for electropolishing metal components that must have a perfect finish. Contrary to classical electro-chemical polishing methods DryLyte is a dry process that utilizes solid particles containing electrolytes. Acid baths or other process liquids are completely eliminated. Benefits of this revolutionary technology are an excellent surface finish, a high geometrical consistency of the work pieces, a lower CO2 footprint and lower costs for waste disposal. The costly and complex treatment of used process liquids is completely eliminated, and the finished work pieces are discharged from the system perfectly clean.

Whether for cosmetic or functional reasons – the providers of surface finishing solutions are confronted with numerous challenges. On the one side demands for lower surface roughness values and geometrical consistency of the finished work pieces must be met, whereas on the other side the finishing processes must be cost-efficient and eco-friendly. Issues such as energy requirements, consumption of valuable resources, prevention of potentially hazardous substances and waste disposal are becoming more important. In addition, the customers are demanding absolutely consistent results and processes that

38 | IMD November 2023

can be perfectly reproduced. All these requirements can only partially be met with manual finishing or traditional electropolishing methods with liquid electrolytes. With its innovative DryLyte polishing technology GPA Innova, a partner of Rösler Oberflächentechnik, offers an excellent method for finishing geometrically complex components made from conductive metals.

From deburring to high gloss polishing – a sustainable and highly efficient technology The fully automatic DryLyte system simplifies and helps standardize different surface finishing tasks such as deburring, surface smoothing, surface grinding, high gloss polishing and, even, post processing of 3D printed components. Depending on the initial surface conditions und the specified finishing results, dry electropolishing can be utilized as stand-alone process or in combination with known mass finishing, shot blasting and other pre-grinding methods.

The DryLyte technology is based on the principle of electro-chemical material removal from the surface of components. However, the technology does not use liquid electrolytes but a multitude of polymer pellets in different sizes containing electrolyte media that are precisely adapted to the respective finishing task. In contrast to the traditional electropolishing systems no hazardous vapors are generated requiring energy-intensive exhaust systems and special protective gear for the operator. Since the material

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removed from the work piece surface is absorbed by the electrolyte medium, no dust or metal particles are getting into the environment, as happens with manual grinding and polishing operations. High-quality, consistent processing results are achieved throughout the usable life of the electrolyte medium. This must only be replaced once the dry electrolyte has been saturated with the metal removed from the work piece surface. The waste disposal of the saturated electrolytes is similar to the disposal of grinding media. The saturation rate is monitored by the machine so that the operator is always up-to-date and informed about the remaining usage time. This guarantees absolutely stable, and consistent finishing results and the optimal utilization of the electrolyte. It also helps minimize the costs for labor and waste disposal. Finally, because of the efficient resource utilization the CO2 footprint is reduced..

A precise and gentle finishing process that maintains the geometrical integrity of the work pieces During the dry electropolishing process the work pieces, mounted to a fixture, are slowly moving through the dry electrolyte. This ensures complete coverage of the entire surface. If required, internal surface areas can also be finished by using special electrodes. The DryLyte method removes primarily the roughness peaks from the surface. Therefore, the metal removal rate is minimal, and the overall process is very gentle. The finished work pieces have a highly homogeneous surface with no pressure points or an orange peel effect. Even in the case of delicate work pieces with complex shapes no damage in the form of scratches or breakage occurs.

The targeted and “controlled” processing ensures that in case of precision components like machining tools or tools for the pharmaceutical industry their geometrical integrity is not affected, and their edges are not radiused.

In addition, the highly effective smoothing effect on the surface prevents micro cracks and pitting. This improves the corrosion resistance and “fatigue” characteristics and, thus, extends the usable life of the components. Compared to components treated with traditional electropolishing, dryelectropolished components corrode 4 to 15 times slower as proven in corrosion tests in a saltwater solution containing 30 grams/liter NaCL. In the case of gear components used in mechanical systems, dry electropolishing increases the material load ratio, reduces friction and guarantees the optimal distribution of lubricants on the work piece surface.

The improved surface conditions result in a lower wear rate and, at the same time, reduce the noise level.

Another significant benefit of the DryLyte technology are the relatively short cycle times. Depending on the finishing application, initial surface roughness and required results, they can vary between a few minutes and 1.5 hours.

The process creates not only a smoother surface but, if needed it can also produce a high gloss polish in one single process. For post processing of 3D printed components with their typically very high surface roughness, the electropolishing operation is preceded by a mass finishing process utilizing abrasive grinding media.

The dry electropolishing technology enables the reproducible and resourcesaving generation of perfect high-gloss surfaces in short process times.

Easy adaptation to many finishing applications The unique, patented dry electropolishing technology was initially developed for finishing prototype castings and dental crowns made from cobalt chrome and titanium.

In the meantime the dry electropolishing method from GPA Innova is used for finishing stainless steel, steel, hard metals as well as nickel, aluminum and copper alloys along with other conductive metals. Today the process is used whenever high finishing qualities are required in industries such as aerospace, pharmaceutical, machine building as well as luxury and consumer goods. Because of the proven biocompatibility of the finished components dry electropolishing is also used in medial engineering for the production of implants and instruments.

Process development and definition of the process parameters for the respective finishing application takes place in the customer experience center at Rösler. For this purpose, the CEC is equipped with different machine types allowing fully automatic operation. This approach guarantees that the finishing processes for the customer components are always based on precisely defined and validated parameters.

ABOUT RÖSLER OBERFLÄCHENTECHNIK GMBH For over 80 years, the privately owned Rösler Oberflächentechnik GmbH has been actively engaged in the field of surface preparation and surface finishing. As global market leader, we offer a comprehensive portfolio of equipment, consumables and services around the mass finishing and shot blasting technologies for a wide spectrum of different industries. Our range of about 15,000 consumables, developed in our Customer Experience Centers and laboratories located all over the world, specifically serves our customers for resolving their individual finishing needs. Under the brand name AM Solutions, we offer numerous equipment solutions and services in the area of additive manufacturing/3D printing.

Last-but-not-least, as our central training center the Rösler Academy offers practical, hands-on seminars to the subjects mass finishing, shot blasting and lean management. The Rösler group has a global network of 15 locations and approx. 150 sales agents.

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IMD | 39

10 Industry Insight

F

Areas Manufacturers Might See an Impact from AI

ew technologies have changed the manufacturing industry as much as ERP software. From automated scheduling to precision inventory management, automated purchasing, real-time job costing and more, ERP simplifies production processes so manufacturers can work faster and more efficiently while delivering a quality product on time every time. The next transformative technology – artificial intelligence (AI) and machine learning (ML) – is already having a significant impact on our industry by changing the way manufacturers collect, process, and analyze data.

Over the past decade, one of the biggest advances in ERP has been the ability to communicate and integrate with machines and external software programs to lower costs and increase efficiency. For example, BOM Compare software can reduce engineering costs and get jobs into production much faster by expediting the design to production process. Integrating ERP with Nesting software can significantly lower material and labor costs and reduce

40 | IMD November 2023

scrap by automatically determining the most efficient way to cut parts on a piece of metal.

AI takes these capabilities to new levels with unprecedented predictive data tracking and analysis. AI can be programmed to learn from the data ERP software gathers to make deeper and more accurate predictions regarding customers, buying habits, inventory levels, markets, material purchasing and more.

Before we list 10 ways AI is enhancing ERP capabilities, let’s look at what makes it a game-changing technology.

AI: Computer Self-Learning at Your Service The magic of AI is that it gives machines the ability to learn from experience so they can adapt to new inputs and perform tasks that have always been performed by humans. This requires computers to engage in deep learning and natural language processing so they can understand, interpret and manipulate human language.

When computers integrate with these technologies, they

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can be trained to accomplish specific tasks by processing and recognizing patterns in vast amounts of data.

This doesn’t mean AI can accomplish tasks without human guidance. AI needs people to set up the system to recognize patterns and ask the right questions. When programmed correctly, AI can: » Automate repetitive learning » Add intelligence to existing products » Achieve incredible accuracy through deep neural networks » Adapt itself through progressive learning algorithms so the data can do the programming ERP gives manufacturers an advantage by tracking data in every aspect of the business. AI goes a giant step further by analyzing more data at a deeper level. When AI algorithms become selflearning, the data becomes an extremely valuable asset.

10 Ways AI Can Make Your Manufacturing Better The goal with integrating AI and ERP is essentially the same as ERP when it was first developed – simplifying manufacturing to improve operational efficiency and increase profitability while growing the company. The difference is that with AI manufacturers can track and analyze predictive data as well as current and historical. With its self-learning capabilities, AI can also assist manufacturers in their decision-making when the relevant data, parameters, and variables exceed human understanding.

1

INVENTORY MANAGEMENT AI-integrated ERP software helps manufacturers optimize inventory management by predicting demand, identifying slow-moving products, and automating order fulfillment. According to a study by McKinsey, companies that utilize AI to optimize inventory can reduce inventory levels by up to 50%.

Managing inventory is mostly a reactive process, measuring stock levels and ordering materials based on historical usage and seasonal trends combined with estimates of expected customer orders. AI-based inventory planning makes it more proactive with: » Increased visibility of inventory KPIs » Improved product, channel and location forecasting that includes seasonality and trend data » Automatic classifying of SKUs to identify what’s needed to meet demand » Replenishing SKUs faster with predictive ordering based on anticipated changes in supply and demand

2

QUALITY CONTROL AI-based inspection systems can identify defects and anomalies in manufacturing processes in real-time, thereby reducing the risk of product recalls and improving overall quality. For example, image recognition algorithms are capable of analyzing images of products on the assembly line to identify defects that may not be visible to the human eye.

AI is also changing the way quality gets inspected.

Machine vision is an integral part of many quality applications. With its deep learning capabilities, AI-powered quality control software can self-learn which aspects are vital and create rules that determine the features needed to define quality products.

3

PRICING OPTIMIZATION AI-powered ERP software can optimize pricing by analyzing market trends, competitor pricing, and customer behavior. With this data, manufacturers can make better-informed decisions to optimize prices for their products, resulting in higher profits and better customer satisfaction.

AI’s deep data dives allow you to model how customers will respond to price changes based on historical sales data. It also lets you factor customer behavior into pricing strategies, predict how different prices will impact sales, and combine experience and data to increase prices without damaging sales. AI predictions aren’t 100% accurate, but they inform gut feelings about effective pricing strategies.

4

DEMAND FORECASTING AI can be used to predict demand for products based on historical data, market trends, and customer behavior, helping to optimize production schedules, reduce lead times, and avoid stockouts. With AI you can predict consumer demand for every SKU by taking into account seasonality, pricing, promotions, and product lifecycles.

AI offers the unique ability to engage in demand forecasting across different time horizons. This includes near-term demand sensing, a forecasting method that combines AI and real-time data to create a forecast based on current supply chain conditions. Other AI-enabled forecasting includes direct-to-consumer and e-commerce.

AI can also combine supply, sales, finance, and marketing projections into a holistic view of demand across your entire enterprise.

5

SUPPLY CHAIN MANAGEMENT As we all experienced during and after COVID, disruptions to supply chains can create serious problems. AI-powered ERP software helps optimize supply chain management by predicting supplier lead times, identifying bottlenecks, and optimizing logistics routes to reduce lead times, lower costs, and increase customer satisfaction.

AI algorithms analyze data to predict which products will be in demand and in what quantities, reducing strains on specific links of your supply chain. AI can also provide upgrades to important supply chain elements, including: » Improving warehouse supply and demand management » Improving the health and longevity of your transportation vehicles INDUSTRIAL MACHINERY DIGEST.COM

IMD | 41

» Making your loading processes more efficient » Helping supply chain managers reduce costs and increase revenues

6

PREDICTIVE MAINTENANCE SCHEDULING Proper maintenance is essential to minimizing downtime, reducing repair costs and extending the life of your machines and equipment. AI helps achieve these goals by predicting equipment failure and scheduling preventative maintenance before a breakdown occurs.

AI collects and processes data from sensors, cameras, logs, and other sources. Engineers then analyze the data to make predictions and recommend maintenance actions. In addition to protecting your machines and equipment, AI can: » Improve safety by minimizing human errors and accidents » Reduce quality defects » Increase efficiency and productivity » Support innovation, sustainability and environmental compliance with data-driven decision making

7

LABOR MANAGEMENT Labor costs are often the biggest line item in the manufacturing budget. AIpowered ERP software can help reduce labor costs and increase productivity by predicting employee productivity, identifying training needs, and optimizing scheduling.

AI can also alleviate another costly labor problem – workplace injuries – by limiting shop floor personnel’s exposure to powerful, unwieldy machinery and dangerous tasks. AI does this by streamlining or automating risky processes that can lead to serious injuries.

8

REAL-TIME ANALYTICS AI-powered ERP software provides real-time analytics on key performance indicators such as production rates, inventory levels, and quality metrics to help you make data-driven decisions and identify areas for improvement. While conventional data analysis methods do

42 | IMD November 2023

a good job of organizing and distributing IoT data, AI does it faster and with greater precision by identifying patterns and inconsistencies in real-time. AI algorithms process data from different sources and present it in a consistent manner, making it easier to structure the data for analysis. AI speeds up real-time analytics by preparing, analyzing and assessing data as soon as it is available.

9

LABOR SHORTAGES AI can even help with labor shortages through robotic automation, additive manufacturing, and machine vision. AI applications enable robot arms to safely handle objects on the production line regardless of their orientation, speed, or placement. With these abilities, robots can be trained to perform various types of assembly line work done by humans. Assembly line work is repetitive, labor intensive, and prone to error. Even with years of experience, highly skilled designers and engineers often use a “best guess” approach when creating design solutions. AI empowers the development of complex, highly optimized designs that can be accurately produced with 3D printing. AI-driven autonomous machine vision can count and track items, identify defects, and properly sort products using cameras and specific lighting conditions.

10

AUTONOMOUS MANUFACTURING AI can be used to automate manufacturing processes, reducing the need for human intervention and increasing efficiency. AI robots tap into machine learning algorithms to automate repetitive tasks and decisionmaking. Robotic process automation can perform repetitive tasks like data entry and order processing, but it can also handle more complex tasks, such as spotting anomalies on the production line.

AI-powered robots can work side-by-side with humans. Autonomous mobile robots can transport packages within the warehouse, while collaborative robots (cobots) assemble products alongside humans on the production line. These factory robots combine the precision

and efficiency of machines with the skills and intelligence of human operators, taking product quality to new levels.

Say Hello to Big Data As with many industries, manufacturing has begun to gravitate toward Big Data. ERP made it possible for manufacturers to make data-based decisions by tracking large amounts of information. Big Data enables predictive forecasts regarding sales, pricing, material availability, and other key metrics. AI makes gathering and analyzing those

mountains of data provided by ERP possible.

The complexity of AI algorithms can be daunting. Yet, their ability to look into the future as well as today and the past are mind-boggling and exciting.

ABOUT THE AUTHOR John Davis serves at CTO for Global Shop Solutions and is a 20-year veteran of the ERP and manufacturing industry. As a graduate of Utah State University, Davis is exceptionally gifted at building ERP software that simplifies manufacturing for Global Shop Solutions customers.

INDUSTRIAL MACHINERY DIGEST.COM

IMD | 43

Product Showcase

PRODUCT SHOWCASE Industrial Machinery Digest's Monthly Product Showcase features the latest from some of the manufacturing industry's top suppliers.

WANT TO BE FEATURED? Send your latest product information to editorial@indmacdig.com

Allied Machine announces Wohlhaupter line of fine boring lay down cartridges Allied Machine and Engineering, a leader in metal-cutting holemaking and finishing tools, has announced its latest innovation in the Wohlhaupter product line: the ES-Bore (Easy Set Bore) series of fine boring lay down cartridges.

These new cartridges are set to be available from October 16th and offer enhanced flexibility and precision in custom tool design.

The ES-Bore cartridges are uniquely designed to mount easily onto the body of custom boring tools.

They are compatible with existing tool bodies, replacing current lay down cartridges, and integrate with 3ETECH+ functionality. Featuring a broad diameter range of 1.1 to 128 inches (28 to 3200 millimeters), these cartridges are adaptable for various standard Wohlhaupter components.

The range for custom tools is unlimited, depending on specific applications. The cartridges cater to two different insert sizes: the ISO form 101 and Wohlhaupter’s form 20 insert, applicable across all common materials.

Further enhancing their appeal, the ES-Bore series is available in both analog and digital versions. The digital variant includes the new 3ETECH+ digital readout module, boasting a larger OLED display for improved visibility, one-micron diameter adjustment accuracy, and a USB-C rechargeable battery.

The launch of the ES-Bore lay down cartridges marks a significant advancement in the realm of custom tool design, offering shorter delivery times and reduced costs for special tools. Customers can now create their specialized tools more efficiently by simply adding an ES-Bore cartridge to their manufacturing process.

Axel Wagner, the business development manager at Wohlhaupter, highlights the blend of simplicity and

44 | IMD November 2023

precision these new cartridges bring to lay down cartridges and fine boring.

One-Step Production with ANCA's Automated Blanket Grinding Solution

ANCA, a global leader in CNC grinding machines, has introduced an innovative solution to streamline production and enhance efficiency: blanket grinding. Kaine Mulder, ANCA's Product Manager, emphasizes how this approach, especially in a time of supply chain challenges and increasing demand for rapid turnaround, offers a crucial advantage in tool manufacturing.

Blanket grinding, enabled by ANCA's unique robot cells available on all machine platforms, simplifies tool production. It transforms longer bar stock into complete tools through a continuous, automated process. This method eliminates extra processes and handling, delivering finished tools directly from ground bar stock without operator intervention. Key benefits include small batch production, quick turnaround, product development, consistency over batches, and support for automated "lights out" operation.

The TX machine platform, distinguished by its large working envelope and high torque spindle, is particularly suited for blanket grinding. It accommodates longer bar lengths and a broader range of tool sizes and geometries.

ANCA's RoboMate and TXcell robot cells further enhance

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this capability, offering automation solutions for various production needs.

Blanket grinding addresses the modern market's demand for unique, complex products with rapid response and shorter delivery times. By reducing manual handling, planning, and utilizing machinery more efficiently, it not only boosts productivity but also contributes to cost-effectiveness. This approach enables manufacturers to respond swiftly to customer requests without disrupting ongoing production, ensuring high-quality output.

Additionally, blanket grinding can minimize the production area by consolidating processes into a single machine footprint, streamlining changes in parts and features.

ANCA's commitment to innovation through solutions like blanket grinding reflects its position as a market leader, catering to diverse industries such as automotive, aerospace, and medical. The company, founded in 1974, continues to be at the forefront of CNC grinder manufacturing and remains a key player in shaping the future of precision tool production.

Beckhoff C6040 Boosts Ultra-Compact IPC Performance Beckhoff has enhanced its C60xx series with the new C6040 ultra-compact Industrial PC (IPC), incorporating 12th Gen Intel® Core™ processors, to handle demanding 2022 IMD AD final 11-21-2.pdf 1 11/22/22 12:16 AM automation tasks in a remarkably small package. Measuring

just 132 x 202 x 76 mm, the C6040 is designed for complex projects, making it particularly suitable for applications requiring multi-axis motion, advanced HMI applications, machine learning, and machine vision, all within very short cycle times.

A key feature of the C6040 is its use of 12th Gen Intel® Core™ i7 and i9 processors in a hybrid architecture. Unlike other processors categorized exclusively into performance or efficiency cores, the C6040's processors combine these two types, adding four efficiency cores to the Core™ i7 and eight to the Core™ i9. This innovative blend enables applications to utilize a total of 12 or 16 processor cores.

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The performance cores excel in high-performance, singlethread applications, while the additional efficiency cores can handle many threads in real time or user mode.

Each core in the C6040 can be individually tuned via clock frequency, offering a tailored approach to various computing demands. Beckhoff also integrates an additional power supply developed and produced in-house, ensuring sufficient power to maximize the processors' vast computing capabilities.

This advancement in IPC technology by Beckhoff underlines its commitment to providing powerful, space-efficient solutions for increasingly sophisticated automation tasks. The C6040 IPC represents a significant leap in the performance and versatility of ultra-compact controllers, accommodating complex and intensive processes within a reduced footprint.

CRIBWISE goes for growth with tooling inventory management software

CRIBWISE, a key player in tooling inventory management software and a subsidiary of the global Sandvik Group, has reported a significant growth spurt, with a 50% increase in active licenses since November 2022, now totaling 1,500 globally. This uptick is seen across SMEs, Enterprise manufacturers, machine shops, and precision engineering operations worldwide. The software is primarily distributed through reseller partners, and the company boasts a strong international presence with partnerships in India, China, the UK, Sweden, Brazil, and a recent addition in Canada with CAM Solutions Inc. The surge in CRIBWISE's popularity is attributed to its focused approach in tackling a prevalent challenge in manufacturing – managing the time, administration, and operational aspects of tooling and inventory stocks.

Users benefit from its simplicity, comprehensive real-time reporting, data insights, and compatibility with leading tooling and storage systems, leading to quick gains in productivity, efficiency, and cost-saving.

Head of CRIBWISE, Joakim Johansson, underscores the software’s role in assisting manufacturers in controlling their tooling inventory, thus enhancing cost-efficiency and overall operational efficacy. He highlights the significant uptake in digital solutions within the manufacturing sector, driven by the tangible benefits and rapid ROI delivered by CRIBWISE.

46 | IMD November 2023

Innovation remains a cornerstone of CRIBWISE's strategy. The Stock Optimization feature, powered by Artificial Intelligence, is one such innovation, streamlining stock levels and automating procurement processes.

Moreover, the company is expanding its offering through collaborations with top-tier storage and integration partners like Zoller TMS and Modula, aiming to provide comprehensive management and storage solutions to customers. These efforts and partnerships indicate a robust commitment to continual development and customer-focused innovation in inventory management.

Flex Machine Tools Launches the FlexJet FLX Waterjet Cutting System Flex Machine Tools has unveiled the FlexJet FLX, a cutting-edge waterjet cutting system designed to excel in performance, service, and innovation, catering to the high expectations of modern manufacturers. The FlexJet FLX distinguishes itself with its gantry-style, two-piece construction, offering robustness and reliability. This design enhances the machine's maximum rapid movement and travel speed, effectively reducing cycle times and boosting productivity.

Ease of use is a significant advantage of the FlexJet FLX. It features versatile and user-friendly software, enabling customizable operations to suit different working styles. The software's intuitive nature facilitates quick starts and efficient, high-quality part production.

A standout aspect of the FlexJet FLX is its innovative 5-axis cutting head, a pioneering design in the industry.

Unlike conventional focal point designs, the FlexJet FLX's 5-axis head employs a true 5-axis mechanism, enhancing taper control and precision. The head's infinite C-axis movement eliminates travel and rotation limits, avoiding the need for rewinding. This functionality ensures optimal compensation for stream lag and kerf taper, allowing for tighter tolerances and faster cutting. The head's advanced technology also supports tangential following for enhanced accuracy and speed. The capability of the 5-axis head to tilt up to ±120° broadens its utility, enabling complex 3D cuts beyond traditional bevels.

Flex Machine Tools prioritizes customer service, underlined by a comprehensive network of service engineers and experienced professionals. This commitment guarantees swift, effective solutions and minimized downtime. Flex Machine Tools also offers extensive maintenance packages, ensuring the FlexJet FLX remains in peak condition for optimal performance.

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